Komatsu BR500JG-1 Mobile Crusher Service Repair Shop Manual (1006 and up) - SEBM012103

This Complete Service Repair Workshop Manual PDF Download for the BR500JG-1 Komatsu Mobile Crusher (SN: 1006 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu BR500JG-1 Mobile Crusher
Serial Numbers : 1006 and up


TABLE OF CONTENTS :

01 GENERAL
10 STRUCTURE AND FUNCTION
20 TESTING AND ADJUSTING
30 DISASSEMBLY AND ASSEMBLY
40 MAINTENANCE STANDARD
90 OTHERS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Bookmarked : Yes
Searchable : Yes
Printable : Yes
Product Code : SEBM012103
Total Pages : 391


This manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

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COVER
CONTENTS
01 GENERAL
DIMENSION
SPECIFICATIONS
TABLE OF OIL AND COOLANT CAPACITIES

10 STRUCTURE AND FUNCTION
PARTS RELATED TO ENGINE
RADIATOR, OIL COOLER
DRIVE SYSTEMS FOR EACH COMPONENT
FINAL DRIVE
TRACK FRAME, RECOIL SPRING
TRACK SHOE
HYDRAULIC TANK, HYDRAULIC FILTER
HYDRAULIC PUMP
CONTROL VALVE
SUCTION SAFETY VALVE
SELF-REDUCING PRESSURE VALVE
CLSS
CRUSHER MOTOR
TRAVEL MOTOR
TRAVEL PPC VALVE
HYDRAULIC CYLINDER
ELECTRIC CIRCUIT DIAGRAM
ENGINE CONTROL SYSTEM
MACHINE MONITOR SYSTEM
BELT CONVEYOR MACHINERY
BELT CONVEYOR MOTOR
SOLENOID VALVE (6-SPOOL)
SOLENOID VALVE (FOR CRUSHER MOTOR)
PPC VALVE
FIRST BELT CONVEYOR
GRIZZLY FEEDER
VIBRATOR
FLOW CONTROL VALVE
CRUSHER

20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
TOOLS FOR TASTING, ADJUSTING, AND TROUBLESHOOTING
MEASURING ENGINE SPEED
MEASURING EXHAUST COLOR
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
MEASURING BLOW-BY PRESSURE
TESTING AND ADJUSTING FUEL INJECTION TIMING
MEASURING ENGINE OIL PRESSURE
TESTING AND ADJUSTING FAN BELT TENSION
ADJUSTING ENGINE SPEED SENSOR
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT AND TRAVEL CIRCUIT
TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE
TESTING SOLENOID VALVE OUTPUT PRESSURE
MEASURING PPC VALVE OUTPUT PRESSURE
TESTING TRAVEL DEVIATION
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
TESTING AND ADJUSTING TRACK SHOE TENSION
BLEEDING AIR FROM HYDRAULIC CIRCUIT
ADJUSTING FUEL CONTROL LEVER
TESTING AND ADJUSTING CRUSHER
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
1. FOR CHASSIS
2. FOR CRUSHER
3. FOR BELT CONVEYOR
CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR ARRANGEMENT DIAGRAM
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
METHOD OF PROCEEDING WITH TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
E-1 TRAVEL LOCK DOES NOT WORK NORMALLY
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)
M-1 WHEN STARTING SWITCH IS TURNED ON, NO DISPLAY IS GIVEN
M-2 WHEN STARTING SWITCH IS TURNED ON, LAMPS LIGHT UP FOR 3 SECONDS, BUT THEN DO NOT GO OUT
M-3 WHEN STARTING SWITCH IS TURNED ON, SOME LAMPS DO NOT LIGHT UP FOR 3 SECONDS
a) NO GAUGE LAMPS LIGHT UP (CAUTION LAMPS LIGHT UP)
b) TRAVEL LOCK, PREHEATING LAMPS DO NOT LIGHT UP
c) CHARGE CAUTION LAMP DOES NOT LIGHT UP
d) ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP
M-4 WHEN POWER IS TURNED ON (BEFORE ENGINE IS STARTED), CHARGE CAUTION LAMP DOES NOT LIGHT UP
M-5 WHEN POWER IS TURNED ON (BEFORE ENGINE IS STARTED), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP
M-6 DURING PREHEATING, PREHEATING PILOT LAMP DOES NOT LIGHT UP
M-7 WHEN SWITCH IS OPERATED, TRAVEL LOCK LAMP DOES NOT LIGHT UP
M-8 ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING
M-9 CHARGE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING
M-10 ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE
a) AFTER ENGINE IS STARTED, LEVEL STAYS AT BOTTOM (WHITE RANGE) AND DOES NOT MOVE
b) AFTER ENGINE IS STARTED, LEVEL IMMEDIATELY RISES ENGINE IS NOT OVERHEATING BUT INDICATOR ENTERS RED RANGE
c) ENGINE WATER TEMPERATURE GAUGE GOES OUT
M-11 ABNORMALITY IN FUEL GAUGE
a) ALL FUEL GAUGE SEGMENTS GO OUT
b) EVEN WHEN FUEL LEVEL GOES DOWN, FUEL GAUGE CONTINUES TO SHOW FULL
c) EVEN WHEN TANK IS FILLED, FUEL GAUGE DOES NOT SHOW FULL
M-12 DEFECTIVE OPERATION OF ALARM BUZZER
a) BUZZER DOES NOT SOUND (WHEN ABNORMAL)
b) BUZZER CONTINUES TO SOUND AND DOES NOT STOP (WHEN NORMAL)
M-13 ENGINE IS RUNNING, BUT SERVICE METER DOES NOT MOVE
a) CHARGE CAUTION LAMP LIGHTS UP
b) CHARGE CAUTION LAMP DOES NOT LIGHT UP
M-14 NIGHT LIGHTING DOES NOT LIGHT UP
a) GAUGE LIGHTING DOES NOT LIGHT UP
b) SERVICE METER LIGHTING DOES NOT LIGHT UP (SERVICE METER IS WORKING NORMALLY)

30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOL LIST
SKETCHES OF SPECIAL TOOLS
STARTING MOTOR ASSEMBLY
REMOVAL AND INSTALLATION
ALTERNATOR ASSEMBLY
REMOVAL AND INSTALLATION
ENGINE OIL COOLER ASSEMBLY
REMOVAL AND INSTALLATION
FUEL INJECTION PUMP ASSEMBLY
REMOVAL
INSTALLATION
WATER PUMP ASSEMBLY
REMOVAL AND INSTALLATION
NOZZLE HOLDER ASSEMBLY
REMOVAL AND INSTALLATION
TURBOCHARGER ASSEMBLY
REMOVAL AND INSTALLATION
THERMOSTAT ASSEMBLY
REMOVAL AND INSTALLATION
ENGINE FRONT SEAL
REMOVAL AND INSTALLATION
ENGINE REAR SEAL
REMOVAL
INSTALLATION
CYLINDER HEAD ASSEMBLY
REMOVAL
INSTALLATION
AFTERCOOLER CORE ASSEMBLY
REMOVAL AND INSTALLATION
HYDRAULIC COOLER ASSEMBLY
REMOVAL
INSTALLATION
RADIATOR, HYDRAULIC COOLER ASSEMBLY
REMOVAL
INSTALLATION
ENGINE, MAIN PUMP ASSEMBLY
REMOVAL
INSTALLATION
DAMPER ASSEMBLY
REMOVAL AND INSTALLATION
FUEL TANK ASSEMBLY
REMOVAL AND INSTALLATION
FINAL DRIVE ASSEMBLY
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
SPROCKET
REMOVAL AND INSTALLATION
IDLER, RECOIL SPRING ASSEMBLY
REMOVAL AND INSTALLATION
IDLER ASSEMBLY
DISASSEMBLY
ASSEMBLY
RECOIL SPRING ASSEMBLY
DISASSEMBLY
ASSEMBLY
TRACK ROLLER ASSEMBLY
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
CARRIER ROLLER ASSEMBLY
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
TRACK SHOE ASSEMBLY
REMOVAL AND INSTALLATION
HYDRAULIC TANK ASSEMBLY
REMOVAL
INSTALLATION
CONTROL PUMP ASSEMBLY
REMOVAL AND INSTALLATION
MAIN PUMP ASSEMBLY
REMOVAL
INSTALLATION
MAIN PUMP INPUT SHAFT OIL SEAL
REMOVAL AND INSTALLATION
SERVO VALVE ASSEMBLY FOR FRONT PUMP
REMOVAL AND INSTALLATION
SERVO VALVE ASSEMBLY FOR REAR PUMP
REMOVAL AND INSTALLATION
TRAVEL PPC VALVE ASSEMBLY
DISASSEMBLY
ASSEMBLY
CONVEYOR MACHINERY, MOTOR ASSEMBLY
REMOVAL AND INSTALLATION
CONVEYOR MACHINERY ASSEMBLY
DISASSEMBLY
ASSEMBLY
CHEEK PLATE
REMOVAL
INSTALLATION
FIXED JAW PLATE
REMOVAL AND INSTALLATION
SWING JAW PLATE
REMOVAL
INSTALLATION
TOGGLE PLATE
REMOVAL
INSTALLATION
TOGGLE SEAT
REMOVAL AND INSTALLATION
FLYWHEEL AND V SHEAVE
REMOVAL AND INSTALLATION
SWING JAW
REPLACEMENT
BEARING
REPLACEMENT
THRUST SEAT
REPLACEMENT
CHEEK PLATE
REPLACEMENT
FIXED JAW TEETH
TURNING AND REPLACEMENT
SWING JAW TEETH
TURNING AND REPLACEMENT
TOGGLE PLATE
REPLACEMENT
TOGGLE SEAT
REPLACEMENT
HYDRAULIC RAM
HANDLING
FLYWHEEL AND V-PULLEY
REPLACEMENT
SWING JAW
REPLACEMENT
BEARING
REPLACEMENT

40 MAINTENANCE STANDARD
ENGINE MOUNT
FINAL DRIVE
TRACK FRAME AND RECOIL SPRING
IDLER
CARRIER ROLLER
TRACK ROLLER
TRACK
HYDRAULIC PUMP
CONTROL PUMP AND RELIEF VALVE
SUCTION-SAFETY VALVE
SELF-REDUCING PRESSURE VALVE
CRUSHER MOTOR
TRAVEL MOTOR
TRAVEL PPC VALVE
BELT CONVEYOR MACHINERY
BELT CONVEYOR MOTOR
CRUSHER
WEAR MEASUREMENT OF MAJOR CONSUMABLE PARTS

90 OTHERS
HYDRAULIC CIRCUIT DIAGRAM (SERIAL NO.: 1006-1103)
HYDRAULIC CIRCUIT DIAGRAM (SERIAL NO.: 1201 AND UP)
ELECTRIC CIRCUIT DIAGRAM (SERIAL NO.: 1002-1006)
ELECTRIC CIRCUIT DIAGRAM (SERIAL NO.: 1007-1103)
ELECTRIC CIRCUIT DIAGRAM (SERIAL NO.: 1201 AND UP)

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