Komatsu BR550JG-1 Mobile Crusher Shop Manual SEBM022504 PDF
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Komatsu BR550JG-1 Mobile Crusher Shop Manual SEBM022504 – PDF DOWNLOAD
- MACHINE MODEL SERIAL NUMBER
BR550JG-1 1001 AND UP
Description
Komatsu BR550JG-1 Mobile Crusher Shop Manual SEBM022504 – PDF DOWNLOAD
FILE DETAILS:
Komatsu BR550JG-1 Mobile Crusher Shop Manual SEBM022504 – PDF DOWNLOAD
Language : English
Pages : 668
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Komatsu BR550JG-1 Mobile Crusher Shop Manual SEBM022504 – PDF DOWNLOAD
- MACHINE MODEL SERIAL NUMBER
BR550JG-1 1001 AND UP
COVER 1
CONTENTS 2
01 GENERAL 27
SPECIFICATION DRAWINGS 28
SPECIFICATIONS 29
WEIGHT TABLE 32
TABLE OF FUEL, COOLANT, AND LUBRICANTS 33
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 35
ENGINE MOUNT AND DAMPER 36
RADIATOR, OIL, AND AFTERCOOLER 38
POWER TRAIN 39
FINAL DRIVE 41
TRACK FRAME AND RECOIL SPRING 43
IDLER 44
CARRIER ROLLER 45
TRACK ROLLER 46
TRACK SHOE 47
HYDRAULIC PIPING DIAGRAM 50
HYDRAULIC TANK AND FILTER 51
HYDRAULIC PUMP 52
MAIN PUMP 53
TCV, LC VALVE 58
FUNCTION 60
OPERATION-LS VALVE 61
OPERATION-TVC VALVE 65
CONTROL VALVE 72
SELF-REDUCING PRESSURE VALVE 78
CLASS 83
OUTLINE OF CLASS 83
BASIC PRINCIPLE 84
HYDRAULIC CIRCUIT DIAGRAM 86
WHEN UPLOAD VALVE IS ACTUATED 89
INTRODUCTION OF LS PRESSURE 91
LS BYPASS VALVE 92
PRESSURE COMPENSATION VALVE 93
SHUTTLE VALVE INSIDE PRESSURE COMPENSATION VALVE 95
MERGE FLOW DIVIDER VALVE 98
CRUSHER MOTOR 100
GRIZZLY FEEDER MOTOR 102
TRAVEL MOTOR (FIXED SWASH PLATE) 103
OPERATION OF PARKING BRAKE 105
COUNTERBALANCE AND CHECK VALVE 106
SAFETY VALVE 107
TRAVEL PPC VALVE 110
TRAVEL JUNCTION VALVE 114
4-SPOOL SOLENOLD VALVE 117
8-SPOOL EPC VALVE 119
EPC VALVE 120
LS-EPC VALVE 123
ELECTROMAGNETIC SELECTOR VALVE 126
ENGINE CONTROL SYSTEM 128
OPERATION OF SYSTEM 129
COMPONENTS OF SYSTEM 130
ENGINE THROTTLE – PUMP CONTROLLER 132
INPUT AND OUTPUT SIGNALS 133
LX CONTROLLER 134
INPUT AND OUTPUT SIGNALS 135
TROUBLESHOOTING DISPLAY OF LX CONTROLLER 137
ERROR CODES 139
MACHINE MONITOR SYSTEM 141
MACHINE MONITOR 142
MONITOR DISPLAY 143
CONTENT OF DISPLAY 144
OIL MAINTENANCE FUNCTION 145
SENSORS 147
ELECTRONIC CONTROL SYSTEM 150
PUMP PRESSURE SENSOR 150
EMERGENCY PUMP DRIVE RESISTOR 151
ENGINE SPEED SENSOR 152
GRIZZLY FEEDER SEMI-AUTO SYSTEM 153
SYSTEM DRAWING 154
ABNORMAL LOAD STOP SYSTEM 155
CRUSHER LOAD SETTING DIAL 156
PRIMARY CONVEYOR MACHINERY 158
PRIMARY CONVEYOR MOTOR 159
PRIMARY BELT CONVEYOR 160
GRIZZLY FEEDER 161
CRUSHER 164
PRINCIPLE OF CRUSHING 166
METHOD OF USING JAW CRUSHER 167
20 TESTING AND ADJUSTING 170
STANDARD VALUE TABLE FOR ENGINE 171
STANDARD VALUE TABLE FOR CHASSIS 172
STANDARD VALUE TABLE FOR ELECTRICAL PARTS 177
TESTING AND ADJUSTING 181
SERVICE TOOLS TABLE 182
MEASURING ENGINE SPEED 183
MEASURING EXHAUST COLOR 184
ADJUSTING VALVE CLEARANCE 185
MEASURING COMPRESSION PRESSURE 186
MEASURING BLOW-BY PRESSURE 187
FUEL INJECTION TIMING 188
MEASURING ENGINE OIL PRESSURE 190
TESTING AND ADJUSTING FAN BELT TENSION 191
ADJUSTING ENGINE SPEED SENSOR 192
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE) 193
GOVERNOR MOTOR LEVER STROKE 194
WORK EQUIPMENT AND TRAVEL CIRCUIT 195
TVC VALVE OUTPUT PRESSURE 197
LS VALVE OUTPUT AND DIFFERENTIAL PRESSURE 199
CONTROL CIRCUIT OIL PRESSURE 203
SOLENOID VALVE OUTPUT PRESSURE 204
TRAVEL DEVIATION 205
MEASURING OIL LEAKAGE 206
TESTING WEAR OF SPROCKET 207
TRACK SHOE TENSION 208
BLEEDING AIR 209
JAW CRUSHER 212
TENSION OF CRUSHER DRIVE BELT 218
PRIMARY BELT CONVEYOR 219
REFERENCE (RADIO CONTROLLER SUPPORT POINT) 220
TROUBLESHOOTING 221
POINTS TO REMEMBER WHEN TROUBLESHOOTING 222
SEQUENCE OF EVENTS IN TROUBLESHOOTING 224
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 225
CHECKS BEFORE TROUBLESHOOTING 233
CONNECTOR TYPES AND MOUNTING LOCATIONS 234
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 250
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM 267
DISPLAY METHOD AND SPECIAL FUNCTION OF MONITORING PANEL 270
METHOD OF USING JUDGEMENT TABLE 278
METHOD OF USING TROUBLESHOOTING CHARTS 280
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE 282
SERVICE CODE TABLE 285
TROUBLESHOOTING OF COMMUNICATION ABNORMALITY (N MODE) 286
N-1 [E218] COMMUNICATION ABNORMALITY 287
TROUBLESHOOTING OF ENGINE THROTTLE AND PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE) 289
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE THROTTLE AND PUMP CONTROLLER SYSTEM 290
ACTIONS TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE 291
JUDGEMENT TABLE FOR ENGINE THROTTLE AND PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS 295
ELECTRICAL CIRCUIT DIAGRAM FOR E-MODE 297
E-1 ABNORMALITY IN ENGINE THROTTLE AND PUMP CONTROLLER POWER SUPPLY- (CONTROLLER LED IS OFF) 299
E-2 [E308](ABNORMALITY IN INPUT VALUE FROM FUEL CONTROL DIAL) IS DISPLAYED 300
E-3 [E317](DISCONNECTION IN MOTOR DRIVE SYSTEM) IS DISPLAYED 301
E-4 [E318](SHORT CIRCUIT IN MOTOR DRIVE SYSTEM) IS DISPLAYED 302
E-5 [E306](ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM) IS DISPLAYED 303
E-6 [E315](SHORT CIRCUIT IN OUTPUT SYSTEM TO BATTERY RELAY) IS DISPLAYED 304
E-7 [E316](STEP-OUT IN MOTOR) IS DISPLAYED 305
E-8 ENGINE DOES NOT START 306
E-9 ENGINE SPEED IS IRREGULAR 309
E-10 LACK OF OUTPUT-ENGINE HIGH IDLING, SPEED IS TOO LOW 313
E-11 ENGINE DOES NOT STOP 315
E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM, ENGINE DOES NOT STOP 317
TROUBLESHOOTING OF ENGINE THROTTLE AND PUMP CONTROLLER (PUMP CONTROLLER SYSTEM)(C MODE) 319
POINTS TO REMEMBER WHEN TROUBLESHOOTING CONTROLLER SYSTEM 320
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE 321
JUDGEMENT TABLE FOR ENGINE THROTTLE, PUMP CONTROLLER(PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS 329
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE 331
C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF) 333
C-2 [E232] (SHORT CIRCUIT IN FRONT PUMP TVC SOLENOID SYSTEM) IS DISPLAYED 334
C-3 [E233] (DISCONNECTION IN FRONT PUMP TVC SOLENOID SYSTEM) IS DISPLAYED 336
C-4 [E236] (SHORT CIRCUIT IN REAR PUMP TVC SOLENOID SYSTEM) IS DISPLAYED 338
C-5 [E237] (DISCONNECTION IN REAR PUMP TVC SOLENOID SYSTEM) IS DISPLAYED 340
C-6 [E207] (SHORT CIRCUIT IN DUMMY RESISTOR) IS DISPLAYED 342
C-7 [E208] (DISCONNECTION IN DUMMY RESISTOR) IS DISPLAYED 343
C-8 [E203] (SHORT CIRCUIT IN DUMMY RESISTOR) IS DISPLAYED 344
C-9 [E213] (DISCONNECTION IN DUMMY RESISTOR) IS DISPLAYED 345
C-10 [E204] (SHORT CIRCUIT IN DUMMY RESISTOR) IS DISPLAYED 346
C-11 [E214] (DISCONNECTION DUMMY RESISTOR) IS DISPLAYED 347
C-12 [E206] (SHORT CIRCUIT IN DUMMY RESISTOR) IS DISPLAYED 348
C-13 [E216] (DISCONNECTION IN DUMMY RESISTOR) IS DISPLAYED 349
C-14 [E217] (SHORT CIRCUIT IN DUMMY RESISTOR) IS DISPLAYED 350
C-15 [E235] (DISCONNECTION IN DUMMY RESISTOR) IS DISPLAYED 351
C-16 [E217] (MODEL SELECTION INPUT ERROR) IS DISPLAYED 352
C-17 [E222] (SHORT CIRCUIT IN LS-EPC SOLENOID SYSTEM) IS DISPLAYED (DUMMY RESISTOR CIRCUIT) 353
C-18 [E223] (DISCONNECTION IN LS-EPC SOLENOID SYSTEM) IS DISPLAYED (DUMMY RESISTOR CIRCUIT) 354
C-19 [E224] (ABNORMALITY IN FRONT PUMP PRESSURE SENSOR SYSTEM) IS DISPLAYED 355
C-20 [E225] (ABNORMALITY IN REAR PUMP PRESSURE SENSOR SYSTEM) IS DISPLAYED 356
C-21 [E226] (ABNORMALITY IN PRESSURE SENSOR POWER SUPPLY SYSTEM) IS DISPLAYED 357
C-22 [E227] (ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED 358
TROUBLESHOOTING OF ENGINE THROTTLE AND PUMP CONTROLLER(INPUT SIGNAL SYSTEM) (F MODE) 359
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE 360
F-1 BIT PATTERN 20-[2] (TRAVEL OIL PRESSURE SWITCH) DOES NOT LIGHT UP 362
F-2 BIT PATTERN 22-[5] (KEROSENE MODE CONNECTION) DOES NOT LIGHT UP 363
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE) 364
SOLENOID VALVE OPERATION 365
TABLE OF FAILURE MODES AND CAUSES (1/2) 366
TABLE OF FAILURE MODES AND CAUSES (2/2) 368
H-1 SPEED OF ALL WORK EQUIPMENT, TRAVEL ARE SLOW OR LACK POWER 370
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS 372
H-3 NEITHER WORK EQUIPMENT, NOR TRAVEL MOVE 372
H-4 ABNORMAL NOISE GENERATED AROUND PUMP 373
H-5 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR 373
H-6 CONVEYOR DOES NOT OPERATE 374
H-7 CONVEYOR SPEED IS LOW OR ITS POWER IS INSUFFICIENT 375
H-8 CRUSHER DOES NOT OPERATE 376
H-9 CRUSHER SPEED IS LOW OR ITS POWER IS INSUFFICIENT 377
H-10 FEEDER DOES NOT FEED WELL (VIBRATION FREQUENCY IS LOW) 378
H-11 LOCK CYLINDER DOES NOT RETRACT OR DOES NOT EXTEND 379
H-12 MUCK DISCHARGE CONVEYOR SPEED IS LOW OR ITS POWER IS INSUFFICIENT 380
H-13 MAGNETIC SEPARATOR BELT SPEED IS LOW 381
H-14 MUCK DISCHARGE CONVEYOR DOES NOT MOVE UP OR DOES NOT MOVE DOWN CONVEYOR DOES NOT MOVE UP OR DOES NOT MOVE DOWN OPENING/CLOSING HOPPER DOES NOT OPERATE 382
H-15 MACHINE DOES NOT TRAVEL WHEN SWITCHES ON RADIO CONTROLLER ARE PRESSED(RIGHT REVERSE, RIGHT REVERSE, LEFT REVERSE, LEFT FORWARD) 382
H-16 TRAVEL SPEED IS LOW 383
H-17 TRAVEL DEVIATION 385
H-18 STEERING DOES NOT TURN EASILY OR LACKS POWER 386
H-19 TRAVEL DOES NOT MOVE ON ONE SIDE 387
H-20 MACHINE DOES NOT TRAVEL (WHEN TRAVEL LEVER IS OPERATED) 387
TROUBLESHOOTING OF MONITOR SYSTEM (M MODE) 388
ACTIONS TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE 389
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE 391
M-1 [E101] (ABNORMALITY IN ERROR DATA) IS DISPLAYED [E102] (ERROR IN CLOCK DATA) IS DISPLAYED 393
M-2 [E103] (SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24 V WIRING HARNESS WITH BUZZER DRIVE) IS DISPLAYED 394
M-3 [E104] (AIR CLEANER CLOGGING DETECTED) IS DISPLAYED 395
M-4 [E106] (DROP IN ENGINE OIL HI PRESSURE DETECTED) IS DISPLAYED 395
M-5 [E108] (ENGINE WATER TEMPERATURE 105℃ DETECTED) IS DISPLAYED 396
M-6 WHEN STARTING SWITCH IS TURNED ON, NONE OF LAMPS ON MONITOR PANEL LIGHT UP FOR THREE SECONDS 397
M-7 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT 399
M-8 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIGHTED UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE(MODEL) 399
M-9 WHEN STARTING SWITCH IS TURNED ON, ENGINE STOPPED, BASIC CHECK ITEMS FLASH 400
M-10 PREHEATING IS NOT BEING USED, BUT PREHEATING MONITOR LIGHTS UP 403
M-11 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH 404
M-12 WHEN STARTING SWITCH IS TURNED ON, ENGINE STOPPED,CAUTION ITEMS AND EMERGENCY ITEMS FLASH(BATTERY AND ENGINE OIL PRESSURE LAMPS DO NOT LIGHT UP) 406
M-13 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS,EMERGENCY ITEMS FLASH(WHEN THERE IS NO ABNORMALITY IN ENGINE OR ITEMS TO CHECK BEFORE TROUBLESHOOTING) 408
M-14 WHEN STARTING SWITCH IS TURNED ON,ENGINE STOPPED, BUZZER DOES NOT SOUND FOR ONE SECOND CAUTION ITEM FLASHES BUT BUZZER DOES NOT SOUND 411
M-15 NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS 411
M-16 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP(LIQUID CRYSTAL DISPLAY IS NORMAL) 412
M-17 COOLANT TEMPERATURE GAUGE DOES NOT RISE 413
M-18 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY(NONE OF GAUGE LAMPS LIGHT UP DURING OPERATION) 414
M-19 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL 415
M-20 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY 416
M-21 WHEN MODE SELECTOR SWITCH IS TURNED ON(WORK,MAINTENANCE),TRAVEL LOCK MONITOR DOES NOT LIGHT UP 417
M-22 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING 419
M-23 WHEN START SWITCH IS AT OFF AND TIME SWITCH IS PRESSED,TIME AND SERVICE METER ARE NOT DISPLAYED 419
M-24 FAULTY FUEL LEVEL SENSOR SYSTEM 420
M-25 FAULTY COOLANT TEMPERATURE SENSOR SYSTEM 421
M-26 FAULTY ENGINE OIL LEVEL SENSOR SYSTEM 422
M-27 FAULTY COOLANT LEVEL SENSOR SYSTEM 423
M-28 FAULTY HYDRAULIC OIL LEVEL SENSOR SYSTEM 424
TROUBLESHOOTING OF WORK EQUIPMENT CONTROLLER SYSTEM (W MODE) 425
PRECAUTIONS FOR TROUBLESHOOTING WORK EQUIPMENT CONTROLLER SYSTEM 427
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE 429
JUDGEMENT TABLE OF TROUBLES CONCERNED TO WORK EQUIPMENT CONTROL SYSTEM AND HYDRAULIC EQUIPMENT(1/2) 443
JUDGEMENT TABLE OF TROUBLES CONCERNED TO WORK EQUIPMENT CONTROL SYSTEM AND HYDRAULIC EQUIPMENT(2/2) 445
ELECTRICAL CIRCUIT DIAGRAM FOR W MODE 447
HOW TO READ YES/NO TROUBLESHOOTING 451
W-1 ABNORMALITY IN CONTROLLER POWER SUPPLY SYSTEM(CONTROLLER LED IS OFF) 452
W-2 [E-10] DISCONNECTION IN EMERGENCY STOP SWITCH SYSTEM 453
W-3 [E-11] SHORT CIRCUIT IN CONVEYOR ON SWITCH SYSTEM 460
W-4 [E-12] DISCONNECTION IN CONVEYOR OFF SWITCH SYSTEM 461
W-5 [E-13] SHORT CIRCUIT IN CRUSHER ON SWITCH SYSTEM 462
W-6 [E-14] DISCONNECTION IN CRUSHER OFF SWITCH SYSTEM 464
W-7 [E-15] SHORT CIRCUIT IN CRUSHER MANUAL FORWARD SWITCH SYSTEM 466
W-8 [E-16] SHORT CIRCUIT IN CRUSHER MANUAL REVERSE SWITCH SYSTEM 467
W-9 [E-17] SHORT CIRCUIT IN FEEDER ON SWITCH SYSTEM 468
W-10 [E-18] DISCONNECTION IN FEEDER OFF SWITCH SYSTEM 470
W-11 [E-19] SHORT CIRCUIT IN CRUSHER CLEARANCE EXTENSION SWITCH SYSTEM 472
W-12 [E-1A] SHORT CIRCUIT IN CRUSHER CLEARANCE RETRACTION SWITCH SYSTEM 473
W-13 [E-1B] SHORT CIRCUIT IN MUCK CONVEYOR ON SWITCH SYSTEM 474
W-14 [E-1C] SHORT CIRCUIT IN MUCK CONVEYOR OFF SWITCH SYSTEM 475
W-15 [E-1D] SHORT CIRCUIT IN MAGNETIC SEPARATOR ON SWITCH SYSTEM 476
W-16 [E-1E] SHORT CIRCUIT IN MAGNETIC SEPARATOR OFF SWITCH SYSTEM 477
W-17 [E-20] ABNORMALITY IN CRUSHER LOAD SETTING DIAL SYSTEM 478
W-18 [E-21] ABNORMALITY IN CRUSHER SPEED DIAL SYSTEM 479
W-19 [E-22] ABNORMALITY IN FEEDER SPEED DIAL SYSTEM 480
W-20 [E-23] SHORT CIRCUIT IN TRAVEL R H REVERSE SWITCH SYSTEM 481
W-21 [E-24] SHORT CIRCUIT IN TRAVEL R H FORWARD SWITCH SYSTEM 482
W-22 [E-25] SHORT CIRCUIT IN TRAVEL L H REVERSE SWITCH SYSTEM 483
W-23 [E-26] SHORT CIRCUIT IN TRAVEL L H FORWARD SWITCH SYSTEM 484
W-24 [E-27] SHORT CIRCUIT IN MUCK CONVEYOR RAISE OR LOWER SWITCH SYSTEM 485
W-25 [E-28] SHORT CIRCUIT IN CONVEYOR RAISE OR LOWER SWITCH SYSTEM 486
W-26 [E-2C] ABNORMALITY IN CONVEYOR PRESSURE SENSOR SYSTEM 487
W-27 [E-2D] ABNORMALITY IN MUCK CONVEYOR PRESSURE SENSOR SYSTEM 489
W-28 [E-2E] ABNORMALITY IN CRUSHER PRESSURE SYSTEM 491
W-29 [E-2F] ABNORMALITY IN S-NET SYSTEM 493
W-30a [E-30] Abnormality in model selection 494
W-30b [E-31] Abnormality in crusher pressure sensor system (reverse rotation side) 495
W-31 [E-50] DISCONNECTION IN ACCESSORY EPC VALVE SYSTEM 497
W-32 [E-51] SHORT CIRCUIT IN ACCESSORY EPC VALVE SYSTEM 498
W-33 [E-52] DISCONNECTION IN FEEDER EPC VALVE SYSTEM 499
W-34 [E-53] SHORT CIRCUIT IN FEEDER EPC VALVE SYSTEM 500
W-35 [E-54] DISCONNECTION IN CONVEYOR EPC VALVE SYSTEM 501
W-36 [E-55] SHORT CIRCUIT IN CONVEYOR 502
W-37 [E-56] DISCONNECTION IN TRAVEL LOCK EPC VALVE SYSTEM 503
W-38 SHORT CIRCUIT IN TRAVEL LOCK EPC VALVE SYSTEM 504
W-39 [E-58] DISCONNECTION IN CRUSHER FORWARD EPC VALVE SYSTEM 505
W-40 [E-59] SHORT CIRCUIT IN CRUSHER FORWARD EPC VALVE SYSTEM 506
W-41 [E-5A] DISCONNECTION IN CRUSHER REVERSE EPC VALVE SYSTEM 507
W-42 [E-5B] SHORT CIRCUIT IN CRUSHER REVERSE EPC VALVE SYSTEM 508
W-43 [E-5C] DISCONNECTION IN LOCK CYLINDER RETRACTION SOLENOID SYSTEM 509
W-44 [E-5D] SHORT CIRCUIT IN LOCK CYLINDER RETRACTION SOLENOID SYSTEM 510
W-45 [E-5E] DISCONNECTION IN LOCK CYLINDER EXTENSION SOLENOID SYSTEM 511
W-46 [E-5F] SHORT CIRCUIT IN LOCK CYLINDER EXTENSION SOLENOID SYSTEM 512
W-47 [E-60] DISCONNECTION IN MUCK DISCHARGE CONVEYOR SOLENOID SYSTEM 513
W-48 [E-61] SHORT CIRCUIT IN MUCK DISCHARGE CONVEYER SOLENOID SYSTEM 514
W-49 [E-62] DISCONNECTION IN MAGNETIC SEPARATOR SOLENOID SYSTEM 515
W-50 [E-63] SHORT CIRCUIT IN MAGNETIC SEPARATOR SOLENOID SYSTEM 516
W-51 [E-64] DISCONNECTION IN TRAVEL R H REVERSE SOLENOID SYSTEM 517
W-52 [E-65] SHORT CIRCUIT IN TRAVEL R H REVERSE SOLENOID SYSTEM 518
W-53 [E-66] DISCONNECTION IN TRAVEL L H REVERSE SOLENOID SYSTEM 519
W-54 [E-67] SHORT CIRCUIT IN TRAVEL L H REVERSE SOLENOID SYSTEM 520
W-55 [E-68] DISCONNECTION IN TRAVEL L H FORWARD SOLENOID SYSTEM 521
W-56 [E-69] SHORT CIRCUIT IN TRAVEL L H FORWARD SOLENOID SYSTEM 522
W-57 [E-6A] DISCONNECTION IN TRAVEL R H FORWARD SOLENOID SYSTEM 523
W-58 [E-6B] SHORT CIRCUIT IN TRAVEL R H FORWARD SOLENOID SYSTEM 524
W-59 [E-6D] SHORT CIRCUIT IN HORN RELAY COIL SYSTEM 525
W-60 [E-6E] SHORT CIRCUIT IN ROTARY LAMP RELAY SYSTEM 526
W-61 [E-70] DISCONNECTION IN LS EPC VALVE SYSTEM 527
W-62 [E-71] SHORT CIRCUIT IN LS EPC VALVE SYSTEM 528
30 DISASSEMBLY AND ASSEMBLY 529
METHOD OF USING MANUAL 530
PRECAUTIONS WHEN CARRYING OUT OPERATION 532
SPECIAL TOOL LIST 535
FUEL INJECTION PUMP 540
REMOVAL 540
INSTALLATION 541
NOZZLE HOLDER 542
REMOVAL AND INSTALLATION 542
TURBOCHARGER 543
REMOVAL AND INSTALLATION 543
CYLINDER HEAD 544
REMOVAL 544
INSTALLATION 546
ENGINE FRONT SEAL 549
REMOVAL AND INSTALLATION 549
ENGINE REAR SEAL 550
REMOVAL AND INSTALLATION 550
ENGINE AFTERCOOLER 553
REMOVAL AND INSTALLATION 553
ENGINE, MAIN PUMP 554
REMOVAL 554
INSTALLATION 556
DAMPER 557
REMOVAL AND INSTALLATION 557
RADIATOR, HYDRAULIC COOLER 558
REMOVAL 558
INSTALLATION 559
FUEL TANK 560
REMOVAL AND INSTALLATION 560
FINAL DRIVE 561
REMOVAL AND INSTALLATION 561
RECOIL SPRING 569
DISASSEMBLY AND ASSEMBLY 569
IDLER 571
DISASSEMBLY AND ASSEMBLY 571
TRACK ROLLER 574
DISASSEMBLY 574
ASSEMBLY 575
CARRIER ROLLER 577
DISASSEMBLY 577
ASSEMBLY 578
TRACK SHOE 580
REMOVAL AND INSTALLATION 580
HYDRAULIC TANK 581
REMOVAL 581
INSTALLATION 582
MAIN PUMP 583
REMOVAL 583
INSTALLATION 584
PRESSURE REDUCING VALVE 585
DISASSEMBLY AND ASSEMBLY 585
TRAVEL JUNCTION VALVE 586
DISASSEMBLY AND ASSEMBLY 586
TRAVEL PPC VALVE 587
DISASSEMBLY 587
ASSEMBLY 588
CONTROL VALVE 589
REMOVAL 589
INSTALLATION 590
DISASSEMBLY AND ASSEMBLY 591
PRESSURE COMPENSATION VALVE 592
DISASSEMBLY AND ASSEMBLY 592
PUMP MERGE/DIVIDER VALVE 593
DISASSEMBLY AND ASSEMBLY 593
UNLOAD VALVE 594
DISASSEMBLY AND ASSEMBLY 594
SUCTION, SAFETY VALVE 595
DISASSEMBLY AND ASSEMBLY 595
MAIN RELIEF VALVE 596
DISASSEMBLY AND ASSEMBLY 596
CRUSHER MOTOR 597
REMOVAL AND INSTALLATION 597
FEEDER MOTOR 598
REMOVAL AND INSTALLATION 598
CONVEYOR MOTOR, MACHINERY MOTOR 599
REMOVAL AND INSTALLATION 599
DISASSEMBLY 600
ASSEMBLY 602
MUCK DISCHARGE CONVEYOR MOTOR 605
REMOVAL AND INSTALLATION 605
MAGNETIC SEPARATOR MOTOR 606
REMOVAL AND INSTALLATION 606
HYDRAULIC CYLINDER 607
DISASSEMBLY 607
ASSEMBLY 608
CRUSHER 610
DISASSEMBLY AND ASSEMBLY 610
FLYWHEEL COVER ASSEMBLY 611
REMOVAL AND INSTALLATION 611
V-SHEAVE COVER ASSEMBLY 611
REMOVAL AND INSTALLATION 611
CHEEK PLATE 612
FIXED JAW PLATE 613
TOGGLE PLATE 615
TOGGLE SEAT 619
FLYWEEL AND V-SHEAVE 621
REMOVAL AND INSTALLATION 621
SWING JAW ASSEMBLY 622
REMOVAL AND INSTALLATION 622
CRUSHER MAIN BEARING 623
REMOVAL 623
INSTALLATION 626
CRUSHER ASSEMBLY 629
REMOVAL 629
INSTALLATION 631
CRUSHER HOUSING 632
FEEDER ASSEMBLY 649
REMOVAL AND INSTALLATION 649
CONVEYOR BELT 650
REMOVAL 650
INSTALLATION 651
CONVEYOR HEAD PULLEY 652
REMOVAL AND INSTALLATION 652
CONVEYOR TAIL PULLEY 653
REMOVAL AND INSTALLATION 653
MUCK DISCHARGE CONVERYOR BELT 654
REMOVAL 654
INSTALLATION 655
MUCK DISCHARGE CONVERYOR HEAD PULLEY 656
REMOVAL AND INSTALLATION 656
MUCK DISCHARGE CONVERYOR TAIL PULLEY 657
REMOVAL AND INSTALLATION 657
MAGNETIC SEPARATOR ASSEMBLY 658
REMOVAL 658
INSTALLATION 659
90 OTHERS 660
Electrical circuit diagram (1/3) Serial number 1001 – 1066 661
Electrical circuit diagram (2/3) Serial number 1001 – 1066 662
Electrical circuit diagram (3/3) Serial number 1001 – 1066 663
Electrical circuit diagram (1/3) Serial number 1067 and up 664
Electrical circuit diagram (2/3) Serial number 1067 and up 665
Electrical circuit diagram (3/3) Serial number 1067 and up 666
Hydraulic circuit diagram Serial number 1001 – 1066 667
Hydraulic circuit diagram Serial number 1067 and up 668
DESCRIPTION:
Komatsu BR550JG-1 Mobile Crusher Shop Manual SEBM022504 – PDF DOWNLOAD
- MACHINE MODEL SERIAL NUMBER
BR550JG-1 1001 AND UP
Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
• Always wear safety glasses when hitting parts with a hammer.
Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.
5. Keep all tools in good condition and learn the correct way to use them.
PREPARATIONS FOR WORK:
7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
9. When disassembling or assembling, sup- port the machine with blocks, jacks or stands before starting work.
10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out.
Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit.
12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned.
Wait for the oil and water to cool before carrying out any work on the oil or water circuits.
13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (-) terminal first.
14. When raising heavy components, use a hoist or crane.
Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity.
Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hit- ting any other part. Do not work with any part still raised by the hoist or crane.
15. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
16. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires.
G.B 18/12/24
