Komatsu BR580JG-1 Mobile Crusher Shop Manual SEN02602-07 – Serial 1001 and Up

Description

Komatsu BR580JG-1 Mobile Crusher Shop Manual SEN02602-07 – Serial 1001 and Up

The Komatsu BR580JG-1 Mobile Crusher Shop Manual SEN02602-07 – Serial 1001 and Up is a workshop-focused technical reference for the BR580JG-1 mobile crusher from serial number 1001 and up. Across 1,076 PDF pages, it brings together machine specifications, structure and function information, maintenance standards, standard service values, testing and adjustment procedures, troubleshooting, component removal and installation, disassembly and assembly, and hydraulic and electrical diagrams. The manual is organized around the machine’s major systems so a technician can move from understanding how a circuit or component works to checking its condition, measuring performance, diagnosing a fault, and carrying out the required service work.

File Details

• Manual type: Shop Manual
• Brand / model: Komatsu BR580JG-1 mobile crusher
• Serial coverage: 1001 and up
• Manual form: SEN02602-07
• Language: English
• Page count: 1,076 pages
• File format: PDF

Machine Coverage and Technical Depth

This BR580JG-1 shop manual identifies the machine with the SAA6D125E-5 engine and includes technical data for the crusher, feeder, hopper, undercarriage, hydraulic equipment, travel system, conveyors, electrical controls and monitoring systems. The specification section records an operating weight of 49,000 kg, the KCJ4430 single-toggle jaw crusher with nominal dimensions of 1,120 × 700 mm, a two-level grizzly feeder, and the machine’s principal transport and working dimensions. It also provides engine data, hydraulic pump information, component weights, and a fuel, coolant and lubricant section with reservoir capacities.

The service material goes substantially beyond a specifications sheet. Structure and function chapters explain components such as the final drive, track frame, hydraulic pump, control valve, CLSS, crusher and feeder motors, travel motor, solenoid and EPC valves, jaw crusher equipment, machine monitor and controllers. Maintenance-standard pages give dimensional criteria, clearances, wear limits and repair limits for components such as the final drive, sprocket, idler, track rollers and track shoes. This makes the Komatsu BR580JG-1 Mobile Crusher Shop Manual SEN02602-07 – Serial 1001 and Up useful when inspection results need to be compared with stated service criteria rather than judged by appearance alone.

Chapters Covered

• 00 Index and foreword
  • Shop manual composition and table of contents
  • Safety notice and workshop precautions
  • How to read the shop manual and maintenance-standard terminology
  • Handling electrical equipment, hydraulic components and engine connectors
  • Electric wire codes, push-pull couplers and operation precautions
  • Standard tightening torque and conversion tables
• 01 Specification
  • Specification dimension drawings
  • Machine specifications and technical data
  • Component weight table
  • Fuel, coolant and lubricant information
• 10 Structure, function and maintenance standard
  • Engine mounting, damper, radiator, oil cooler and aftercooler
  • Power train, component drive system, final drive and sprocket
  • Track frame, recoil spring, idler, guide plate, track roller and track shoe
  • Hydraulic piping, tank, filter and HPV160+160 hydraulic pump
  • Control valve, self pressure reducing valve and CLSS
  • Crusher, grizzly feeder, conveyor and travel hydraulic motors
  • Valve control, solenoid valves, EPC valves and hydraulic cylinders
  • Grizzly feeder systems, primary conveyor, crusher and tooth-tip adjustment
  • Engine control, work equipment and pump controller, machine monitor, sensors and KOMTRAX
• 20 Standard value table
  • Engine standard service values
  • Chassis standard service values
  • Performance checks for travel, work equipment and hydraulic pump
• 30 Testing and adjusting
  • Testing tools and measurement procedures
  • Engine speed, boost pressure, exhaust temperature, compression, blow-by and oil pressure
  • Fuel pressure, return rate, leakage checks and fuel-circuit air bleeding
  • Valve clearance, fan belt and alternator belt adjustment
  • Track tension and travel deviation checks
  • Work and travel hydraulic pressure, control pressure, PC and LS circuit pressure
  • Solenoid valve and PPC valve output-pressure checks
  • Jaw crusher, outlet clearance and crusher drive V-belt adjustment
  • Primary conveyor, magnetic separator and muck discharge conveyor checks
  • Machine-monitor special functions, KOMTRAX preparation and diode testing
• 40 Troubleshooting
  • Failure-code table and fuse locations
  • Troubleshooting sequence, preliminary checks and connector information
  • Failure-code diagnosis across crusher, conveyor, feeder, sensors, controllers and engine circuits
  • Electrical-system troubleshooting in E-mode
  • Hydraulic and mechanical troubleshooting in H-mode
  • Engine troubleshooting in S-mode
• 50 Disassembly and assembly
  • General procedures, coating materials and special tools
  • Engine and cooling-system component removal and installation
  • Final drive removal, installation, disassembly and assembly
  • Track roller, idler, recoil spring, sprocket and track-shoe work
  • Hydraulic tank, pump, control valve and hydraulic-motor service
  • Crusher lock cylinder and conveyor/feeder/magnetic-separator motor work
  • Cheek plates, fixed tooth, swing tooth, toggle plate and fixing link
  • Swing jaw, crusher main bearing, crusher motor, V-sheaves and balance weight
  • Crusher assembly and primary belt conveyor removal and installation
  • Muck discharge conveyor and magnetic separator procedures where equipped
  • Engine controller and work equipment/pump controller removal and installation
• 90 Diagrams and drawings
  • Hydraulic circuit diagrams
  • Electrical circuit diagrams
  • Connector arrangement diagrams

Taken together, these sections provide a continuous service path for the BR580JG-1: identify the correct machine and serial range, review system construction, compare measurements with service values, follow testing procedures, isolate faults through dedicated troubleshooting modes and failure codes, then use the relevant removal, installation, disassembly or assembly instructions. Hydraulic and electrical drawings support circuit tracing when a problem extends beyond a single component.

Testing, Diagnosis and Adjustment

A major part of this Komatsu BR580JG-1 shop manual is devoted to measurement rather than simple component identification. Engine checks include speed, intake-air pressure, exhaust temperature, exhaust-gas color, valve clearance, compression pressure, blow-by pressure, engine-oil pressure and fuel-system checks. Hydraulic testing covers work-equipment and travel circuits, control-circuit basic pressure, pump PC and LS control pressures, solenoid output pressure, PPC output pressure and oil leakage. The manual also explains air-bleeding procedures and travel-deviation testing.

Crusher-specific adjustment information includes checking and adjusting the jaw crusher, outlet clearance and crusher-drive V-belt tension. The primary conveyor, magnetic separator and muck discharge conveyor also receive dedicated inspection or adjustment coverage. Standard-value tables provide reference values and permissible values under stated measurement conditions, including travel speed, travel deviation, crusher speed, feeder vibration, conveyor belt speed and hydraulic-pump performance. For fault finding, the manual separates electrical problems, hydraulic/mechanical problems and engine symptoms into dedicated troubleshooting paths, while extensive fault-code sections address specific circuit and controller abnormalities.

Removal, Installation and Component Service

The disassembly and assembly portion is especially useful when diagnosis leads to physical repair. General instructions explain special-tool notation, removal and installation conventions, coating materials, tightening-torque symbols, drained and refill quantities, component weights and workshop precautions. Procedures then cover major machine assemblies and systems.

Engine-area work includes the fuel supply pump, injectors, front and rear seals, cylinder head, engine and hydraulic pump assembly, radiator, oil cooler, aftercooler and fuel tank. Power-train and undercarriage procedures include the final drive, track rollers, idlers, recoil spring, sprocket, guide plate and track shoe. Hydraulic work covers the tank, pump, control valve, crusher motor, lock cylinder and conveyor or feeder motors. The work-equipment section reaches into the jaw crusher itself, including cheek plates, fixed and swing teeth, toggle plate, fixing link, swing jaw assembly, crusher main bearing, crusher motor and housing, V-sheaves, crusher assembly and conveyor assemblies. The crusher assembly removal procedure includes dedicated lifting and disconnection steps, reflecting the scale of the machine and the need to follow the manual’s stated precautions.

Diagrams for Hydraulic and Electrical Work

The final diagram section adds hydraulic circuit drawings, multi-sheet electrical circuit drawings and connector arrangement information. These drawings complement the troubleshooting and structure sections by showing how pumps, valves, motors, sensors, switches and controllers connect across the BR580JG-1. When diagnosing a no-travel condition, crusher or feeder control problem, abnormal sensor indication, hydraulic performance issue or electrical fault code, the circuit information can be used alongside the diagnostic steps and standard values rather than as an isolated schematic.

Service the BR580JG-1 with the Correct Technical Reference

The Komatsu BR580JG-1 Mobile Crusher Shop Manual SEN02602-07 – Serial 1001 and Up supports a wide range of workshop jobs: specification checks, maintenance-standard inspections, hydraulic and electrical diagnosis, engine and chassis testing, crusher and conveyor adjustment, component removal and installation, and detailed machine disassembly and assembly. Having the stated procedures, service values, torque guidance, wear criteria and circuit diagrams together matters when repairs need to be planned and checked against the machine’s documented requirements.

After payment, the manual is delivered instantly as a PDF with no shipping delay. It can be opened on a computer, tablet or phone and printed whenever a paper reference is useful at the machine or in the workshop.