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Komatsu BR580JG-1 Mobile Crusher Shop Manual 1001 and up – PDF DOWNLOAD
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Description
Komatsu BR580JG-1 Mobile Crusher Shop Manual 1001 and up
FILE DETAILS:
Komatsu BR580JG-1 Mobile Crusher Shop Manual 1001 and up
Brands: Komatsu
Equipment Type: Mobile Crusher
Manuals Type: Shop Manual
Machine Model: BR580JG-1
Serial Number: 1001 and up
Book Code: SEN02602-05
Language: English
Pages: 1067
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu BR580JG-1 Mobile Crusher Shop Manual 1001 and up
HOW TO READ THE SHOP MANUAL:
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. FOREWORD:
This section explains the safety and basic information.
01. GENERAL:
This section explains the specifications of the machine.
10. STRUCTURE AND FUNCTION, MAINTENANCE STANDARD:
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. TESTING AND ADJUSTING:
Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in
the Chassis volume and Engine volume. In this case, see the Chassis volume.
30. DISASSEMBLY AND ASSEMBLY:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. OTHERS (chassis volume)/Repair and replacement of parts (engine volume):
• Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
• Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu BR580JG-1 Mobile Crusher Shop Manual 1001 and up
COVER............................................................................................................................ 1 00 Index and foreword............................................................................................................ 0 Index........................................................................................................................ 2 Composition of shop manual............................................................................................... 3 Table of contents........................................................................................................ 5 Foreword and general information............................................................................................. 14 Safety notice............................................................................................................ 15 How to read the shop manual.............................................................................................. 20 Explanation of terms for maintenance standard............................................................................ 22 Handling of electric equipment and hydraulic component................................................................... 24 Handling of connectors newly used for engines............................................................................ 33 How to read electric wire code........................................................................................... 36 Precautions when carrying out operation.................................................................................. 39 Method of disassembling and connecting push-pull type coupler............................................................ 42 Standard tightening torque table......................................................................................... 45 Conversion table......................................................................................................... 49 01 Specification................................................................................................................. 0 Specification and technical data............................................................................................. 56 Specification dimension drawings......................................................................................... 57 Specifications........................................................................................................... 58 Weight table............................................................................................................. 60 Table of fuel, coolant and lubricants.................................................................................... 61 10 Structure, function and maintenance standard.................................................................................. 0 Engine and cooling system.................................................................................................... 64 Engine mount, damper..................................................................................................... 65 Radiator, oil cooler and aftercooler..................................................................................... 66 Power train.................................................................................................................. 68 Power train.............................................................................................................. 69 Drive system for components.............................................................................................. 70 Final drive.............................................................................................................. 71 Sprocket................................................................................................................. 73 Undercarriage and frame...................................................................................................... 76 Track frame and recoil spring............................................................................................ 77 Idler.................................................................................................................... 79 Guide plate.............................................................................................................. 81 Track roller............................................................................................................. 82 Track shoe............................................................................................................... 83 Hydraulic system, Part 1..................................................................................................... 88 Hydraulic piping drawing................................................................................................. 89 Hydraulic tank and hydraulic oil filter.................................................................................. 90 Hydraulic pump........................................................................................................... 91 Hydraulic system, Part 2..................................................................................................... 116 Control valve............................................................................................................ 117 Self pressure reducing valve............................................................................................. 129 CLSS..................................................................................................................... 133 Functions and operation by valve......................................................................................... 137 Hydraulic system, Part 3..................................................................................................... 154 Crusher motor............................................................................................................ 155 Grizzly feeder motor..................................................................................................... 157 Conveyor motor........................................................................................................... 159 Travel motor............................................................................................................. 160 Valve control............................................................................................................ 171 Solenoid valve........................................................................................................... 181 8-spool EPC valve........................................................................................................ 183 Solenoid valve for travel................................................................................................ 187 PPC shuttle valve (if equipped).......................................................................................... 188 Electromagnetic selector valve........................................................................................... 189 Hydraulic cylinder....................................................................................................... 191 Work equipment............................................................................................................... 194 Grizzly feeder semiautomatic system...................................................................................... 195 Abnormal load stop system................................................................................................ 197 Primary belt conveyor.................................................................................................... 198 Grizzly feeder........................................................................................................... 201 Crusher.................................................................................................................. 204 Crusher tooth tip adjustment system...................................................................................... 208 Vibrator................................................................................................................. 211 Electrical system............................................................................................................ 214 Engine control........................................................................................................... 215 Work equipment and pump controller....................................................................................... 227 Electronic control system................................................................................................ 230 Machine monitor system................................................................................................... 244 Sensor................................................................................................................... 269 KOMTRAX system........................................................................................................... 272 20 Standard value table.......................................................................................................... 0 Standard service value table................................................................................................. 276 Standard value table for engine.......................................................................................... 277 Standard value table for chassis......................................................................................... 278 30 Testing and adjusting......................................................................................................... 0 Testing and adjusting, Part 1................................................................................................ 284 Tools for testing, adjusting and troubleshooting......................................................................... 286 Measuring engine speed................................................................................................... 289 Measuring intake air pressure (boost pressure)........................................................................... 290 Measuring exhaust temperature............................................................................................ 291 Checking exhaust gas color............................................................................................... 292 Adjusting valve clearance................................................................................................ 293 Measuring compression pressure........................................................................................... 295 Measuring blow-by pressure............................................................................................... 297 Measuring engine oil pressure............................................................................................ 298 Testing EGR valve and bypass valve drive oil pressure.................................................................... 299 Handling fuel system parts............................................................................................... 300 Releasing residual pressure from fuel system............................................................................. 300 Measuring fuel pressure.................................................................................................. 301 Handling during cylinder cut-out operation............................................................................... 302 Handling during no injection cranking operation.......................................................................... 302 Measuring fuel return rate and leakage................................................................................... 303 Bleeding air from fuel circuit........................................................................................... 306 Checking fuel circuit for leakage........................................................................................ 307 Checking and adjusting fan belt and alternator belt...................................................................... 308 Checking and adjusting track shoe tension................................................................................ 309 Measuring and adjusting oil pressure in work equipment and travel circuits............................................... 310 Measuring control circuit basic pressure................................................................................. 314 Measuring and adjusting oil pressure in pump PC control circuit.......................................................... 315 Measuring and adjusting oil pressure in pump LS control circuit.......................................................... 318 Measuring solenoid valve output pressure................................................................................. 322 Measuring PPC valve output pressure...................................................................................... 326 Measuring oil leakage.................................................................................................... 327 Bleeding air from each part.............................................................................................. 328 Testing travel deviation................................................................................................. 331 Adjusting mirrors........................................................................................................ 332 Testing and adjusting, Part 2................................................................................................ 336 Special functions of machine monitor..................................................................................... 337 Testing and adjusting, Part 3................................................................................................ 372 Check and adjustment of jaw crusher...................................................................................... 373 Check and adjustment of outlet clearance................................................................................. 375 Testing and adjusting tension of crusher drive V-belt.................................................................... 390 Check and adjustment of primary conveyor................................................................................. 391 Inspection and maintenance of magnetic separator......................................................................... 397 Check and adjustment of muck discharge conveyor.......................................................................... 399 List of companies which handles radio controllers........................................................................ 401 Handling voltage circuit of engine controller............................................................................ 402 Procedure for turning on KOMTRAX terminal................................................................................ 403 KOMTRAX terminal lamp indications........................................................................................ 406 Preparation work for troubleshooting for electrical system............................................................... 409 Procedure for testing diodes............................................................................................. 411 40 Troubleshooting............................................................................................................... 0 Failure code table and fuse locations........................................................................................ 414 Failure code table....................................................................................................... 415 Fuse locations........................................................................................................... 419 General information on troubleshooting....................................................................................... 422 Points to remember when troubleshooting.................................................................................. 423 Sequence of events in troubleshooting.................................................................................... 424 Checks before troubleshooting............................................................................................ 425 Classification and procedures of troubleshooting......................................................................... 427 Contents of troubleshooting table........................................................................................ 428 Connection table for connector pin numbers............................................................................... 433 T- branch box and T- branch adapter table................................................................................ 470 Troubleshooting by failure code, Part 1...................................................................................... 474 Failure code [7RC1KB] Short circuit conveyor ON switch................................................................... 477 Failure code [7RC2KA] Disconnection in conveyor OFF switch............................................................... 479 Failure code [7RC5KB] Short circuit in feeder ON switch.................................................................. 481 Failure code [7RD2KB] Short circuit in discharge conveyor reverse solenoid............................................... 483 Failure code [7RD2KZ] Disconnection or short circuit in discharge conveyor reverse solenoid.............................. 484 Failure code [7RE1KB] Short circuit in crusher ON switch................................................................. 485 Failure code [7RE2KA] Disconnection in crusher OFF switch................................................................ 487 Failure code [7RE6KB] Short circuit in muck discharge conveyor ON switch................................................. 489 Failure code [7RE7KA] Disconnection in muck discharge conveyor OFF switch................................................ 491 Failure code [7RE8KB] Short circuit in magnetic separator ON switch...................................................... 493 Failure code [7RE9KA] Disconnection in magnetic separator OFF switch..................................................... 495 Failure code [7REAKB] Short circuit in accessory input circuit 1......................................................... 497 Failure code [7REDMA] Abnormality in conveyor pressure sensor............................................................ 499 Failure code [7REEMA] Abnormality in muck conveyor pressure sensor....................................................... 501 Failure code [7REHKB] Short circuit in accessory input circuit 2......................................................... 503 Failure code [7RENKZ] Abnormality in clearance potentiometer............................................................. 505 Failure code [7REPKA] Disconnection in feeder OFF switch................................................................. 507 Failure code [7RESKB] Short circuit in one-touch start switch............................................................ 509 Failure code [7RETKA] Disconnection in one-touch stop switch............................................................. 511 Failure code [7RF2KA] Disconnection in crusher forward EPC valve......................................................... 513 Failure code [7RF2KB] Short circuit in crusher forward EPC valve......................................................... 514 Failure code [7RF2KY] Short circuit in crusher forward EPC valve......................................................... 515 Failure code [7RF3KA] Disconnection in crusher reverse EPC valve......................................................... 516 Failure code [7RF3KB] Short circuit in crusher reverse EPC valve......................................................... 517 Failure code [7RF3KY] Short circuit in crusher reverse EPC valve......................................................... 518 Failure code [7RF4KA] Disconnection in feeder forward EPC valve.......................................................... 519 Failure code [7RF4KB] Short circuit in feeder forward EPC valve.......................................................... 520 Failure code [7RF4KY] Short circuit in feeder forward EPC valve.......................................................... 521 Failure code [7RF8KA] Disconnection in accessory 2 EPC valve............................................................. 522 Failure code [7RF8KB] Short circuit in accessory 2 EPC valve............................................................. 523 Failure code [7RF8KY] Short circuit in accessory 2 EPC solenoid.......................................................... 524 Troubleshooting by failure code, Part 2...................................................................................... 526 Failure code [7RFAKY] Short circuit in engine stop relay................................................................. 529 Failure code [7RFAKZ] Disconnection or short circuit in engine stop relay................................................ 531 Failure code [7RFBKB] Short circuit in muck conveyor solenoid............................................................ 533 Failure code [7RFBKZ] Disconnection or short circuit in muck conveyor solenoid........................................... 534 Failure code [7RFHKA] Disconnection in conveyor forward EPC valve........................................................ 535 Failure code [7RFHKB] Short circuit in conveyor forward EPC valve........................................................ 536 Failure code [7RFHKY] Short circuit in conveyor forward EPC valve........................................................ 537 Failure code [7RFKKB] Short circuit in lock cylinder pull relay.......................................................... 539 Failure code [7RFKKY] Short circuit in lock cylinder pull relay.......................................................... 541 Failure code [7RFLKA] Disconnection in accessory 1 EPC solenoid.......................................................... 543 Failure code [7RFLKB] Short circuit in accessory 1 EPC solenoid.......................................................... 544 Failure code [7RFLKY] Short circuit in accessory 1 EPC solenoid.......................................................... 545 Failure code [7RFMKY] Short circuit in abnormal pressure relay........................................................... 547 Failure code [7RFMKZ] Disconnection or short circuit in abnormal pressure relay.......................................... 549 Failure code [7RFNKA] Disconnection in lock cylinder unlock solenoid valve............................................... 551 Failure code [7RFNKB] Short circuit in lock cylinder unlock solenoid valve............................................... 552 Failure code [7RFNKY] Short circuit in lock cylinder unlock solenoid valve............................................... 553 Failure code [7RFPKB] Short circuit in lock cylinder push relay.......................................................... 555 Failure code [7RFPKY] Short circuit in lock cylinder push relay.......................................................... 557 Failure code [7RGAMA] Abnormality in 2nd conveyor pressure sensor........................................................ 559 Failure code [7RJAKA] Disconnection in travel lock EPC solenoid valve.................................................... 561 Failure code [7RJAKB] Short circuit in travel lock EPC solenoid valve.................................................... 563 Failure code [7RJAKY] Short circuit in travel lock EPC solenoid valve.................................................... 565 Failure code [7RJDMA] Abnormality in crusher forward pressure sensor..................................................... 567 Failure code [7RJEMA] Abnormality in crusher reverse pressure sensor..................................................... 569 Failure code [7RJLKA] Disconnection in magnetic separator EPC valve...................................................... 571 Failure code [7RJLKB] Short circuit in magnetic separator EPC valve...................................................... 572 Failure code [7RJLKY] Short circuit in magnetic separator EPC valve...................................................... 573 Failure code [7RJMMW] Lock cylinder slipping............................................................................. 575 Failure code [7RJPKB] Short circuit in radio control work-mode switch.................................................... 577 Failure code [7RJQKB] Short circuit in radio control travel-mode switch.................................................. 579 Failure code [7RJRKB] Short circuit on travel signal..................................................................... 581 Failure code [7RJSMA] Abnormality in magnetic separator pressure sensor.................................................. 583 Failure code [AA10NX] Air cleaner Clogging............................................................................... 585 Failure code [AB00KE] Charge voltage too low............................................................................. 587 Troubleshooting by failure code, Part 3...................................................................................... 590 Failure code [B@BAZG] Engine oil pressure too low........................................................................ 592 Failure code [B@BAZK] Engine oil level reduction......................................................................... 593 Failure code [B@BCNS] Engine coolant overheat............................................................................ 594 Failure code [B@BCZK] Radiator coolant level reduction................................................................... 595 Failure code [B@HANS] Hydraulic Oil Overheat............................................................................. 596 Failure code [CA111] ECM Critical Internal Failure....................................................................... 597 Failure code [CA115] Eng Ne and Bkup Speed Sens Error.................................................................... 599 Failure code [CA122] Chg Air Press Sensor High Error..................................................................... 600 Failure code [CA123] Chg Air Press Sensor Low Error...................................................................... 602 Failure code [CA131] Throttle Sensor High Error.......................................................................... 603 Failure code [CA132] Throttle Sensor Low Error........................................................................... 605 Failure code [CA135] Eng Oil Press Sensor High Error..................................................................... 606 Failure code [CA141] Eng Oil Press Sensor Low Error...................................................................... 608 Failure code [CA144] Coolant Temp Sens High Error........................................................................ 609 Failure code [CA145] Coolant Temp Sens Low Error......................................................................... 611 Failure code [CA153] Chg Air Temp Sensor High Error...................................................................... 612 Failure code [CA154] Chg Air Temp Sensor Low Error....................................................................... 614 Failure code [CA187] Sens Supply 2 Volt Low Error........................................................................ 614 Failure code [CA221] Ambient Press Sens High Error....................................................................... 615 Failure code [CA222] Ambient Press Sens Low Error........................................................................ 617 Failure code [CA227] Sens Supply 2 Volt High Error....................................................................... 618 Failure code [CA234] Eng Overspeed....................................................................................... 620 Failure code [CA238] Ne Speed Sens Supply Volt Error..................................................................... 621 Failure code [CA263] Fuel Temp Sensor High Error......................................................................... 623 Failure code [CA265] Fuel Temp Sensor Low Error.......................................................................... 625 Failure code [CA273] PCV2 Short Error.................................................................................... 626 Failure code [CA274] PCV2 Open Error..................................................................................... 627 Failure code [CA322] Inj #1 (L#1) Open/Short Error....................................................................... 629 Failure code [CA323] Inj #5 (L#5) Open/Short Error....................................................................... 631 Failure code [CA324] Inj #3 (L#3) Open/Short Error....................................................................... 633 Failure code [CA325] Inj #6 (L#6) Open/Short Error....................................................................... 635 Failure code [CA331] Inj #2 (L#2) Open/Short Error....................................................................... 637 Failure code [CA332] Inj #4 (L#4) Open/Short Error....................................................................... 639 Troubleshooting by failure code, Part 4...................................................................................... 642 Failure code [CA342] Calibration Code Incompatibility.................................................................... 644 Failure code [CA351] INJ. Drive Circuit Error............................................................................ 645 Failure code [CA352] Sens Supply 1 Volt Low Error........................................................................ 647 Failure code [CA386] Sens Supply 1 Volt High Error....................................................................... 649 Failure code [CA441] Battery Voltage Low Error........................................................................... 651 Failure code [CA442] Battery Voltage High Error.......................................................................... 653 Failure code [CA449] Rail Press Very High Error.......................................................................... 654 Failure code [CA451] Rail Press Sensor High Error........................................................................ 655 Failure code [CA452] Rail Press Sensor Low Error......................................................................... 657 Failure code [CA553] Rail Press High Error............................................................................... 657 Failure code [CA554] Rail Press Sensor In Range Error.................................................................... 658 Failure code [CA559] Rail Press Low Error................................................................................ 659 Failure code [CA689] Eng Ne Speed Sensor Error........................................................................... 663 Failure code [CA731] Eng Bkup Speed Sens Phase Error..................................................................... 665 Failure code [CA757] All Persistent Data Lost Error...................................................................... 666 Failure code [CA778] Eng Bkup Speed Sensor Error......................................................................... 667 Failure code [CA1228] EGR Valve Servo Error 1............................................................................ 669 Failure code [CA1625] EGR Valve Servo Error 2............................................................................ 670 Failure code [CA1633] CAN Communication Error (engine controller)........................................................ 671 Failure code [CA2185] Throt Sens Sup Volt High Error..................................................................... 673 Failure code [CA2186] Throt Sens Sup Volt Low Error...................................................................... 675 Failure code [CA2249] Rail Press Very Low Error.......................................................................... 676 Failure code [CA2271] EGR Valve Lift Position Sens High Error............................................................ 677 Failure code [CA2272] EGR Valve Lift Position Sens Low Error............................................................. 679 Failure code [CA2351] EGR Valve Sol Current High Error................................................................... 680 Failure code [CA2352] EGR Valve Sol Current Low Error.................................................................... 682 Failure code [CA2555] Grid Heater Relay Open Error....................................................................... 683 Failure code [CA2556] Grid Heater Relay Short Error...................................................................... 685 Troubleshooting by failure code, Part 5...................................................................................... 688 Failure code [D162KY] Short circuit in horn relay........................................................................ 691 Failure code [D162KZ] Disconnection or short circuit in horn relay....................................................... 693 Failure code [DA22KK] Solenoid power source too low...................................................................... 695 Failure code [DA25KP] Abnormality in pressure sensor power source........................................................ 697 Failure code [DA2RMC] CAN communication error (work equipment and pump controller)....................................... 701 Failure code [DA2SKQ] Abnormality in model code input.................................................................... 703 Failure code [DAFRMC] CAN communication error (monitor controller)....................................................... 705 Failure code [DDA6KA] Disconnection in engine stop switch................................................................ 707 Failure code [DGH2KB] Short circuit in hydraulic oil temperature sensor.................................................. 709 Failure code [DHPAMA] Abnormality in F pump pressure sensor.............................................................. 711 Failure code [DHPBMA] Abnormality in R pump pressure sensor.............................................................. 713 Failure code [DUB0KY] Short circuit in beacon solid state relay.......................................................... 715 Failure code [DUB0KZ] Disconnection or short circuit in beacon solid state relay......................................... 717 Failure code [DXA0KA] Disconnection in PC-EPC Solenoid................................................................... 719 Failure code [DXA0KB] Short circuit in PC-EPC Solenoid................................................................... 720 Failure code [DXA0KY] Short circuit in PC-EPC Solenoid................................................................... 721 Failure code [DXE0KA] Disconnection in LS-EPC solenoid................................................................... 722 Failure code [DXE0KB] Short circuit in LS-EPC solenoid................................................................... 723 Failure code [DXE0KY] Short circuit in LS-EPC solenoid................................................................... 724 Troubleshooting of electrical system (E-mode)................................................................................ 726 Information in troubleshooting table..................................................................................... 728 E-1 Engine does not start (Engine does not turn)......................................................................... 729 E-2 The engine stops while it is running................................................................................. 733 E-3 Automatic warming-up does not operate................................................................................ 735 E-4 Preheater does not operate........................................................................................... 737 E-5 The whole work equipment stops suddenly.............................................................................. 739 E-6 The red mark of emergency stop is indicated just after the engine is started......................................... 743 E-7 The machine monitor does not display any item........................................................................ 747 E-8 Some items are not displayed on the machine monitor.................................................................. 749 E-9 Contents of display by machine monitor are different from applicable machine......................................... 749 E-10 Fuel level monitor was lighted in red while engine running.......................................................... 750 E-11 Engine coolant temperature gauge does not indicate normally......................................................... 751 E-12 The fuel level gauge does not display normally...................................................................... 753 E-13 The hydraulic oil temperature gauge does not display normally....................................................... 754 E-14 The travel, work, and inspection modes do not change................................................................ 755 E-15 The crusher clearance adjustment mode does not change............................................................... 757 E-16 The crusher rotation direction does not change...................................................................... 759 E-17 Machine does not travel............................................................................................. 761 E-18 Travel cannot be controlled by radio control........................................................................ 763 E-19 The feeder cannot be turned ON and OFF by radio control............................................................. 767 E-20 One-touch start, stop switch cannot be operated by radio control.................................................... 771 E-21 The monitor switches do not work.................................................................................... 774 E-22 The crusher cannot be operated with the crusher manual FORWARD/REVERSE switch on the monitor........................ 775 E-23 The conveyor cannot be operated with the conveyor manual FORWARD/REVERSE switch on the monitor...................... 776 E-24 KOMTRAX system does not operate normally............................................................................ 777 Troubleshooting of hydraulic and mechanical system (H-mode).................................................................. 780 System chart for hydraulic and mechanical systems........................................................................ 783 Information contained in troubleshooting table........................................................................... 785 H-1 The speed or power of the whole work equipment and travel is low..................................................... 787 H-2 The engine speed lowers extremely or the engine stalls............................................................... 789 H-3 The work equipment and travel systems do not work.................................................................... 790 H-4 Abnormal sound comes out from around the hydraulic pump.............................................................. 790 H-5 Fine control performance or response is low.......................................................................... 791 H-6 The conveyor does not operate........................................................................................ 792 H-7 The speed or power of the conveyor is low............................................................................ 793 H-8 The crusher does not operate......................................................................................... 794 H-9 The speed or power of crusher is low................................................................................. 795 H-10 The feeder does not operate......................................................................................... 795 H-11 The feeder does not feed smoothly (Vibration frequency is low)...................................................... 796 H-12 The magnetic separator does not operate............................................................................. 796 H-13 The speed of magnetic separator belt is low......................................................................... 797 H-14 The muck discharge conveyor does not operate........................................................................ 797 H-15 The speed or power of the muck discharge conveyor is low............................................................ 798 H-16 The primary conveyor does not move up and down...................................................................... 798 H-17 The muck discharge conveyor does not move up and down............................................................... 799 H-18 The open and close hopper does not move up and down................................................................. 800 H-19 The machine deviates during travel.................................................................................. 801 H-20 The travel speed is low............................................................................................. 803 H-21 The machine is not steered well or steering power is low............................................................ 805 H-22 The travel motor does not work (only one side)...................................................................... 806 H-23 When the travel switch of the wired remote control or radio controller is depressed, the machine does not travel.... 807 H-24 The crusher clearance cannot be adjusted............................................................................ 808 Troubleshooting of engine (S-mode)........................................................................................... 810 Method of using troubleshooting chart.................................................................................... 813 S-1 Starting performance is poor......................................................................................... 817 S-2 Engine does not start................................................................................................ 819 S-3 Engine does not pick up smoothly..................................................................................... 823 S-4 Engine stops during operations....................................................................................... 824 S-5 Engine does not rotate smoothly...................................................................................... 825 S-6 Engine lacks output (or lacks power)................................................................................. 826 S-7 Exhaust smoke is black (incomplete combustion)....................................................................... 827 S-8 Oil consumption is excessive (or exhaust smoke is blue).............................................................. 829 S-9 Oil becomes contaminated quickly..................................................................................... 830 S-10 Fuel consumption is excessive....................................................................................... 831 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)............................................... 832 S-12 Oil pressure drops.................................................................................................. 833 S-13 Oil level rises (Entry of coolant or fuel).......................................................................... 834 S-14 Coolant temperature becomes too high (overheating).................................................................. 836 S-15 Abnormal noise is made.............................................................................................. 837 S-16 Vibration is excessive.............................................................................................. 838 50 Disassembly and assembly...................................................................................................... 0 General information on disassembly and assembly.............................................................................. 840 How to read this manual.................................................................................................. 841 Coating materials list................................................................................................... 843 Special tool list........................................................................................................ 847 Sketches of special tools................................................................................................ 850 Engine and cooling system.................................................................................................... 854 Removal and installation of fuel supply pump assembly.................................................................... 855 Removal and installation of fuel injector assembly....................................................................... 859 Removal and installation of engine front seal............................................................................ 866 Removal and installation of engine rear seal............................................................................. 869 Removal and installation of cylinder head assembly....................................................................... 874 Removal and installation of engine and hydraulic pump assembly........................................................... 885 Removal and installation of radiator assembly............................................................................ 892 Removal and installation of hydraulic oil cooler assembly................................................................ 894 Removal and installation of aftercooler assembly......................................................................... 896 Removal and installation of fuel tank assembly........................................................................... 898 Power train.................................................................................................................. 902 Removal and installation of final drive assembly......................................................................... 903 Disassembly and assembly of final drive assembly......................................................................... 905 Undercarriage and frame...................................................................................................... 914 Disassembly and assembly of track roller assembly........................................................................ 915 Disassembly and assembly of idler assembly............................................................................... 916 Disassembly and assembly of recoil spring................................................................................ 919 Removal and installation of sprocket..................................................................................... 921 Repair of guide plate with wear plates................................................................................... 922 Spreading and installation of track shoe assembly........................................................................ 924 Hydraulic system............................................................................................................. 930 Removal and installation of hydraulic tank assembly...................................................................... 931 Removal and installation of hydraulic pump assembly...................................................................... 935 Removal and installation of control valve assembly....................................................................... 938 Disassembly and assembly of control valve assembly....................................................................... 945 Removal and installation of crusher motor assembly....................................................................... 949 Removal and installation of crusher lock cylinder assembly............................................................... 950 Disassembly and assembly of crusher lock cylinder assembly............................................................... 953 Bleeding air from crusher lock cylinder.................................................................................. 957 Removal and installation of primary belt conveyor motor.................................................................. 959 Removal and installation of feeder vibrator motor assembly............................................................... 962 Removal and installation of muck discharge conveyor motor assembly....................................................... 964 Removal and installation of magnetic separator motor assembly............................................................ 965 Work equipment............................................................................................................... 968 Removal and installation of cheek plates................................................................................. 970 Removal and installation of fixed tooth.................................................................................. 974 Removal and installation of swing tooth.................................................................................. 978 Removal and installation of toggle plate................................................................................. 983 Removal and installation of fixing link.................................................................................. 988 Removal and installation of swing jaw assembly........................................................................... 992 Removal and installation of crusher main bearing......................................................................... 995 Removal and installation of crusher motor and motor housing assembly.....................................................1000 Removal and installation of crusher motor V-sheave.......................................................................1002 Removal and installation of V-sheave and balance weight..................................................................1005 Removal and installation of potentiometer................................................................................1009 Removal and installation of fixing link lifting spring assembly..........................................................1010 Removal and installation of link pin dust cover..........................................................................1012 Removal and installation of crusher assembly.............................................................................1014 Removal and installation of primary belt conveyor assembly...............................................................1023 Removal and installation of primary belt conveyor head pulley frame......................................................1027 Removal and installation of muck discharge conveyor assembly (if equipped)...............................................1034 Removal and installation of muck discharge conveyor head pulley (if equipped)............................................1037 Removal and installation of muck discharge conveyor tail pulley (if equipped)............................................1042 Removal and installation of magnetic separator assembly..................................................................1044 Electrical system............................................................................................................1048 Removal and installation of engine controller assembly...................................................................1049 Removal and installation of work equipment and pump controller assembly..................................................1050 90 Diagrams and drawings......................................................................................................... 0 Hydraulic diagrams and drawings..............................................................................................1052 Hydraulic circuit diagram (1/2)..........................................................................................1054 Hydraulic circuit diagram (2/2)..........................................................................................1055 Electrical diagrams and drawings.............................................................................................1058 Electrical circuit diagram (1/4).........................................................................................1060 Electrical circuit diagram (2/4).........................................................................................1061 Electrical circuit diagram (3/4).........................................................................................1062 Electrical circuit diagram (4/4).........................................................................................1063 Connector arrangement diagram (1/2)......................................................................................1064 Connector arrangement diagram (2/2)......................................................................................1065
KOMATSU BR580JG-1 MOBILE CRUSHER SHOP MANUAL 1001 AND UP – PDF DOWNLOAD:
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