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KOMATSU GALEO BR550JG-1 MOBILE CRUSHER OPERATION & MAINTENANCE MANUAL (SN:1001-1066) – PDF DOWNLOAD
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- KOMATSU GALEO BR550JG-1 MOBILE CRUSHER OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:1001-1066
- PUBLICATION NUMBER:SEAM064600T
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Description
KOMATSU GALEO BR550JG-1 MOBILE CRUSHER OPERATION & MAINTENANCE MANUAL (SN:1001-1066)
KOMATSU GALEO BR550JG-1 MOBILE CRUSHER OPERATION & MAINTENANCE MANUAL (SN:1001-1066) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU GALEO BR550JG-1 MOBILE CRUSHER OPERATION & MAINTENANCE MANUAL (SN:1001-1066)
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.
TABLE OF CONTENTS:
KOMATSU GALEO BR550JG-1 MOBILE CRUSHER OPERATION & MAINTENANCE MANUAL (SN:1001-1066)
COVER............................................................................ 1 FORWORD.......................................................................... 2 FORWORD...................................................................... 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 OF ENTER SERIAL NO. AND DISTRIBUTOR................................ 10 CONTENTS......................................................................... 11 SAFETY........................................................................... 14 SAFETY....................................................................... 15 SAFETY LABELS................................................................ 18 POSITION OF SAFETY PICTOGRAMS............................................ 19 SAFETY LABELS............................................................ 20 GENERAL PRECAUTIONS.......................................................... 27 SAFETY RULES............................................................. 27 IF ABNORMALITIES ARE FOUND............................................... 27 CLOTHING AND PERSONAL PROTECTIVE ITEMS................................... 27 FIRE EXTINGUISHER AND FIRST AID KIT...................................... 27 SAFETY FEATURES.......................................................... 27 KEEP MACHINE CLEAN....................................................... 28 ON OPERATOR'S PLATFORM................................................... 28 ALWAYS APPLY LOCK WHEN LEAVING UPPER OPERATION DECK ..................... 28 HANDRAILS AND STEPS...................................................... 29 MOUNTING AND DISMOUNTING................................................. 29 NO PEOPLE ON ATTACHMENTS................................................. 29 PREVENTION OF BURNS...................................................... 30 FIRE PREVENTION.......................................................... 30 ACTION IF FIRE OCCURS.................................................... 31 PRECAUTIONS FOR ATTACHMENTS.............................................. 31 UNAUTHORIZED MODIFICATION................................................ 31 SAFETY AT WORKSITE....................................................... 32 WORKING ON LOOSE GROUND.................................................. 32 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES................................... 32 ENSURE GOOD VISIBILITY................................................... 33 VENTILATION FOR ENCLOSED AREAS........................................... 33 CHECKING SIGNALMAN'S SIGNALS AND SIGNS................................... 33 BE CAREFUR ABOUT ASBESTOS DUST........................................... 33 PRECAUTIONS FOR OPERATION.................................................... 34 STARTING ENGINE.......................................................... 34 CHECKS BEFORE STARTING ENGINE........................................ 34 PRECAUTIONS WHEN STARTING............................................ 34 PRECAUTIONS IN COLD AREAS............................................ 35 OPERATION................................................................ 36 CHECK BEFORE OPERATION............................................... 36 PRECAUTIONS WHEN CHANGING DIRECTION.................................. 36 PRECAUTIONS WHEN TRAVELING........................................... 36 TRAVELING ON SLOPES.................................................. 37 PRECAUTIONS WHILE IN OPERATION....................................... 37 OPERATE CAREFULLY ON SNOW............................................ 37 PARKING MACHINE...................................................... 38 CRUSHER OPERATION........................................................ 39 CHECKS AROUND MACHINE................................................ 39 TURN OPERATION MODE SELECTOR SWITCH TO WORK POSITION................. 39 ENSURE SAFETY WHILE OPERATING IN TANDEM WITH HYDRAULIC EXCAVATOR..... 39 CHECKS OF CRUSHER BEFORE STARTING OPERATION.......................... 40 PRECAUTIONS FOR CRUSHING WORK........................................ 40 EMERGENCY STOP TO WARD OFF DANGERS WHILE IN CRUSHING WORK............ 41 TRANSPORTATION........................................................... 42 LOADING AND UNLOADING................................................ 42 SHIPPING............................................................. 42 BATTERY.................................................................. 43 BATTERY HAZARD PREVENTION............................................ 43 STARTING WITH BOOSTER CABLE.......................................... 44 TOWING................................................................... 45 WHEN TOWING.......................................................... 45 PRECAUTIONS FOR MAINTENANCE.................................................. 46 WARNING TAG.............................................................. 46 KEEP WORK PLACE CLEAN AND TIDY........................................... 46 APPOINT LEADER WHEN WORKING WITH OTHERS.................................. 46 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE............... 46 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING....................... 47 PRECAUTIONS FOR CONVEYOR MAINTENANCE..................................... 47 PROPER TOOLS............................................................. 48 PERSONNEL................................................................ 48 PRECAUTIONS WHEN MOUNTING, DISMANTLING AND STORING ATTACHMENTS........... 48 PRECAUTIONS FOR WORK UNDER MACHINE....................................... 48 NOISE.................................................................... 48 PRECAUTIONS WHEN USING HAMMER............................................ 49 REPAIR WELDING........................................................... 49 REMOVING BATTERY TERMINAL................................................ 49 PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION...... 49 DO NOT DISASSEMBLE RECOIL SPRING......................................... 49 PRECAUTIONS WITH HIGH-PRESSURE OIL....................................... 50 HANDLING HIGH-PRESSURE HOSES............................................. 50 WASTE MATERIAL........................................................... 50 COMPRESSED AIR........................................................... 50 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS............................ 51 OPERATION........................................................................ 52 GENERAL VIEW................................................................. 53 GENERAL VIEW OF MACHINE.................................................. 53 GENERAL VIEW OF CONTROLS AND GAUGES...................................... 54 EXPLANATION OF COMPONENTS.................................................... 56 MACHINE MONITOR.......................................................... 56 SWITCHES................................................................. 67 CONTROL LEVERS........................................................... 76 OPTION-RELATED SWITCHES.................................................. 77 CAP, COVER WITH LOCK..................................................... 78 REVOLVING WORKING LAMP................................................... 80 ADDITIONAL WORKING LAMP.................................................. 81 FUSIBLE LINK............................................................. 81 CONTROLLERS.............................................................. 82 FUSE..................................................................... 82 TOOL BOX................................................................. 83 OPERATION.................................................................... 84 CHECK BEFORE STARTING ENGINE............................................. 84 STARTING ENGINE..........................................................101 OPERATIONS AND CHECKS AFTER STARTING ENGINE..............................104 STOPPING ENGINE..........................................................106 CHECK AFTER STOPPING ENGINE..............................................106 MACHINE OPERATION........................................................107 STEERING MACHINE.........................................................111 OPERATION OF WORK EQUIPMENT..............................................113 WATER SPRINKLER..........................................................118 OPENING-CLOSING TYPE HOPPER..............................................119 CHECK AND CONFIRMATION OF JAW CRUSHER AFTER WORK.........................127 CHECK AFTER FINISHING WORK...............................................127 LOCKING..................................................................127 RUN-IN OPERATION OF JAW CRUSHER..........................................128 PRECAUTIONS WHEN OPERATING JAW CRUSHER...................................131 EFFICIENT USE OF JAW CRUSHER.............................................133 SCOPE OF WORKS USING MOBILE CRUSHER......................................138 PROHIBITIONS FOR OPERATION...............................................144 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS..............................146 TRANSPORTATION...............................................................147 TRANSPORTATION PROCEDURE.................................................147 PROCEDURE FOR DISASSEMBLY AND FOLDING....................................149 LOADING, UNLOADING WORK..................................................150 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 BEFOR STORAGE............................................................160 DURING STORAGE...........................................................160 AFTER STORAGE............................................................160 STARTING MACHINE AFTER LONG-TERM STORAGE.................................160 TROUBLESHOOTING..............................................................161 PHENOMENA THAT ARE NOT FAILURES..........................................161 METHOD OF TOWING MACHINE.................................................161 IF BATTERY IS DISCHARGED.................................................162 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 AIR-BLEEDING FROM HYDRAULIC CIRCUIT......................................179 WEAR PARTS...................................................................180 WEAR PARTS LIST..........................................................180 JAW CRUSHER RELATED PARTS................................................181 PRIMARY BELT CONVEYOR RELATED PARTS......................................183 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.........185 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...............................187 CRUSHER ACCESSORY TOOLS..................................................187 TORQUE LIST..............................................................189 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................................190 SAFETY CRITICAL PARTS....................................................190 MAINTENANCE SCHEDULE CHART...................................................191 MAINTENANCE SCHEDULE CHART...............................................191 SERVICE PROCEDURE............................................................193 INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)...........193 WHEN REQUIRED............................................................194 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT.........................194 CLEAN INSIDE OF COOLING SYSTEM.......................................197 CHECK AND TIGHTEN TRACK SHOE BOLT....................................201 CHECK AND ADJUST TRACK TENSION.......................................202 CHECK AND ADJUSTMENT OF JAW CRUSHER..................................204 CHECK AND ADJUSTMENT OF PRIMARY BELT CONVEYOR........................225 CHECK BEFORE STARTING....................................................227 EVERY 100 HOURS SERVICE..................................................228 GREASING CRUSHER BEARING SEAT........................................228 DRAIN WATER, SEDIMENT FROM FUEL TANK.................................228 GREASING PRIMARY BELT CONVEYOR.......................................229 EVERY 250 HOURS SERVICE..................................................230 CHECK LEVEL OF BATTERY ELECTROLYTE...................................230 CHECK FAN BELT AND ALTERNATOR BLET TENSION, ADJUST...................232 CHECK AND ADJUSTMENT OF JAW CRUSHER V-BELT...........................233 CHECK OF OIL LEVEL IN CRUSHER MOTOR BEARING CASE AND ADDING OIL......234 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE....235 EVERY 500 HOURS SERVICE..................................................237 REPLACE FUEL FILTER CARTRIDGE........................................237 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.........................238 REPLACE HYDRAULIC FILTER ELEMENT.....................................239 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS.....................240 REPLACE HYDRAULIC TANK BREATHER ELEMENT..............................241 REPLACE ADDITIONAL FUEL FILTER CARTRIDGE.............................242 EVERY 1000 HOURS SERVICE.................................................244 CHANGE OF OIL IN CRUSHER MOTOR BEARING CASE..........................244 CHANGE OF OIL IN GRIZZLY FEEDER VIBRATOR CASE........................245 CHANGE OIL IN DAMPER CASE............................................246 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER...........................246 CHECK PLAY OF TURBOCHARGE ROTOR......................................246 RRPLACE CORROSION RESISTOR CARTRIDGE.................................247 CHANGE OF OIL CONVEYOR MOTOR MACHINERY CASE..........................248 EVERY 2000 HOURS SERVICE.................................................249 CHANGE OIL IN FINAL DRIVE CASE.......................................249 CHECK ALTERNATOR, STARTING MOTOR.....................................249 CHECK ENGINE VALVE CLEARANCE, ADJUST.................................249 CLEAN HYDRAULIC TANK STRAINER........................................250 CLEAN ENGINE BREATHER................................................250 CLEAN, CHECK TURBOCHARGER............................................250 EVERY 4000 HOURS SERVICE.................................................251 CHECK WATER PUMP.....................................................251 EVERY 5000 HOURS SERVICE.................................................252 CHANGE OIL IN HYDRAULIC TANK AND CLEAN STRAINER......................252 SPECIFICATIONS...................................................................256 SPECIFICATIONS...............................................................257 ATTACHMENTS, OPTIONS.............................................................259 GENERAL PRECAUTIONS..........................................................260 PRECAUTIONS RELATED TO SAFETY............................................260 HYDRAULIC TYPE MAGNETIC SELECTOR.............................................261 SAFETY PRECAUTIONS.......................................................262 PROCEDURES FOR CONNECTION WITH CRUSHER...................................262 PRECAUTIONS IN USE.......................................................262 CHECK AND INSPECTION.....................................................263 FAILURES AND CORRECTIVE ACTIONS..........................................264 LIST OF CHECKPOINT.......................................................264 SPECIFICATIONS...........................................................265 LIST OF WEARING PARTS....................................................266 DEBRIS DISCHARGING CONVEYOR..................................................267 LIFTING PROCEDURES.......................................................267 ASSEMBLING PROCEDURES....................................................268 PROCEDURES FOR FOLDING DEBRIS DISCHARGING CONVEYOR.......................269 GREASING DEBRIS DISCHARGING CONVEYOR.....................................270 CHECK AND ADJUSTMENT OF DEBRIS DISCHARGING CONVEYOR......................271 FAILURES AND CORRECTIVE ACTIONS..........................................273 WEARING PARTS............................................................275 SPECIFICATIONS...........................................................277 RADIO CONTROL UNIT...........................................................278 DIRECTIONS FOR USE.......................................................278 OVERVIEW.................................................................280 ON USE OF RADIO CONTROL UNIT.............................................281 BELT CONVEYOR PROTECTIVE PLATE...............................................286 PROCEDURES FOR CONNECTING OPTIONAL ATTACHMENTS...............................287 LOCATION OF PORTS FOR CONNECTING OPTIONAL ATTACHMENTS....................287 PROCEDURES FOR CONNECTING OPTIONAL ATTACHMENTS...........................288 INDEX............................................................................290
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