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Komatsu GALEO BR380JG-1 Mobile Crusher Operation & Maintenance Manual TEN00006-03 – PDF DOWNLOAD
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Komatsu GALEO BR380JG-1 Mobile Crusher Operation & Maintenance Manual
Book Code :TEN00006-03
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Description
Komatsu GALEO BR380JG-1 Mobile Crusher Operation & Maintenance Manual
TABLE OF CONTENTS:
Komatsu GALEO BR380JG-1 Mobile Crusher Operation & Maintenance Manual
COVER............................................................................................ 1 FOREWORD......................................................................................... 2 FOREWORD..................................................................................... 3 SAFETY INFORMATION........................................................................... 6 INTRODUCTION................................................................................. 8 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE............................................. 8 BREAKING IN THE NEW 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 OF 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.......................................................................... 29 SAFETY RULES............................................................................. 29 IF ABNORMALITIES ARE FOUND............................................................... 29 CLOTHING AND PERSONAL PROTECTIVE ITEMS................................................... 29 FIRE EXTINGUISHER AND FIRST AID KIT...................................................... 29 SAFETY FEATURES.......................................................................... 29 KEEP MACHINE CLEAN....................................................................... 30 ON OPERATOR'S PLATFORM................................................................... 30 ALWAYS APPLY LOCK WHEN LEAVING UPPER OPERATOR'S PLATFORM................................. 30 HANDRAILS AND STEPS...................................................................... 31 PRECAUTIONS WHEN WORKING IN HIGH PLACES.................................................. 31 MOUNTING AND DISMOUNTING................................................................. 31 NO PEOPLE ON ATTACHMENTS................................................................. 31 CRUSHING OR CUTTING PREVENTION........................................................... 31 PREVENTION OF BURNS...................................................................... 32 FIRE PREVENTION.......................................................................... 32 ACTION IF FIRE OCCURS.................................................................... 33 PRECAUTIONS FOR ATTACHMENTS.............................................................. 33 UNAUTHORIZED MODIFICATION................................................................ 33 SAFETY AT WORKSITE....................................................................... 33 WORKING ON LOOSE GROUND.................................................................. 34 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES................................................... 34 ENSURE GOOD VISIBILITY................................................................... 34 VENTILATION FOR ENCLOSED AREAS........................................................... 35 CHECKING SIGNALMAN'S SIGNALS AND SIGNS................................................... 35 BE CAREFUL ABOUT ASBESTOS DUST........................................................... 35 MAGNETIC SEPARATOR....................................................................... 36 PRECAUTIONS FOR OPERATION.................................................................... 37 STARTING ENGINE.......................................................................... 37 CHECKS BEFORE STARTING ENGINE........................................................ 37 PRECAUTIONS WHEN STARTING............................................................ 37 PRECAUTIONS IN COLD AREAS............................................................ 37 OPERATION................................................................................ 39 CHECK 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 TRANSPORTATION........................................................................... 45 LOADING AND UNLOADING................................................................ 45 SHIPPING............................................................................. 45 BATTERY.................................................................................. 46 BATTERY HAZARD PREVENTION............................................................ 46 STARTING WITH BOOSTER CABLE.......................................................... 47 TOWING................................................................................... 48 WHEN TOWING.......................................................................... 48 PRECAUTIONS FOR MAINTENANCE.................................................................. 49 WARNING TAG.............................................................................. 49 KEEP WORK PLACE CLEAN AND TIDY........................................................... 49 APPOINT LEADER WHEN WORKING WITH OTHERS.................................................. 49 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE............................... 49 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING....................................... 50 PRECAUTIONS FOR CONVEYOR MAINTENANCE..................................................... 50 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE OF FEEDER, CRUSHER............................. 51 PROPER TOOLS............................................................................. 51 PERSONNEL................................................................................ 51 PRECAUTIONS WHEN MOUNTING, DISMANTLING AND STORING ATTACHMENTS........................... 51 PRECAUTIONS FOR WORK UNDER MACHINE....................................................... 51 NOISE.................................................................................... 52 PRECAUTIONS WHEN USING HAMMER............................................................ 52 REPAIR WELDING........................................................................... 52 REMOVING BATTERY TERMINAL................................................................ 52 PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION...................... 52 DO NOT DISASSEMBLE RECOIL SPRING......................................................... 53 PRECAUTIONS WITH HIGH-PRESSURE OIL....................................................... 54 HANDLING HIGH-PRESSURE HOSES............................................................. 54 WASTE MATERIAL........................................................................... 54 COMPRESSED AIR........................................................................... 54 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................................................................................. 87 CONTROL LEVERS........................................................................... 96 OPTION-RELATED SWITCHES.................................................................. 97 CAP, COVER WITH LOCK..................................................................... 99 REVOLVING WARNING LAMP...................................................................101 ELECTRIC POWER TAKEOFF...................................................................102 FUSIBLE LINK.............................................................................104 CONTROLLERS..............................................................................104 FUSE.....................................................................................104 TOOL BOX.................................................................................105 OPERATION....................................................................................106 CHECK BEFORE STARTING ENGINE.............................................................106 STARTING ENGINE..........................................................................125 OPERATIONS AND CHECKS AFTER STARTING ENGINE..............................................129 STOPPING ENGINE..........................................................................134 CHECK AFTER STOPPING ENGINE..............................................................134 MACHINE OPERATION........................................................................135 STEERING MACHINE.........................................................................141 OPERATION OF WORK EQUIPMENT..............................................................143 CHECK AND CONFIRMATION OF JAW CRUSHER AFTER WORK.........................................152 CHECK AFTER FINISHING WORK...............................................................152 LOCKING..................................................................................153 RUN-IN OPERATION OF JAW CRUSHER..........................................................154 PRECAUTIONS WHEN OPERATING JAW CRUSHER...................................................156 EFFICIENT USE OF JAW CRUSHER.............................................................160 SCOPE OF WORKS USING MOBILE CRUSHER......................................................166 PROHIBITIONS FOR OPERATION...............................................................174 PRECAUTIONS WHEN TRAVELING UP OR DOWNHILLS...............................................176 TRANSPORTATION...............................................................................177 TRANSPORTATION PROCEDURE.................................................................177 LOADING, UNLOADING WORK..................................................................177 LIFTING MACHINE..........................................................................183 COLD WEATHER OPERATION.......................................................................184 PRECAUTIONS FOR LOW TEMPERATURE..........................................................184 AFTER COMPLETION OF WORK.................................................................186 AFTER COLD WEATHER.......................................................................186 LONG-TERM STORAGE............................................................................187 BEFORE STORAGE...........................................................................187 DURING STORAGE...........................................................................187 AFTER STORAGE............................................................................187 STARTING MACHINE AFTER LONG-TERM STORAGE.................................................187 TROUBLESHOOTING..............................................................................188 AFTER RUNNING OUT OF FUEL................................................................188 PHENOMENA THAT ARE NOT FAILURES..........................................................188 METHOD OF TOWING MACHINE.................................................................189 IF BATTERY IS DISCHARGED.................................................................190 OTHER TROUBLE............................................................................193 MAINTENANCE......................................................................................202 GUIDE TO MAINTENANCE.........................................................................203 OUTLINE OF SERVICE...........................................................................205 HANDLING AND PERFORMANCE OF OIL CLINIC FOR OIL, FUEL, COOLANT............................205 RELATING TO ELECTRIC SYSTEM..............................................................208 OUTLINE OF HYDRAULIC EQUIPMENT...........................................................208 AIR-BLEEDING FROM HYDRAULIC CIRCUIT......................................................209 WEAR PARTS...................................................................................210 WEAR PARTS LIST..........................................................................210 JAW CRUSHER RELATED PARTS................................................................211 PRIMARY CONVEYOR RELATED PARTS...........................................................213 RECOMMENDED FUEL, COOLANT AND LUBRICANTS.....................................................214 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....216 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...............................................217 CRUSHER ACCESSORY TOOLS..................................................................217 TORQUE LIST..............................................................................219 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................................................220 SAFETY CRITICAL PARTS....................................................................220 MAINTENANCE SCHEDULE CHART...................................................................221 MAINTENANCE SCHEDULE CHART...............................................................221 SERVICE PROCEDURE............................................................................223 INITIAL 250 HOURS SERVICE (FIRST MAINTENANCE FOR NEW MACHINE ONLY).......................223 INITIAL 1000 HOURS SERVICE (FIRST MAINTENANCE FOR NEW MACHINE ONLY)......................223 WHEN REQUIRED............................................................................224 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT.........................................224 CLEAN INSIDE OF COOLING SYSTEM.......................................................229 CHECK AND TIGHTEN TRACK SHOE BOLT....................................................232 CHECK AND ADJUST TRACK TENSION.......................................................233 INSPECTION OF ELECTRIC HEATER........................................................235 CHECK AND ADJUSTMENT OF JAW CRUSHER..................................................236 CHECK AND ADJUSTMENT OF PRIMARY CONVEYOR.............................................258 INSPECTION AND MAINTENANCE OF MAGNETIC SEPARATOR.....................................262 METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT..........................265 CHECK BEFORE STARTING....................................................................267 EVERY 10 HOURS SERVICE...................................................................268 GREASING CRUSHER BEARING SEAT........................................................268 GREASING CRUSHER LINK................................................................268 EVERY 100 HOURS SERVICE..................................................................269 GREASING CRUSHER LOCK CYLINDER SECURING POINT........................................269 GREASING PRIMARY CONVEYOR............................................................270 EVERY 250 HOURS SERVICE..................................................................271 CHECK LEVEL OF BATTERY ELECTROLYTE...................................................271 CHECK AND ADJUSTMENT OF JAW CRUSHER V-BELT...........................................274 CHECK OF OIL LEVEL IN CRUSHER MOTOR BEARING CASE AND ADDING OIL......................274 EVERY 500 HOURS SERVICE..................................................................275 REPLACE FUEL FILTER CARTRIDGE........................................................275 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.........................................276 CLEAN, INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS......................277 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE....................278 REPLACE HYDRAULIC TANK BREATHER ELEMENT..............................................279 EVERY 1000 HOURS SERVICE.................................................................280 CHANGE OF OIL IN CRUSHER MOTOR BEARING CASE..........................................280 CHANGE OF OIL IN GRIZZLY FEEDER VIBRATOR CASE........................................281 CHANGE OIL IN DAMPER CASE............................................................282 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER...........................................282 CHECK PLAY OF TURBOCHARGER ROTOR.....................................................282 CHECK AND REPLACE OF FAN BELT TENSION................................................282 REPLACE HYDRAULIC FILTER ELEMENT.....................................................283 EVERY 2000 HOURS SERVICE.................................................................284 CHANGE OIL IN FINAL DRIVE CASE.......................................................284 CLEAN HYDRAULIC TANK STRAINER........................................................285 CLEAN, CHECK TURBOCHARGER............................................................285 CHECK ALTERNATOR, STARTING MOTOR.....................................................285 CHECK ENGINE VALVE CLEARANCE, ADJUST.................................................285 CHECK VIBRATION DAMPER...............................................................285 EVERY 4000 HOURS SERVICE.................................................................286 CHECK WATER PUMP.....................................................................286 EVERY 5000 HOURS SERVICE.................................................................287 CHANGE OIL IN HYDRAULIC TANK AND CLEAN STRAINER......................................287 SPECIFICATIONS...................................................................................288 SPECIFICATIONS...............................................................................289 ATTACHMENTS, OPTIONS.............................................................................291 GENERAL PRECAUTIONS..........................................................................292 PRECAUTIONS RELATED TO SAFETY............................................................292 ATTACHMENTS, OPTIONS.........................................................................293 ATTACHMENTS, OPTIONS CHART...............................................................293 METHOD FOR CONNECTING HYDRAULIC HOSES FOR OPTIONS........................................293 RADIO CONTROL UNIT...........................................................................294 ON USE OF RADIO CONTROL UNIT.............................................................294 DIRECTIONS FOR USE.......................................................................297 REMOTE CONTROL OPERATION.................................................................301 MUCK DISCHARGE CONVEYOR......................................................................309 PROCEDURE FOR RAISING (BENDING) MUCK DISCHARGE CONVEYOR..................................309 PROCEDURE FOR LOWERING MUCK DISCHARGE CONVEYOR...........................................310 GREASING MUCK DISCHARGE CONVEYOR.........................................................313 CHECK AND ADJUSTMENT OF MUCK DISCHARGE CONVEYOR..........................................314 FAILURES AND CORRECTIVE ACTIONS..........................................................316 WEARING PARTS............................................................................318 SPECIFICATIONS...........................................................................319 M-TYPE CHUTE.................................................................................320 METHOD OF OPERATION......................................................................320 BELT CONVEYOR PROTECTIVE PLATE...............................................................321 GRIZZLY BAR OPENING..........................................................................323 HANDLING MACHINES EQUIPPED WITH KOMTRAX......................................................324 BASIC PRECAUTIONS........................................................................324 MACHINES THAT CAN INSTALL ATTACHMENTS........................................................325 NAMES OF CONTROL PANEL SWITCHES..........................................................325 HYDRAULIC POWER TAKEOFF PORT.............................................................325 ATTACHMENT PORT..........................................................................326 PROCEDURE FOR CONNECTING OPTIONS.........................................................327 HYDRAULIC VIBRATORY SIEVE....................................................................329 SPECIFICATION............................................................................329 GENERAL VIEW.............................................................................329 CAUTIONS TO BE NOTED FOR SAFETY..........................................................330 CONNECTING METHOD TO MACHINE BODY........................................................330 PRECAUTIONS DURING OPERATION.............................................................330 HYDRAULIC SECONDARY CONVEYOR.................................................................331 SPECIFICATIONS...........................................................................331 GENERAL VIEW.............................................................................331 INCLINED LEG CONNECTING METHOD...........................................................333 LIFTING METHOD...........................................................................334 CONNECTING METHOD TO MACHINE BODY........................................................334 PRECAUTIONS ON OPERATION.................................................................334 INSPECTION, MAINTENANCE AND ADJUSTMENT...................................................335 TROUBLES AND CORRECTIVE ACTIONS..........................................................337 CONSUMABLE PARTS OF HYDRAULIC SECONDARY CONVEYOR.........................................339 SPRINKLER....................................................................................341 EXPLANATIONS FOR COMPONENT PARTS.........................................................341 HOW TO USE SPRINKLER.....................................................................342 INSPECTION AND MAINTENANCE...............................................................345 INDEX............................................................................................347
KOMATSU GALEO BR380JG-1 MOBILE CRUSHER OPERATION & MAINTENANCE MANUAL TEN00006-03 – PDF DOWNLOAD:
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DESCRIPTION:
Komatsu GALEO BR380JG-1 Mobile Crusher Operation & Maintenance Manual
- 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.
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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