Komatsu Mobile Crusher BR500JG-1 Operator & Maintenance Manual SN 1201 and up – PDF DOWNLOAD

Description

Komatsu Mobile Crusher BR500JG-1 Operator & Maintenance Manual

FILE DETAILS:

Komatsu Mobile Crusher BR500JG-1 Operator & Maintenance Manual 

Size: 8.33 MB
Fomat: PDF
language: English
Brand: Komatsu
Type of machine: Mobile Crusher
Type of document: Operator & Maintenance Manual
Model: BR500JG-1
Serial: 1201 and up
Number of Page: 266

KOMATSU MOBILE CRUSHER BR500JG-1 OPERATOR & MAINTENANCE MANUAL SN 1201 AND UP – PDF DOWNLOAD:

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu Mobile Crusher BR500JG-1 Operator & Maintenance Manual 

FOREWORD:

• This manual provides rules and guidelines which will help you use this machine safely and effectively. Keep this manual in the manual holder inside the tool box so that it is easy to use, and have all personnel read it periodically. if this manual has been lost or has become dirty and can not be read, request a replacement manual from Komatsu or your Komatsu distributor.
• if you sell the machine, be sure to give this manual to the new owners. Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual.
• Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual. This manual may contain attachments and optional equipment that are not available in your area. Con5ult Komatsu or your Komatsu distributor for those items. you may require.

TABLE OF CONTENTS:

Komatsu Mobile Crusher BR500JG-1 Operator & Maintenance Manual 

COVER.................................................................................................................  1
1. FOREWORD...........................................................................................................  2
2. SAFETY INFORMATION.................................................................................................  5
3. TO THE USER........................................................................................................  6
4. LOCATION OF PLATES,TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.......................................................  7
5. CONTENTS...........................................................................................................  8
SAFETY................................................................................................................ 12
	1. GENERAL PRECAUTIONS............................................................................................ 13
	2. PRECAUTIONS DURING OPERATION................................................................................... 19
		2.1 BEFORE STARTING ENGINE.................................................................................... 19
		2.2 AFTER STARTING ENGINE..................................................................................... 20
		2.3 CRUSHER (CRUSHING) OPERATIONS............................................................................. 27
		2.4 BATTERY................................................................................................... 30
		2.5 TOWING.................................................................................................... 32
	3. PRECAUTIONS FOR MAINTENANCE.................................................................................... 33
	4. POSITION FOR ATTACHING SAFETY LABELS........................................................................... 37
OPERATION............................................................................................................. 41
	1. GENERAL VIEW................................................................................................... 42
	2. EXPLANATION OF INSTRUMENTS..................................................................................... 43
		2.1 VEHICLE MONITORING SYSTEM................................................................................. 43
		2.2 SWITCH UNIT............................................................................................... 47
		2.3 CONTROL LEVER,DIAL,PATROL LIGHT........................................................................... 49
		2.4 CAP AND COVER WITH LOCK................................................................................... 50
		2.5 DUST INDICATOR............................................................................................ 51
		2.6 FUSIBLE LINK.............................................................................................. 51
		2.7 FUSE...................................................................................................... 52
		2.8 ADDITIONAL LAMP CONNECTOR................................................................................. 52
		2.9 RADIO CONTROL............................................................................................. 53
	3.OPERATING PROCEDURES............................................................................................ 61
		3.1 CHECK BEFORE STARTING..................................................................................... 61
		3.2 STARTING THE ENGINE....................................................................................... 69
		3.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE............................................................... 72
		3.4 MOVING MACHINE OFF........................................................................................ 73
		3.5 STEERING (CHANGING THE COURSE)............................................................................ 74
		3.6 STOPPING THE VEHICLE...................................................................................... 74
		3.7 STARTING CRUSHER OPERATIONS............................................................................... 75
		3.8 OPERATIONS STARTING PROCEDURES OF (NEW) CRUSHER........................................................... 76
		3.9 BASIC HANDLING OF GRIZZLY FEEDER (EFFECTIVE MUCK REMOVING METHOD)......................................... 77
		3.10 WATER SPRINKLER.......................................................................................... 80
		3.11 FINISHING OPERATIONS..................................................................................... 80
		3.12 AFTER COMPLETING OPERATIONS.............................................................................. 81
		3.13 STOPPING THE ENGINE...................................................................................... 81
		3.14 CHECKS AFTER STOPPING ENGINE............................................................................. 82
		3.15 REVERSE ROTATION FUNCTION OF CRUSHER..................................................................... 82
		3.16 AUTOMATIC STOPPING OF BELT CONVEYOR...................................................................... 82
		3.17 PROHIBITED OPERATIONS.................................................................................... 83
		3.18 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS.............................................................. 84
	4. TRANSPORTATION................................................................................................. 85
		4.1 PACKING STYLE FOR TRANSPORTATION.......................................................................... 85
		4.2 LOADING,UNLOADING WORK.................................................................................... 91
		4.3 PRECAUTIONS FOR LOADING................................................................................... 92
		4.4 PRECAUTIONS FOR TRANSPORTATION............................................................................ 93
	5. LONG-TERM STORAGE.............................................................................................. 94
		5.1 BEFORE STORAGE............................................................................................ 94
		5.2 DURING STORAGE............................................................................................ 94
		5.3 AFTER STORAGE............................................................................................. 94
	6. TROUBLESHOOTING................................................................................................ 95
		6.1 PHENOMENA THAT ARE NOT FAILURES........................................................................... 95
		6.2 METHOD OF TOWING MACHINE.................................................................................. 95
	7. WHEN THE BATTERY HAS DISCHARGED................................................................................ 96
		7.1 BATTERY REMOVAL AND INSTALLATION.......................................................................... 97
		7.2 BATTERY CHARGES........................................................................................... 97
		7.3 STARTING ENGINE WITH BOOSTER CABLES....................................................................... 98
MAINTENANCE...........................................................................................................100
	1. GENERAL INSTRUCTIONS ON MAINTENANCE OPERATIONS.................................................................101
	2. AIR BLEEDING FROM CIRCUIT......................................................................................109
		2.1 AIR BLEEDING IN THE MAIN PUMP.............................................................................110
		2.2 STARTING THE ENGINE.......................................................................................110
		2.3 AIR BLEEDING IN THE CRUSHER MOTOR.........................................................................110
		2.4 BLEEDING AIR FROM GRIZZLY FEEDER MOTOR....................................................................111
		2.5 AIR BLEEDING IN THE BELT CONVEYOR MOTOR...................................................................111
		2.6 AIR BLEEDING IN THE TRAVEL MOTOR (PERFORM THIS ONLY WHEN THE OIL IN THE TRAVEL MOTOR CASE IS DRAINED.)....111
		2.7 AIR BLEEDING IN THE CYLINDER..............................................................................112
		2.8 STARTING OPERATIONS.......................................................................................112
	3. OIL FILLER AND OIL LEVEL GAUGE.................................................................................113
	4. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.................................................................114
		4.1 INTRODUCTION OF NECESSARY TOOLS...........................................................................114
		4.2 TORQUE LIST...............................................................................................117
	5. MAINTENANCE TABLE..............................................................................................118
	6. PERIODIC MAINTENANCE...........................................................................................120
		6.1 CHECK BEFORE STARTING.....................................................................................120
		6.2 EVERY 100 HOURS SERVICE...................................................................................127
		6.3 EVERY 250 HOURS SERVICE...................................................................................129
		6.4 EVERY 500 HOURS SERVICE...................................................................................132
		6.5 EVERY 1000 HOURS SERVICE..................................................................................137
		6.6 EVERY 2000 HOURS SERVICE..................................................................................140
		6.7 EVERY 4000 HOURS SERVICE..................................................................................143
		6.8 EVERY 5000 HOURS SERVICE..................................................................................144
	7. WHEN REQUIRED..................................................................................................149
		7.1 CHECK,CLEANING AND REPLACEMENT OF AIR CLEANER.............................................................149
		7.2 CLEANING OF THE INSIDE OF THE COOLING SYSTEM..............................................................151
		7.3 CHECK AND ADJUSTMENT FOR LOOSENESS OF TRACK SHOE BOLT.....................................................154
		7.4 TENSION CHECK AND ADJUSTMENT FOR THE TRACK SHOE...........................................................154
		7.5 CHECK,ADJUST,REPLACE CRUSHER..............................................................................156
		7.6 CHECK,ADJUST BELT CONVEYOR................................................................................172
	8. WEAR PARTS.....................................................................................................174
		8.1 WEAR PARTS RELATED TO THE BODY............................................................................174
		8.2 WEAR PARTS RELATED TO THE CRUSHER.........................................................................175
		8.3 WEAR PARTS RELATED TO THE BELT CONVEYOR...................................................................177
	9. USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE............................................178
	10. PERIODIC REPLACEMENT OF IMPORTANT PARTS.......................................................................181
	11. TROUBLESHOOTING...............................................................................................183
		11.1 CRUSHER..................................................................................................183
		11.2 ELECTRICAL EQUIPMENT.....................................................................................184
		11.3 BODY.....................................................................................................185
		11.4 ENGINE...................................................................................................186
		11.5 BELT CONVEYOR............................................................................................188
SPECIFICATIONS AND CIRCUIT DIAGRAMS...................................................................................190
	1. EXTERNAL VIEWS.................................................................................................191
	2. SPECIFICATIONS.................................................................................................192
OPTIONS,ATTACHMENTS...................................................................................................193
	1. GENERAL PRECAUTIONS............................................................................................194
		1.1 PRECAUTIONS RELATED TO SAFETY.............................................................................194
	2. HYDRAULIC MAGNETIC SEPARATOR...................................................................................195
		2.1 SPECIFICATION (KMG900L)...................................................................................195
		2.2 GENERAL VIEW (KMG900L)....................................................................................195
		2.3 PRECAUTIONS ON SAFETY.....................................................................................196
		2.4 CONNECTING METHOD TO MACHINE BODY.........................................................................196
		2.5 PRECAUTIONS FOR USE.......................................................................................196
		2.6 INSPECTION AND ADJUSTMENT.................................................................................196
		2.7 TROUBLES AND CORRECTIVE ACTIONS...........................................................................197
		2.8 MAINTENANCE SCHEDULE CHART................................................................................198
	3. DEBRIS DISCHARGE CONVEYOR......................................................................................199
		3.1 SPECIFICATION.............................................................................................199
		3.2 ASSEMBLY PROCEDURE........................................................................................199
	4. HYDRAULIC MAGNETIC SEPARATOR HYDRAULIC HOSE CONNECTING METHOD..................................................202
	5. MUCKING CONVEYOR HYDRAULIC HOSE CONNECTING METHOD..............................................................204

PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]