This is a comprehensive Service Shop Repair Manual for the KOMATSU BR500JG-1 MOBILE CRUSHER. It contains detailed information on maintenance, assembly, disassembly, and servicing of the KOMATSU BR500JG-1 MOBILE CRUSHER.
MACHINE MODEL SERIAL NUMBER
BR500JG-1 - 1006 and up
TABLE OF 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
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOL LIST
SKETCHES OF SPECIAL TOOLS
STARTING MOTOR ASSEMBLY
ALTERNATOR ASSEMBLY
ENGINE OIL COOLER ASSEMBLY
FUEL INJECTION PUMP ASSEMBLY
WATER PUMP ASSEMBLY
NOZZLE HOLDER ASSEMBLY
TURBOCHARGER ASSEMBLY
THERMOSTAT ASSEMBLY
ENGINE FRONT SEAL
ENGINE REAR SEAL
CYLINDER HEAD ASSEMBLY
AFTERCOOLER CORE ASSEMBLY
HYDRAULIC COOLER ASSEMBLY
RADIATOR, HYDRAULIC COOLER ASSEMBLY
ENGINE, MAIN PUMP ASSEMBLY
DAMPER ASSEMBLY
FUEL TANK ASSEMBLY
FINAL DRIVE ASSEMBLY
SPROCKET
IDLER, RECOIL SPRING ASSEMBLY
IDLER ASSEMBLY
RECOIL SPRING ASSEMBLY
TRACK ROLLER ASSEMBLY
CARRIER ROLLER ASSEMBLY
TRACK SHOE ASSEMBLY
HYDRAULIC TANK ASSEMBLY
CONTROL PUMP ASSEMBLY
MAIN PUMP ASSEMBLY
MAIN PUMP INPUT SHAFT OIL SEAL
SERVO VALVE ASSEMBLY FOR FRONT PUMP
SERVO VALVE ASSEMBLY FOR REAR PUMP
TRAVEL PPC VALVE ASSEMBLY
CONVEYOR MACHINERY, MOTOR ASSEMBLY
CONVEYOR MACHINERY ASSEMBLY
CHEEK PLATE
FIXED JAW PLATE
SWING JAW PLATE
TOGGLE PLATE
TOGGLE SEAT
FLYWHEEL AND V SHEAVE
SWING JAW
BEARING
THRUST SEAT
CHEEK PLATE
FIXED JAW TEETH
SWING JAW TEETH
TOGGLE PLATE
TOGGLE SEAT
HYDRAULIC RAM
FLYWHEEL AND V-PULLEY
SWING JAW
BEARING
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)
Model Specification: KOMATSU BR500JG-1 MOBILE CRUSHER
Language: English
File Format: .PDF
Total Pages: 391
Requirements: Adobe Reader
ZOOM IN/OUT: YES
Printable: YES
Compatible: All Versions of Windows & Mac
This manual contains information, data, specs, diagrams, actual real photo illustrations, and schemes, providing complete step-by-step operations on repair, servicing, technical maintenance, and troubleshooting procedures for your machine. It offers the full information needed for repairing your machine, enabling you to find trouble and understand how to repair and maintain your machine without going into service.
All manuals are compatible with Windows Vista32 and 64, XP, ME, 98, NT, 2000, and work with Mac! Upon receipt of your payment, you can find, print, use, and then dispose of it. The manual includes numerous pictures and diagrams, making it easy for any skill level to follow the step-by-step instructions. All pages are printable, allowing you to run off what you need and take it with you into the garage or workshop, saving money by doing your own repairs.
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