Komatsu BR500JG-1 Shop Manual SEBM012103 – PDF DOWNLOAD

Description

Komatsu BR500JG-1 Shop Manual SEBM012103 – PDF DOWNLOAD

FILE DETAILS:

Komatsu BR500JG-1 Shop Manual SEBM012103 – PDF DOWNLOAD

Language : English
Pages :391
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu BR500JG-1 Shop Manual SEBM012103 – PDF DOWNLOAD

TABLE OF CONTENTS:

Komatsu BR500JG-1 Shop Manual SEBM012103 – PDF DOWNLOAD

COVER 1
CONTENTS 2
01 GENERAL 26
DIMENSION 27
SPECIFICATIONS 29
TABLE OF OIL AND COOLANT CAPACITIES 37
10 STRUCTURE AND FUNCTION 40
PARTS RELATED TO ENGINE 41
RADIATOR, OIL COOLER 43
DRIVE SYSTEMS FOR EACH COMPONENT 44
FINAL DRIVE 46
TRACK FRAME, RECOIL SPRING 47
TRACK SHOE 48
HYDRAULIC TANK, HYDRAULIC FILTER 49
HYDRAULIC PUMP 50
CONTROL VALVE 71
SUCTION SAFETY VALVE 77
SELF-REDUCING PRESSURE VALVE 78
CLSS 83
CRUSHER MOTOR100
TRAVEL MOTOR103
TRAVEL PPC VALVE110
HYDRAULIC CYLINDER114
ELECTRIC CIRCUIT DIAGRAM115
ENGINE CONTROL SYSTEM117
MACHINE MONITOR SYSTEM118
BELT CONVEYOR MACHINERY124
BELT CONVEYOR MOTOR125
SOLENOID VALVE (6-SPOOL)126
SOLENOID VALVE (FOR CRUSHER MOTOR)127
PPC VALVE128
FIRST BELT CONVEYOR130
GRIZZLY FEEDER131
VIBRATOR132
FLOW CONTROL VALVE133
CRUSHER134
20 TESTING AND ADJUSTING138
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS139
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS140
TOOLS FOR TASTING, ADJUSTING, AND TROUBLESHOOTING143
MEASURING ENGINE SPEED144
MEASURING EXHAUST COLOR145
ADJUSTING VALVE CLEARANCE146
MEASURING COMPRESSION PRESSURE147
MEASURING BLOW-BY PRESSURE147
TESTING AND ADJUSTING FUEL INJECTION TIMING148
MEASURING ENGINE OIL PRESSURE149
TESTING AND ADJUSTING FAN BELT TENSION150
ADJUSTING ENGINE SPEED SENSOR151
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)152
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT AND TRAVEL CIRCUIT153
TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE155
TESTING SOLENOID VALVE OUTPUT PRESSURE156
MEASURING PPC VALVE OUTPUT PRESSURE156
TESTING TRAVEL DEVIATION157
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT158
TESTING AND ADJUSTING TRACK SHOE TENSION159
BLEEDING AIR FROM HYDRAULIC CIRCUIT160
ADJUSTING FUEL CONTROL LEVER164
TESTING AND ADJUSTING CRUSHER165
TROUBLESHOOTING182
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE183
CHECKS BEFORE TROUBLESHOOTING191
1 FOR CHASSIS191
2 FOR CRUSHER192
3 FOR BELT CONVEYOR194
CONNECTOR TYPES AND MOUNTING LOCATIONS195
CONNECTOR ARRANGEMENT DIAGRAM199
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS217
METHOD OF PROCEEDING WITH TROUBLESHOOTING221
METHOD OF USING TROUBLESHOOTING CHARTS222
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)223
E-1 TRAVEL LOCK DOES NOT WORK NORMALLY224
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)225
M-1 WHEN STARTING SWITCH IS TURNED ON, NO DISPLAY IS GIVEN226
M-2 WHEN STARTING SWITCH IS TURNED ON, LAMPS LIGHT UP FOR 3 SECONDS, BUT THEN DO NOT GO OUT226
M-3 WHEN STARTING SWITCH IS TURNED ON, SOME LAMPS DO NOT LIGHT UP FOR 3 SECONDS227
a) NO GAUGE LAMPS LIGHT UP (CAUTION LAMPS LIGHT UP)227
b) TRAVEL LOCK, PREHEATING LAMPS DO NOT LIGHT UP227
c) CHARGE CAUTION LAMP DOES NOT LIGHT UP227
d) ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP227
M-4 WHEN POWER IS TURNED ON (BEFORE ENGINE IS STARTED), CHARGE CAUTION LAMP DOES NOT LIGHT UP228
M-5 WHEN POWER IS TURNED ON (BEFORE ENGINE IS STARTED), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP 228
M-6 DURING PREHEATING, PREHEATING PILOT LAMP DOES NOT LIGHT UP229
M-7 WHEN SWITCH IS OPERATED, TRAVEL LOCK LAMP DOES NOT LIGHT UP229
M-8 ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING230
M-9 CHARGE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING230
M-10 ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE231
a) AFTER ENGINE IS STARTED, LEVEL STAYS AT BOTTOM (WHITE RANGE) AND DOES NOT MOVE231
b) AFTER ENGINE IS STARTED, LEVEL IMMEDIATELY RISES ENGINE IS NOT OVERHEATING BUT INDICATOR ENTERS RED RANGE231
c) ENGINE WATER TEMPERATURE GAUGE GOES OUT231
M-11 ABNORMALITY IN FUEL GAUGE232
a) ALL FUEL GAUGE SEGMENTS GO OUT232
b) EVEN WHEN FUEL LEVEL GOES DOWN, FUEL GAUGE CONTINUES TO SHOW FULL232
c) EVEN WHEN TANK IS FILLED, FUEL GAUGE DOES NOT SHOW FULL232
M-12 DEFECTIVE OPERATION OF ALARM BUZZER234
a) BUZZER DOES NOT SOUND (WHEN ABNORMAL)234
b) BUZZER CONTINUES TO SOUND AND DOES NOT STOP (WHEN NORMAL)234
M-13 ENGINE IS RUNNING, BUT SERVICE METER DOES NOT MOVE235
a) CHARGE CAUTION LAMP LIGHTS UP 235
b) CHARGE CAUTION LAMP DOES NOT LIGHT UP235
M-14 NIGHT LIGHTING DOES NOT LIGHT UP236
a) GAUGE LIGHTING DOES NOT LIGHT UP236
b) SERVICE METER LIGHTING DOES NOT LIGHT UP (SERVICE METER IS WORKING NORMALLY)236
30 DISASSEMBLY AND ASSEMBLY237
METHOD OF USING MANUAL239
PRECAUTIONS WHEN CARRYING OUT OPERATION241
SPECIAL TOOL LIST243
SKETCHES OF SPECIAL TOOLS245
STARTING MOTOR ASSEMBLY247
REMOVAL AND INSTALLATION247
ALTERNATOR ASSEMBLY248
REMOVAL AND INSTALLATION248
ENGINE OIL COOLER ASSEMBLY249
REMOVAL AND INSTALLATION249
FUEL INJECTION PUMP ASSEMBLY250
REMOVAL 250
INSTALLATION252
WATER PUMP ASSEMBLY253
REMOVAL AND INSTALLATION253
NOZZLE HOLDER ASSEMBLY254
REMOVAL AND INSTALLATION254
TURBOCHARGER ASSEMBLY255
REMOVAL AND INSTALLATION255
THERMOSTAT ASSEMBLY256
REMOVAL AND INSTALLATION256
ENGINE FRONT SEAL257
REMOVAL AND INSTALLATION257
ENGINE REAR SEAL258
REMOVAL258
INSTALLATION259
CYLINDER HEAD ASSEMBLY262
REMOVAL262
INSTALLATION266
AFTERCOOLER CORE ASSEMBLY269
REMOVAL AND INSTALLATION269
HYDRAULIC COOLER ASSEMBLY270
REMOVAL270
INSTALLATION271
RADIATOR, HYDRAULIC COOLER ASSEMBLY272
REMOVAL272
INSTALLATION274
ENGINE, MAIN PUMP ASSEMBLY275
REMOVAL275
INSTALLATION278
DAMPER ASSEMBLY279
REMOVAL AND INSTALLATION279
FUEL TANK ASSEMBLY280
REMOVAL AND INSTALLATION280
FINAL DRIVE ASSEMBLY281
REMOVAL AND INSTALLATION281
DISASSEMBLY282
ASSEMBLY286
SPROCKET292
REMOVAL AND INSTALLATION292
IDLER, RECOIL SPRING ASSEMBLY293
REMOVAL AND INSTALLATION293
IDLER ASSEMBLY294
DISASSEMBLY294
ASSEMBLY295
RECOIL SPRING ASSEMBLY297
DISASSEMBLY297
ASSEMBLY298
TRACK ROLLER ASSEMBLY299
REMOVAL AND INSTALLATION299
DISASSEMBLY300
ASSEMBLY301
CARRIER ROLLER ASSEMBLY303
REMOVAL AND INSTALLATION303
DISASSEMBLY304
ASSEMBLY306
TRACK SHOE ASSEMBLY308
REMOVAL AND INSTALLATION308
HYDRAULIC TANK ASSEMBLY309
REMOVAL309
INSTALLATION310
CONTROL PUMP ASSEMBLY311
REMOVAL AND INSTALLATION311
MAIN PUMP ASSEMBLY312
REMOVAL312
INSTALLATION313
MAIN PUMP INPUT SHAFT OIL SEAL314
REMOVAL AND INSTALLATION314
SERVO VALVE ASSEMBLY FOR FRONT PUMP315
REMOVAL AND INSTALLATION315
SERVO VALVE ASSEMBLY FOR REAR PUMP316
REMOVAL AND INSTALLATION316
TRAVEL PPC VALVE ASSEMBLY317
DISASSEMBLY317
ASSEMBLY318
CONVEYOR MACHINERY, MOTOR ASSEMBLY319
REMOVAL AND INSTALLATION319
CONVEYOR MACHINERY ASSEMBLY320
DISASSEMBLY320
ASSEMBLY323
CHEEK PLATE326
REMOVAL326
INSTALLATION327
FIXED JAW PLATE328
REMOVAL AND INSTALLATION328
SWING JAW PLATE330
REMOVAL330
INSTALLATION331
TOGGLE PLATE332
REMOVAL332
INSTALLATION333
TOGGLE SEAT 334
REMOVAL AND INSTALLATION334
FLYWHEEL AND V SHEAVE335
REMOVAL AND INSTALLATION335
SWING JAW336
REPLACEMENT336
BEARING337
REPLACEMENT337
THRUST SEAT338
REPLACEMENT338
CHEEK PLATE339
REPLACEMENT339
FIXED JAW TEETH341
TURNING AND REPLACEMENT341
SWING JAW TEETH343
TURNING AND REPLACEMENT343
TOGGLE PLATE344
REPLACEMENT344
TOGGLE SEAT347
REPLACEMENT347
HYDRAULIC RAM348
HANDLING348
FLYWHEEL AND V-PULLEY350
REPLACEMENT350
SWING JAW352
REPLACEMENT352
BEARING354
REPLACEMENT354
40 MAINTENANCE STANDARD355
ENGINE MOUNT356
FINAL DRIVE357
TRACK FRAME AND RECOIL SPRING359
IDLER360
CARRIER ROLLER362
TRACK ROLLER363
TRACK364
HYDRAULIC PUMP366
CONTROL PUMP AND RELIEF VALVE367
SUCTION-SAFETY VALVE368
SELF-REDUCING PRESSURE VALVE369
CRUSHER MOTOR370
TRAVEL MOTOR371
TRAVEL PPC VALVE 372
BELT CONVEYOR MACHINERY373
BELT CONVEYOR MOTOR375
CRUSHER376
WEAR MEASUREMENT OF MAJOR CONSUMABLE PARTS379
90 OTHERS381
HYDRAULIC CIRCUIT DIAGRAM (SERIAL NO: 1006-1103)382
HYDRAULIC CIRCUIT DIAGRAM (SERIAL NO: 1201 AND UP)383
ELECTRIC CIRCUIT DIAGRAM (SERIAL NO: 1002-1006)384
ELECTRIC CIRCUIT DIAGRAM (SERIAL NO: 1007-1103)385
ELECTRIC CIRCUIT DIAGRAM (SERIAL NO: 1201 AND UP)386

IMAGES PREVIEW OF THE MANUAL:

S.M 13/12/24