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KOMATSU GALEO BR380JG-1 MOBILE CRUSHER OPERATION & MAINTENANCE MANUAL (SN:1001 & UP) KOMATSU GALEO BR380JG-1 – PDF DOWNLOAD
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- KOMATSU GALEO BR380JG-1 MOBILE CRUSHER OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:1001 & UP
- PUBLICATION NUMBER:SEAM059001T
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KOMATSU GALEO BR380JG-1 MOBILE CRUSHER OPERATION & MAINTENANCE MANUAL (SN:1001 & UP) KOMATSU GALEO BR380JG-1
KOMATSU GALEO BR380JG-1 MOBILE CRUSHER OPERATION & MAINTENANCE MANUAL (SN:1001 & UP) KOMATSU GALEO BR380JG-1 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU GALEO BR380JG-1 MOBILE CRUSHER OPERATION & MAINTENANCE MANUAL (SN:1001 & UP) KOMATSU GALEO BR380JG-1
- This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation and maintenance.
- If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu or your Komatsu distributor. If you sell the machine, be sure to give this manual to the new owners together with the machine.
- Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country.
- If there is any question about whether your product complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before operating the machine.
TABLE OF CONTENTS:
KOMATSU GALEO BR380JG-1 MOBILE CRUSHER OPERATION & MAINTENANCE MANUAL (SN:1001 & UP) KOMATSU GALEO BR380JG-1
COVER............................................................................ 1 FOREWORD......................................................................... 2 FOREWORD..................................................................... 3 SAFETY INFORMATION........................................................... 6 INTRODUCTION................................................................. 8 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE............................. 8 NECESSARY INFORMATION........................................................ 9 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE............. 9 ENGINE SERIAL NO. PLATE AND POSITION..................................... 9 POSITION OF SERVICE METER................................................ 10 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR................................ 10 CONTENTS......................................................................... 11 SAFETY........................................................................... 15 SAFETY....................................................................... 16 SAFETY LABELS................................................................ 19 POSITIONS OF SAFETY PICTOGRAMS........................................... 20 SAFETY LABELS............................................................ 21 GENERAL PRECAUTIONS.......................................................... 30 SAFETY RULES............................................................. 30 IF ABNORMALITIES ARE FOUND............................................... 30 CLOTHING AND PERSONAL PROTECTIVE ITEMS................................... 30 FIRE EXTINGUISHER AND FIRST AID KIT...................................... 30 SAFETY FEATURES.......................................................... 30 KEEP MACHINE CLEAN....................................................... 31 ON OPERATOR'S PLATFORM................................................... 31 ALWAYS APPLY LOCK WHEN LEAVING UPPER OPERATION DECK...................... 31 HANDRAILS AND STEPS...................................................... 32 MOUNTING AND DISMOUNTING................................................. 32 NO PEOPLE ON ATTACHMENTS................................................. 32 CRUSHING OR CUTTING PREVENTION........................................... 32 PREVENTION OF BURNS...................................................... 33 FIRE PREVENTION.......................................................... 33 ACTION IF FIRE OCCURS.................................................... 34 PRECAUTIONS FOR ATTACHMENTS.............................................. 34 UNAUTHORIZED MODIFICATION................................................ 34 SAFETY AT WORKSITE....................................................... 34 WORKING ON LOOSE GROUND.................................................. 35 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES................................... 35 ENSURE GOOD VISIBILITY................................................... 35 VENTILATION FOR ENCLOSED AREAS........................................... 36 CHECKING SIGNALMAN'S SIGNALS AND SIGNS................................... 36 BE CAREFUL ABOUT ASBESTOS DUST........................................... 36 PRECAUTIONS FOR OPERATION.................................................... 37 STARTING ENGINE.......................................................... 37 CHECKS BEFORE STARTING ENGINE........................................ 37 PRECAUTIONS WHEN STARTING............................................ 37 PRECAUTIONS IN COLD AREAS............................................ 38 OPERATION................................................................ 39 CHECKS BEFORE OPERATION.............................................. 39 PRECAUTIONS WHEN CHANGING DIRECTION.................................. 39 PRECAUTIONS WHEN TRAVELING........................................... 39 TRAVELING ON SLOPES.................................................. 40 OPERATIONS ON SLOPES................................................. 40 PRECAUTIONS WHILE IN OPERATION....................................... 40 OPERATE CAREFULLY ON SNOW............................................ 40 PARKING MACHINE...................................................... 41 CRUSHING OPERATION....................................................... 42 CHECKS AROUND MACHINE................................................ 42 TURN MODE SELECTOR SWITCH TO WORK POSITION........................... 42 ENSURE SAFETY WHILE OPERATING IN TANDEM WITH HYDRAULIC EXCAVATOR..... 43 CHECKS OF CRUSHER BEFORE STARTING OPERATION.......................... 43 PRECAUTIONS FOR CRUSHING WORK........................................ 43 EMERGENCY STOP TO WARD OFF DANGERS WHILE IN CRUSHING WORK............ 44 REMOVE FOREIGN MATERIAL FROM INSIDE CRUSHER.......................... 44 MAGNETIC SEPARATOR....................................................... 45 HYDRAULIC MAGNETIC SEPARATOR (HANGING TYPE).......................... 45 TRANSPORTATION........................................................... 46 LOADING AND UNLOADING................................................ 46 SHIPPING............................................................. 46 BATTERY.................................................................. 47 BATTERY HAZARD PREVENTION............................................ 47 STARTING WITH BOOSTER CABLE.......................................... 48 TOWING................................................................... 49 WHEN TOWING.......................................................... 49 PRECAUTIONS FOR MAINTENANCE.................................................. 50 WARNING TAG.............................................................. 50 KEEP WORK PLACE CLEAN AND TIDY........................................... 50 APPOINT LEADER WHEN WORKING WITH OTHERS.................................. 50 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE.............................. 50 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING....................... 51 PRECAUTIONS FOR CONVEYOR MAINTENANCE..................................... 51 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE OF FEEDER, CRUSHER............. 52 PROPER TOOLS............................................................. 52 PERSONNEL................................................................ 52 PRECAUTIONS WHEN MOUNTING, DISMANTLING AND STORING ATTACHMENTS........... 52 PRECAUTIONS FOR WORK UNDER MACHINE....................................... 52 NOISE.................................................................... 53 PRECAUTIONS WHEN USING HAMMER............................................ 53 REPAIR WELDING........................................................... 53 REMOVING BATTERY TERMINAL................................................ 53 PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION...... 53 DO NOT DISASSEMBLE RECOIL SPRING......................................... 54 PRECAUTIONS WITH HIGH-PRESSURE OIL....................................... 54 HANDLING HIGH-PRESSURE HOSES............................................. 54 WASTE MATERIAL........................................................... 54 COMPRESSED AIR........................................................... 55 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS............................ 55 OPERATION........................................................................ 56 GENERAL VIEW................................................................. 57 GENERAL VIEW OF MACHINE.................................................. 57 GENERAL VIEW OF CONTROLS AND GAUGES...................................... 58 EXPLANATION OF COMPONENTS.................................................... 62 MACHINE MONITOR.......................................................... 62 SWITCHES................................................................. 86 CONTROL LEVERS........................................................... 95 OPTION-RELATED SWITCHES.................................................. 96 CAP, COVER WITH LOCK..................................................... 98 REVOLVING WARNING LAMP...................................................100 ELECTRIC POWER TAKEOFF...................................................101 FUSIBLE LINK.............................................................103 CONTROLLERS..............................................................103 FUSE.....................................................................103 TOOL BOX.................................................................104 OPERATION....................................................................105 CHECK BEFORE STARTING ENGINE.............................................105 STARTING ENGINE..........................................................123 OPERATIONS AND CHECKS AFTER STARTING ENGINE..............................127 STOPPING ENGINE..........................................................132 CHECK AFTER STOPPING ENGINE..............................................132 MACHINE OPERATION........................................................133 STEERING MACHINE.........................................................139 OPERATION OF WORK EQUIPMENT..............................................141 CHECK AND CONFIRMATION OF JAW CRUSHER AFTER WORK.........................150 CHECK AFTER FINISHING WORK...............................................150 LOCKING..................................................................151 RUN-IN OPERATION OF JAW CRUSHER..........................................152 PRECAUTIONS WHEN OPERATING JAW CRUSHER...................................154 SCOPE OF WORKS USING MOBILE CRUSHER......................................162 PROHIBITIONS FOR OPERATION...............................................170 PRECAUTIONS WHEN TRAVELING UP OR DOWNHILLS...............................172 TRANSPORTATION...............................................................173 TRANSPORTATION PROCEDURE.................................................173 LOADING, UNLOADING WORK..................................................173 LIFTING MACHINE..........................................................179 COLD WEATHER OPERATION.......................................................180 PRECAUTIONS FOR LOW TEMPERATURE..........................................180 AFTER COMPLETION OF WORK.................................................182 AFTER COLD WEATHER.......................................................183 LONG-TERM STORAGE............................................................184 BEFORE STORAGE...........................................................184 DURING STORAGE...........................................................184 AFTER STORAGE............................................................184 STARTING MACHINE AFTER LONG-TERM STORAGE.................................184 TROUBLESHOOTING..............................................................185 AFTER RUNNING OUT OF FUEL................................................185 PHENOMENA THAT ARE NOT FAILURES..........................................185 METHOD OF TOWING MACHINE.................................................185 IF BATTERY IS DISCHARGED.................................................186 OTHER TROUBLE............................................................189 MAINTENANCE......................................................................198 GUIDES TO MAINTENANCE........................................................199 OUTLINE OF SERVICE...........................................................201 HANDLING AND PERFORMANCE OF OIL CLINIC FOR OIL, FUEL, COOLANT............201 RELATING TO ELECTRIC SYSTEM..............................................204 OUTLINE OF HYDRAULIC EQUIPMENT...........................................204 AIR-BLEEDING FROM HYDRAULIC CIRCUIT......................................205 WEAR PARTS...................................................................206 WEAR PARTS LIST..........................................................206 JAW CRUSHER RELATED PARTS................................................207 PRIMARY CONVEYOR RELATED PARTS...........................................209 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.........210 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...............................214 CRUSHER ACCESSORY TOOLS..................................................214 TORQUE LIST..............................................................216 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................................217 SAFETY CRITICAL PARTS....................................................217 MAINTENANCE SCHEDULE CHART...................................................218 MAINTENANCE SCHEDULE CHART...............................................218 SERVICE PROCEDURE............................................................220 INITIAL 250 HOURS SERVICE (FIRST MAINTENANCE FOR NEW MACHINE ONLY).......220 INITIAL 1000 HOURS SERVICE (FIRST MAINTENANCE FOR NEW MACHINE ONLY)......220 WHEN REQUIRED............................................................221 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT.........................221 CLEAN INSIDE OF COOLING SYSTEM.......................................226 CHECK AND TIGHTEN TRACK SHOE BOLT....................................228 CHECK AND ADJUST TRACK TENSION.......................................229 INSPECTION OF ELECTRIC HEATER........................................231 CHECK AND ADJUSTMENT OF JAW CRUSHER..................................232 CHECK AND ADJUSTMENT OF PRIMARY CONVEYOR.............................253 INSPECTION AND MAINTENANCE OF MAGNETIC SEPARATOR.....................258 METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT..........260 CHECK BEFORE STARTING....................................................262 EVERY 100 HOURS SERVICE..................................................263 GREASING CRUSHER BEARING SEAT........................................263 GREASING PRIMARY CONVEYOR............................................264 EVERY 250 HOURS SERVICE..................................................265 CHECK LEVEL OF BATTERY ELECTROLYTE...................................265 CHECK AND ADJUSTMENT OF JAW CRUSHER V-BELT...........................267 CHECK OF OIL LEVEL IN CRUSHER MOTOR BEARING CASE AND ADDING OIL......267 EVERY 500 HOURS SERVICE..................................................268 REPLACE FUEL FILTER CARTRIDGE........................................268 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.........................269 CLEAN, INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS......270 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE....271 REPLACE HYDRAULIC TANK BREATHER ELEMENT..............................272 GREASE CRUSHER LINK..................................................272 EVERY 1000 HOURS SERVICE.................................................273 CHANGE OF OIL IN CRUSHER MOTOR BEARING CASE..........................273 CHANGE OF OIL IN GRIZZLY FEEDER VIBRATOR CASE........................273 CHANGE OIL IN DAMPER CASE............................................274 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER...........................274 CHECK PLAY OF TURBOCHARGER ROTOR.....................................274 CHECK AND REPLACE OF FAN BELT TENSION................................274 REPLACE HYDRAULIC FILTER ELEMENT.....................................275 EVERY 2000 HOURS SERVICE.................................................276 CHANGE OIL IN FINAL DRIVE CASE.......................................276 CLEAN HYDRAULIC TANK STRAINER........................................277 CLEAN, CHECK TURBOCHARGER............................................277 CHECK ALTERNATOR, STARTING MOTOR.....................................277 CHECK ENGINE VALVE CLEARANCE, ADJUST.................................277 CHECK VIBRATION DAMPER...............................................277 EVERY 4000 HOURS SERVICE.................................................278 CHECK WATER PUMP.....................................................278 EVERY 5000 HOURS SERVICE.................................................279 CHANGE OIL IN HYDRAULIC TANK AND CLEAN STRAINER......................279 SPECIFICATIONS...................................................................280 SPECIFICATIONS...............................................................281 ATTACHMENTS, OPTIONS.............................................................283 GENERAL PRECAUTIONS..........................................................284 PRECAUTIONS RELATED TO SAFETY............................................284 ATTACHMENTS, OPTIONS.........................................................285 ATTACHMENTS, OPTIONS CHART...............................................285 METHOD FOR CONNECTING HYDRAULIC HOSES FOR OPTIONS........................285 RADIO CONTROL UNIT...........................................................286 ON USE OF RADIO CONTROL UNIT.............................................286 DIRECTIONS FOR USE.......................................................289 REMOTE CONTROL OPERATION.................................................293 MUCK DISCHARGE CONVEYOR......................................................302 PROCEDURE FOR RAISING (BENDING) MUCK DISCHARGE CONVEYOR..................302 PROCEDURE FOR LOWERING MUCK DISCHARGE CONVEYOR...........................304 GREASING MUCK DISCHARGE CONVEYOR.........................................305 CHECK AND ADJUSTMENT OF MUCK DISCHARGE CONVEYOR..........................306 FAILURES AND CORRECTIVE ACTIONS..........................................308 WEARING PARTS............................................................310 SPECIFICATIONS...........................................................311 M-TYPE CHUTE.................................................................312 METHOD OF OPERATION......................................................312 BELT CONVEYOR PROTECTIVE PLATE...............................................313 GRIZZLY BAR OPENING..........................................................315 MACHINES THAT CAN INSTALL ATTACHMENTS........................................316 NAMES OF CONTROL PANEL SWITCHES..........................................316 HYDRAULIC POWER TAKEOFF PORT.............................................316 PROCEDURE FOR CONNECTING OPTIONS.........................................317 HYDRAULIC VIBRATORY SIEVE....................................................318 SPECIFICATION............................................................318 GENERAL VIEW.............................................................318 CAUTIONS TO BE NOTED FOR SAFETY..........................................319 CONNECTING METHOD TO MACHINE BODY........................................319 PRECAUTIONS DURING OPERATION.............................................319 HYDRAULIC SECONDARY CONVEYOR.................................................320 SPECIFICATIONS...........................................................320 GENERAL VIEW.............................................................320 INCLINED LEG CONNECTING METHOD...........................................322 LIFTING METHOD...........................................................323 CONNECTING METHOD TO MACHINE BODY........................................323 PRECAUTIONS ON OPERATION.................................................323 INSPECTION, MAINTENANCE AND ADJUSTMENT...................................324 TROUBLES AND CORRECTIVE ACTIONS..........................................326 CONSUMABLE PARTS OF HYDRAULIC SECONDARY CONVEYOR.........................328 INDEX............................................................................330
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