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Komatsu GALEO BR480RG-1 Mobile Crusher Operation & Maintenance Manual SN 1006 and up – PDF DOWNLOAD
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Komatsu GALEO BR480RG-1 Mobile Crusher Operation & Maintenance Manual
Book Code : SEAM047100T
SERIAL NUMBERS 1006 and up
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Description
Komatsu GALEO BR480RG-1 Mobile Crusher Operation & Maintenance Manual
TABLE OF CONTENTS:
Komatsu GALEO BR480RG-1 Mobile Crusher Operation & Maintenance Manual
COVER............................................................................................ 1 FOREWORD......................................................................................... 2 FOREWORD..................................................................................... 3 SAFETY INFORMATION........................................................................... 6 INTRODUCTION................................................................................. 8 FRONT/REAR,LEFT/RIGHT DIRECTIONS OF MAHCINE.............................................. 8 NECESSARY INFORMATION........................................................................ 9 MACHINE SERIAL NO. PLATE AND POSITION.................................................... 9 ENGINE SERIAL NO. PLATE AND POSITION..................................................... 9 POSITION OF SERVICE METER................................................................ 10 TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR................................................ 10 CONTENTS......................................................................................... 11 SAFETY........................................................................................... 14 SAFETY....................................................................................... 15 SAFETY LABELS................................................................................ 18 POSITIONS OF SAFETY PICTOGRAMS........................................................... 18 SAFETY LABELS............................................................................ 19 GENERAL PRECAUTIONS.......................................................................... 24 SAFETY RULES............................................................................. 24 IF ABNORMALITIES ARE FOUND............................................................... 24 CLOTHING AND PERSONAL PROTECTIVE ITEMS................................................... 24 FIRE EXTINGUISHER AND FIRST AID KIT...................................................... 24 SAFETY FEATURES.......................................................................... 24 KEEP MACHINE CLEAN....................................................................... 25 PRECAUTIONS TO BE FOLLOWED IN UPPER OPERATION DECK....................................... 25 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S PLATFROM....................................... 25 HANDRAILS AND STEPS...................................................................... 26 MOUNTING AND DISMOUNTING................................................................. 26 NO PEOPLE ON ATTACHMENTS................................................................. 27 CRUSHING OR CUTTING PREVENTION........................................................... 27 PREVENTION OF BURNS...................................................................... 27 FIRE PREVENTION.......................................................................... 28 ACTION IF FIRE OCCURS.................................................................... 28 PRECAUTIONS FOR ATTACHMENTS.............................................................. 29 UNAUTHORIZED MODIFICATION................................................................ 29 SAFETY AT WORKSITE....................................................................... 29 WORKING ON LOOSE GROUND.................................................................. 29 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES................................................... 30 ENSURE GOOD VISIBILITY................................................................... 30 VENTILATION FOR ENCLOSED AREAS........................................................... 31 CHECKING SIGNALMAN'S SIGNALS AND SIGNS................................................... 31 BE CAREFUR ABOUT ASBESTOS DUST........................................................... 31 PRECAUTIONS FOR OPERATION.................................................................... 32 STARTING ENGINE.......................................................................... 32 CHECKS BEFORE STARTING ENGINE........................................................ 32 PRECAUTIONS WHEN STARTING............................................................ 32 PRECAUTIONS IN COLD AREAS............................................................ 33 OPERATION................................................................................ 34 CHECK BEFORE OPERATION............................................................... 34 PRECAUTIONS WHEN CHANGING DIRECTION.................................................. 34 PRECAUTIONS WHEN TRAVELING........................................................... 34 TRAVELING ON SLOPES.................................................................. 35 OPERATIONS ON SLOPES................................................................. 35 PRECAUTIONS WHILE IN OPERATION....................................................... 35 OPERATE CAREFULLY ON SNOW............................................................ 35 PARKING MACHINE...................................................................... 36 CRUSHING OPERATION....................................................................... 37 CHECKS AROUND MACHINE................................................................ 37 TURN OPERATION MODE SELECTOR SWITCH TO WORK POSITION................................. 37 ENSURE SAFETY WHILE OPERATING IN TANDEM WITH HYDRAULIC EXCAVATOR..................... 37 CHECKS OF CRUSHER BEFORE STARTING OPERATION.......................................... 38 PRECAUTIONS FOR CRUSHING WORK........................................................ 38 EMERGENCY STOP TO WARD OFF DANGERS WHILE IN CRUSHING WORK............................ 40 TRANSPORTATION........................................................................... 41 LOADING AND UNLOADING................................................................ 41 SHIPPING............................................................................. 41 BATTERY.................................................................................. 42 BATTERY HAZARD PREVENTION............................................................ 42 STARTING WITH BOOSTER CABLE.......................................................... 43 TOWING................................................................................... 44 WHEN TOWING.......................................................................... 44 PRECAUTIONS FOR MAINTENANCE.................................................................. 45 WARNING TAG.............................................................................. 45 KEEP WORK PLACE CLEAN AND TIDY........................................................... 45 APPOINT LEADER WHEN WORKING WITH OTHERS.................................................. 45 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE............................... 45 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING....................................... 46 PRECAUTIONS FOR CONVEYOR MAINTENANCE..................................................... 46 PROPER TOOLS............................................................................. 47 PERSONNEL................................................................................ 47 PRECAUTIONS WHEN MOUNTING,DISMANTLING AND STORING ATTACHMENTS............................ 47 PRECAUTIONS FOR WORK UNDER MACHINE....................................................... 47 NOISE.................................................................................... 47 PRECAUTIONS WHEN USING HAMMER............................................................ 48 REPAIR WELDING........................................................................... 48 REMOVING BATTERY TERMINAL................................................................ 48 PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION...................... 48 DO NOT DISASSEMBLE RECOIL SPRING......................................................... 48 PRECAUTIONS WITH HIGH-PRESSURE OIL....................................................... 49 HANDLING HIGH-PRESSURE HOSES............................................................. 49 WASTE MATERIAL........................................................................... 49 COMPRESSED AIR........................................................................... 49 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS............................................ 50 OPERATION........................................................................................ 51 GENERAL VIEW................................................................................. 52 GENERAL VIEW OF MACHINE.................................................................. 52 GENERAL VIEW OF IMPACT CRUSHER........................................................... 53 GENERAL VIEW OF CONTROLS AND GAUGES...................................................... 54 EXPLANATION OF COMPONENTS.................................................................... 56 MACHINE MONITOR.......................................................................... 56 SWITCHES................................................................................. 78 CONTROL LEVERS........................................................................... 88 CAP,COVER WITH LOCK...................................................................... 89 REVOLVING WARNING LAMP................................................................... 90 ADDITIONAL WORKING LAMP.................................................................. 91 FUSIBLELINK.............................................................................. 91 CONTROLLERS.............................................................................. 92 FUSE..................................................................................... 92 OPERATION.................................................................................... 94 CHECK BEFORE STARTING ENGINE............................................................. 94 STARTING ENGINE..........................................................................116 OPERATIONS AND CHECKS AFTER STARTING ENGINE..............................................119 STOPPING ENGINE..........................................................................121 CHECK AFTER STOPPING ENGINE..............................................................121 MACHINE OPERATION........................................................................122 STEERING MACHINE.........................................................................126 OPERATION OF WORK EQUIPMENT..............................................................128 WATER SPRINKLER..........................................................................133 HYDRAULIC TYPE MAGNETIC SELECTOR.........................................................133 CHECK AND CONFIRMATION OF IMPACT CRUSHER AFTER WORK......................................133 CHECK AFTER FINISHING WORK...............................................................133 LOCKING..................................................................................134 PRECAUTIONS WHEN OPERATING IMPACT CRUSHER................................................135 EFFICIENT USE OF IMPACT CRUSHER..........................................................136 SCOPE OF WORKS USING MOBILE CRUSHER......................................................140 PROHIBITIONS FOR OPERATION...............................................................141 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS..............................................143 TRANSPORTATION...............................................................................144 TRANSPORTATION PROCEDURE.................................................................144 LOADING,UNLOADING WORK...................................................................151 LIFTING MACHINE..........................................................................157 COLD WEATHER OPERATION.......................................................................158 PRECAUTIONS FOR LOW TEMPERATURE..........................................................158 AFTER COMPLETION OF WORK.................................................................159 AFTER COLD WEATHER.......................................................................159 LONG-TERM STORAGE............................................................................160 BEFORE STORAGE...........................................................................160 DURING STORAGE...........................................................................160 AFTER STORAGE............................................................................160 STRTING MACHINE AFTER LONG-TERM STORAGE..................................................160 TROUBLESHOOTING..............................................................................161 PHENOMENA THAT ARE NOT FAILURES..........................................................161 METHOD OF TOWING MACHINE.................................................................161 IF BATTERY IS DISCHARGED.................................................................161 OTHER TROUBLE............................................................................165 MAINTENANCE......................................................................................172 GUIDE TO MAINTENANCE.........................................................................173 OUTLINE OF SERVICE...........................................................................175 HANDLING OIL,FUEL,COOLANT,AND PERFORMING OIL CLINIC......................................175 RELATING TO ELECTRIC SYSTEM..............................................................178 OUTLINE OF HYDRAULIC EQUIPMENT...........................................................178 WEAR PARTS...................................................................................179 WEAR PARTS LIST..........................................................................179 IMPACT CRUSHER RELATED PARTS.............................................................180 PRIMARY BELT CONVEYOR RELATED PARTS......................................................184 DEBRIS DISCHARGING BELT CONVEYOR RELATED PARTS...........................................186 USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE..........................188 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...............................................192 TORQUE LIST..............................................................................192 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................................................193 SAFETY CRITICAL PARTS....................................................................193 MAINTENANCE SCHEDULE CHART...................................................................194 MAINTENANCE SCHEDULE CHART...............................................................194 SERVICE PROCEDURE............................................................................196 INITIAL 250 HOURS MAINTENANCE(ONLY AFTER THE FIRST 250 HOURS)............................196 WHEN REQUIRED............................................................................197 CHECK,CLEAN AND REPLACE AIR CLEANER ELEMENT..........................................197 CLEAN INSIDE OF COOLING SYSTEM.......................................................200 CHECK AND TIGHTEN TRACK SHOE BOLT....................................................203 CHECK AND ADJUST TRACK TENSION.......................................................204 ADJUSTMENT OF CLEARANCE BETWEEN BLOW BAR AND IMPACT LINER............................207 CHECK AND ADJUSTMENT OF PRIMARY BELT CONVEYOR........................................213 INSPECTION AND ADJUSTMENT OF IMPACT CRUSHER..........................................215 METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT..........................220 CHECK BEFORE STARTING....................................................................223 EVERY 100 HOURS SERVICE..................................................................224 GREASING CRUSHER BEARING SEAT........................................................224 DRAIN WATER,SEDIMENT FROM FUEL TANK..................................................224 GREASING PRIMARY BELT CONVEYOR.......................................................225 GREASING SIDE CONVEYOR...............................................................225 EVERY 250 HOURS SERVICE..................................................................227 CHECK LEVEL OF BATTERY ELECTROLYTE...................................................227 CHECK FAN BELT AND ALTERNATOR BLET TENSION,ADJUST....................................229 CHECK OF OIL LEVEL IN CRUSHER MOTOR BEARING CASE AND ADDING OIL......................230 CHANGE OIL IN ENGINE OIL PAN,REPLACE ENGINE OIL FILTER CARTRIDGE.....................231 EVERY 500 HOURS SERVICE..................................................................233 REPLACE FUEL FILTER CARTRIDGE........................................................233 CHECK OIL LEVEL IN FINAL DRIVE CASE,ADD OIL..........................................234 REPLACE HYDRAULIC FILTER ELEMENT.....................................................235 REPLACE HYDRAULIC TANK BREATHER ELEMENT..............................................236 EVERY 1000 HOURS SERVICE.................................................................237 CHANGE OF OIL IN CRUSHER MOTOR BEARING CASE..........................................237 CHANGE OF OIL IN GRIZZLY FEEDER VIBRATOR CASE........................................237 CHANGE OIL IN DAMPER CASE............................................................238 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER...........................................238 CHECK PLAY OF TURBOCHARGER...........................................................238 REPLACE CORROSION RESISTOR CARTRIDGE.................................................239 CHANGE OF OIL CONVEYOR MOTOR MACHINERY CASE..........................................240 EVERY 2000 HOURS SERVICE.................................................................241 CHANGE OIL IN FINAL DRIVE CASE.......................................................241 CHECK ALTERNATOR,STARTING MOTOR......................................................241 CHECK ENGINE VALVE CLEARANCE,ADJUST..................................................241 CLEAN HYDRAULIC TANK STRAINER........................................................242 CLEAN ENGINE BREATHER................................................................242 CLEAN,CHECK TURBOCHARGER.............................................................242 EVERY 4000 HOURS SERVICE.................................................................243 CHECK WATER PUMP.....................................................................243 EVERY 5000 HOURS SERVICE.................................................................244 CHANGE OIL IN HYDRAULIC TANK.........................................................244 SPECIFICATIONS...................................................................................245 SPECIFICATIONS...............................................................................246 ATTACHMENTS,OPTIONS..............................................................................248 GENERAL PRECAUTIONS..........................................................................249 PRECAUTIONS RELATED TO SAFETY............................................................249 SPRINKLER....................................................................................250 EXPLANATIONS FOR COMPONENT PARTS.........................................................250 HOW TO USE SPRINKLER.....................................................................251 INSPECTION AND MAINTENANCE...............................................................253 RADIO CONTROL UNIT...........................................................................255 DIRECTIONS FOR USE.......................................................................255 OVERVIEW.................................................................................258 ON USE OF RADIO CONTROL UNIT.............................................................258 INDEX............................................................................................263 COVER............................................................................................265 TABLE OF CONTENTS................................................................................266 PART Ⅰ INTRODUCTION..............................................................................268 1. FOREWORD..................................................................................269 PART ⅡSAFETY.....................................................................................270 1. SAFETY INFORMATION........................................................................271 2. QUALIFICATION FOR OPERATING THE MACHINE...................................................272 2.1 QUALIFICATION REQUIREED FOR OPERATING CRANES.........................................272 3. BASIC RULES...............................................................................273 4. RULES FOR OPERATION.......................................................................279 4.1 BEFORE SATRTING UP ENGINE............................................................279 4.2 AFTER THE ENGINE HAS STARTED.........................................................280 4.3 DURING CRANE OPERATION...............................................................281 5. RULES FOR HANDLING THE BATTERY............................................................282 6. RULES TO OBSERVE IN CONNECTION WITH SERVICE...............................................284 6.1 BEFORE STARTING THE SERVICE WORK.....................................................284 6.2 DURING SERVICE WORK..................................................................286 7. LOCATION FOR AFFIXING CAUTION PLATES......................................................288 8. CAUTION PLATES AND OPERATION MANUAL ORDERING PROCEDURES...................................291 PART Ⅲ OPERATION.................................................................................292 1. NOMENCLATURE OF COMPONENTS................................................................293 2. CRANE OVERVIEW............................................................................294 2.1 KEY SPECIFICATIONS...................................................................294 2.2 GLOSSARY.............................................................................295 2.3 HOW TO READ WORKING RADIUS AND LIFTING HEIGHT DIAGRAM................................296 2.4 HOW TO READ TOTAL RATED LOAD CHART(DS100C-MC053).....................................298 2.5 HOW TO READ LOAD INDICATOR AND MOMENT METER..........................................299 2.6 HOOK OVER-HOIST PREVENTIVE DEVICE....................................................302 3. CRANE OPERATION PROCEDURE(FROM REMOTE CONTROL SWITCHES)...................................303 3.1 NOMENCLATURE OF COMPONENTS ON REMOTE CONTROL DEVICE..................................303 3.2 NOMENCLATURE OF COMPONENTS ON CONTROL CASE...........................................304 3.3 PREPARATIONS FOR OPERATION...........................................................305 3.4 USING THE REMOTE CONTROL SWITCHES....................................................306 3.5 ENDING THE CRANE OPERATION...........................................................308 4. PRECAUTIONS ON USE OF REMOTE CONTROL SWITHCES.............................................309 4.1 BEFORE STARTING THE OPERATION........................................................309 4.2 DURING THE OPERATION.................................................................310 4.3 AFTER THE OPERATION..................................................................311 4.4 OTHERS...............................................................................311 5. REMOTE CONTROL DEVICE CHECK POINTS........................................................312 5.1 TROUBLESHOOTING GUIDE-WHEN THE CRANE IS INOPERABLE FROM THE REMOTE CONTROL DEVICE....313 6. PRECAUTIONS ON USE........................................................................314 6.1 BEFORE STARTING THE OPERATION........................................................314 6.2 HANDLING OF TARGET CARGO OF LIFT.....................................................315 6.3 HANDLING OF WIRE ROPE................................................................316 6.4 AFTER USING THE CRANE................................................................317 6.5 OTHERS...............................................................................317 7. CHECK ITEMS...............................................................................318 7.1 INSPECTION OF THE SWING BEARING MOUNTING BOLT........................................318 8. WIRE ROPE REPLACEMENT PROCEDURE...........................................................319 8.1 PRECAUTIONS ON HANDLING WIRE ROPES...................................................319 8.2 WIRE ROPE REPLACEMENT PROCEDURE......................................................319 9. BOOM TELESCOPING WIRE ROPE ADJUSTING PROCEDURE............................................322 9.1 ADJUSTING PROCEDURE..................................................................322 9.1.1 ADJUSTMENT OF THE BOOM RETRACTING WIRE ROPE....................................322 9.1.2 ADJUSTMENT OF THE BOOM EXTENDING WIRE ROPE.....................................323 10. REPLACEMENT OF DRY CELL ON THE OVER-HOIST PREVENTIVE DEVICE..............................324 11. HYDRAULIC OIL............................................................................325 12. LUBRICATING OIL..........................................................................326 12.1 LUBRICATING POINTS..................................................................326 12.2 CHECK AND REFILLING OF LUBRICATING OIL ON THE SWING GEARBOX.........................326 12.3 LUBRICATING POINTS,LUBRICATING OILS USED AND LUBRICATION INTERVALS..................327 13. REPLACEMENT OF CONSUMABLE PARTS..........................................................328 14. DESCRIPTION OF THE DEVICES EMPLOYED FOR THE CRANE .......................................329 14.1 ALARM SWITCH........................................................................329 14.2 OVER-HOIST PREVENTIVE DEVICE........................................................329 14.3 LOAD INDICATOR......................................................................329 14.4 MOMENT METER........................................................................329 14.5 AUTOMATIC OIL PRESSURE LOCK DEVICE..................................................329
KOMATSU GALEO BR480RG-1 MOBILE CRUSHER OPERATION & MAINTENANCE MANUAL SN 1006 AND UP – PDF DOWNLOAD:
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DESCRIPTION:
Komatsu GALEO BR480RG-1 Mobile Crusher Operation & Maintenance Manual
FOREWORD:
This manual provides rules and guideflnes 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 mles for the operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause hazard when performing operation ard maintenance.
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