SEN02602-08
MOBILE CRUSHER
BR580JG -1 SERIAL NUMBERS
1001
and up
SEN02604-08
MOBILE CRUSHER 1SHOP MANUAL
BR580JG-1
Machine model
Serial number
BR580JG-1
1001 and up
00 Index and foreword
1
Index Composition of shop manual .......................................................................................................................... 2 Table of contents ............................................................................................................................................. 4
BR580JG-1
1
SEN02604-08
00 Index and foreword
Composition of shop manual
1
The contents of this shop manual are shown together with Form No. in a list. Section Title
Form Number
Shop Manual, contents binder, binder label and tabs
SEN02602-08
00 Index and foreword Index Foreword and general information
SEN02603-08 SEN02604-08 SEN02605-02
01 Specification Specification and technical data
SEN02606-01 SEN02607-01
10 Structure, function and maintenance standard Engine and cooling system Power train Undercarriage and frame Hydraulic system, Part 1 Hydraulic system, Part 2 Hydraulic system, Part 3 Work equipment Electrical system
SEN02608-03 SEN02609-00 SEN02610-00 SEN02611-01 SEN02612-00 SEN02613-01 SEN02614-01 SEN02615-01 SEN02616-03
20 Standard value table Standard service value table
SEN03149-01 SEN03150-01
30 Testing and adjusting Testing and adjusting, Part 1 Testing and adjusting, Part 2 Testing and adjusting, Part 3
SEN03151-03 SEN03152-02 SEN03153-00 SEN03154-01
40 Troubleshooting Failure code table and fuse locations General information on troubleshooting Troubleshooting by failure code, Part 1 Troubleshooting by failure code, Part 2 Troubleshooting by failure code, Part 3 Troubleshooting by failure code, Part 4 Troubleshooting by failure code, Part 5 Troubleshooting of electrical system (E-mode) Troubleshooting of hydraulic and mechanical system (H-mode) Troubleshooting of engine (S-mode)
SEN03155-03 SEN03156-01 SEN03157-02 SEN03158-00 SEN03159-00 SEN03160-01 SEN03161-00 SEN03162-00 SEN03163-01 SEN03164-00 SEN03165-01
2
BR580JG-1
00 Index and foreword
SEN02604-08
50 Disassembly and assembly General information on disassembly and assembly Engine and cooling system Power train Undercarriage and frame Hydraulic system Work equipment Electrical system
SEN02623-04 SEN03441-03 SEN03442-01 SEN03443-00 SEN03444-01 SEN03445-00 SEN03446-01 SEN03447-00
90 Diagrams and drawings Hydraulic diagrams and drawings Electrical diagrams and drawings
SEN02617-02 SEN02618-01 SEN02619-02
BR580JG-1
3
SEN02604-08
00 Index and foreword
Table of contents
1
00 Index and foreword Index SEN02604-08 Composition of shop manual............................................................................................................ 2 Table of contents .............................................................................................................................. 4 Foreword and general information SEN02605-02 Safety notice..................................................................................................................................... 2 How to read the shop manual .......................................................................................................... 7 Explanation of terms for maintenance standard............................................................................... 9 Handling of electric equipment and hydraulic component.............................................................. 11 Handling of connectors newly used for engines............................................................................. 20 How to read electric wire code ....................................................................................................... 23 Precautions when carrying out operation ....................................................................................... 26 Method of disassembling and connecting push-pull type coupler .................................................. 29 Standard tightening torque table .................................................................................................... 32 Conversion table ............................................................................................................................ 36 01 Specification Specification and technical data SEN02607-01 Specification dimension drawings .................................................................................................... 2 Specifications ................................................................................................................................... 3 Weight table ..................................................................................................................................... 5 Table of fuel, coolant and lubricants ................................................................................................. 6 10 Structure, function and maintenance standard Engine and cooling system SEN02609-00 Engine mount, damper ..................................................................................................................... 2 Radiator, oil cooler and aftercooler................................................................................................... 3 Power train SEN02610-00 Power train ....................................................................................................................................... 2 Drive system for components ........................................................................................................... 3 Final drive......................................................................................................................................... 4 Sprocket ........................................................................................................................................... 6 Undercarriage and frame SEN02611-01 Track frame and recoil spring ........................................................................................................... 2 Idler .................................................................................................................................................. 4 Guide plate ....................................................................................................................................... 6 Track roller........................................................................................................................................ 7 Track shoe........................................................................................................................................ 8 Hydraulic system, Part 1 SEN02612-00 Hydraulic piping drawing .................................................................................................................. 2 Hydraulic tank and hydraulic oil filter ................................................................................................ 3 Hydraulic pump ................................................................................................................................ 4 Hydraulic system, Part 2 SEN02613-01 Control valve .................................................................................................................................... 2 Self pressure reducing valve .......................................................................................................... 14 CLSS .............................................................................................................................................. 18 Functions and operation by valve................................................................................................... 22
4
BR580JG-1
This is the sample of the manual Click on the download link for complete manual
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00 Index and foreword
SEN02604-08
Hydraulic system, Part 3 SEN02614-01 Crusher motor .................................................................................................................................. 2 Grizzly feeder motor ......................................................................................................................... 4 Conveyor motor................................................................................................................................ 6 Travel motor ..................................................................................................................................... 7 Valve control................................................................................................................................... 18 Solenoid valve................................................................................................................................ 28 8-spool EPC valve.......................................................................................................................... 30 Solenoid valve for travel................................................................................................................. 34 PPC shuttle valve (if equipped)...................................................................................................... 35 Electromagnetic selector valve ...................................................................................................... 36 Hydraulic cylinder........................................................................................................................... 38 Work equipment SEN02615-01 Grizzly feeder semiautomatic system .............................................................................................. 2 Abnormal load stop system .............................................................................................................. 4 Primary belt conveyor ...................................................................................................................... 5 Grizzly feeder ................................................................................................................................... 8 Crusher .......................................................................................................................................... 11 Crusher tooth tip adjustment system.............................................................................................. 15 Vibrator........................................................................................................................................... 18 Electrical system SEN02616-03 Engine control .................................................................................................................................. 2 Work equipment and pump controller ............................................................................................ 14 Electronic control system ............................................................................................................... 17 Machine monitor system ................................................................................................................ 31 Sensor............................................................................................................................................ 56 KOMTRAX system ......................................................................................................................... 59 20 Standard value table Standard service value table SEN03150-01 Standard value table for engine ....................................................................................................... 2 Standard value table for chassis ...................................................................................................... 3 30 Testing and adjusting Testing and adjusting, Part 1 SEN03152-02 Tools for testing, adjusting and troubleshooting ............................................................................... 3 Measuring engine speed.................................................................................................................. 6 Measuring intake air pressure (boost pressure)............................................................................... 7 Measuring exhaust temperature ...................................................................................................... 8 Checking exhaust gas color ............................................................................................................. 9 Adjusting valve clearance .............................................................................................................. 10 Measuring compression pressure .................................................................................................. 12 Measuring blow-by pressure .......................................................................................................... 14 Measuring engine oil pressure ....................................................................................................... 15 Testing EGR valve and bypass valve drive oil pressure ................................................................ 16 Handling fuel system parts ............................................................................................................. 17 Releasing residual pressure from fuel system ............................................................................... 17 Measuring fuel pressure................................................................................................................. 18 Handling during cylinder cut-out operation..................................................................................... 19 Handling during no injection cranking operation ............................................................................ 19 Measuring fuel return rate and leakage ......................................................................................... 20 Bleeding air from fuel circuit ........................................................................................................... 23 Checking fuel circuit for leakage .................................................................................................... 24 Checking and adjusting fan belt and alternator belt ....................................................................... 25 Checking and adjusting track shoe tension.................................................................................... 26 Measuring and adjusting oil pressure in work equipment and travel circuits ................................. 27 Measuring control circuit basic pressure........................................................................................ 31 BR580JG-1
5
SEN02604-08
00 Index and foreword
Measuring and adjusting oil pressure in pump PC control circuit................................................... 32 Measuring and adjusting oil pressure in pump LS control circuit ................................................... 35 Measuring solenoid valve output pressure..................................................................................... 39 Measuring PPC valve output pressure........................................................................................... 43 Measuring oil leakage .................................................................................................................... 44 Bleeding air from each part ............................................................................................................ 45 Testing travel deviation................................................................................................................... 48 Adjusting mirrors ............................................................................................................................ 49 Testing and adjusting, Part 2 SEN03153-00 Special functions of machine monitor............................................................................................... 2 Testing and adjusting, Part 3 SEN03154-01 Check and adjustment of jaw crusher .............................................................................................. 2 Check and adjustment of outlet clearance ....................................................................................... 4 Testing and adjusting tension of crusher drive V-belt ..................................................................... 19 Check and adjustment of primary conveyor ................................................................................... 20 Inspection and maintenance of magnetic separator....................................................................... 26 Check and adjustment of muck discharge conveyor...................................................................... 28 Handling voltage circuit of engine controller................................................................................... 30 Procedure for turning on KOMTRAX terminal ................................................................................ 31 KOMTRAX terminal lamp indications ............................................................................................. 34 Preparation work for troubleshooting for electrical system............................................................. 37 Procedure for testing diodes .......................................................................................................... 39 40 Troubleshooting Failure code table and fuse locations SEN03156-01 Failure code table ............................................................................................................................. 2 Fuse locations .................................................................................................................................. 6 General information on troubleshooting SEN03157-02 Points to remember when troubleshooting....................................................................................... 2 Sequence of events in troubleshooting ............................................................................................ 3 Checks before troubleshooting......................................................................................................... 4 Classification and procedures of troubleshooting............................................................................. 6 Contents of troubleshooting table..................................................................................................... 7 Connection table for connector pin numbers.................................................................................. 12 T- branch box and T- branch adapter table .................................................................................... 49 Troubleshooting by failure code, Part 1 SEN03158-00 Failure code [7RC1KB] Short circuit conveyor ON switch................................................................ 4 Failure code [7RC2KA] Disconnection in conveyor OFF switch ...................................................... 6 Failure code [7RC5KB] Short circuit in feeder ON switch ................................................................ 8 Failure code [7RD2KB] Short circuit in discharge conveyor reverse solenoid ............................... 10 Failure code [7RD2KZ] Disconnection or short circuit in discharge conveyor reverse solenoid .... 11 Failure code [7RE1KB] Short circuit in crusher ON switch............................................................. 12 Failure code [7RE2KA] Disconnection in crusher OFF switch ....................................................... 14 Failure code [7RE6KB] Short circuit in muck discharge conveyor ON switch................................ 16 Failure code [7RE7KA] Disconnection in muck discharge conveyor OFF switch .......................... 18 Failure code [7RE8KB] Short circuit in magnetic separator ON switch .......................................... 20 Failure code [7RE9KA] Disconnection in magnetic separator OFF switch .................................... 22 Failure code [7REAKB] Short circuit in accessory input circuit 1 ................................................... 24 Failure code [7REDMA] Abnormality in conveyor pressure sensor ............................................... 26 Failure code [7REEMA] Abnormality in muck conveyor pressure sensor ...................................... 28 Failure code [7REHKB] Short circuit in accessory input circuit 2 ................................................... 30 Failure code [7RENKZ] Abnormality in clearance potentiometer ................................................... 32 Failure code [7REPKA] Disconnection in feeder OFF switch......................................................... 34 Failure code [7RESKB] Short circuit in one-touch start switch....................................................... 36 Failure code [7RETKA] Disconnection in one-touch stop switch ................................................... 38 Failure code [7RF2KA] Disconnection in crusher forward EPC valve............................................ 40 Failure code [7RF2KB] Short circuit in crusher forward EPC valve ............................................... 41
6
BR580JG-1
00 Index and foreword
SEN02604-08
Failure code [7RF2KY] Short circuit in crusher forward EPC valve ............................................... 42 Failure code [7RF3KA] Disconnection in crusher reverse EPC valve............................................ 43 Failure code [7RF3KB] Short circuit in crusher reverse EPC valve ............................................... 44 Failure code [7RF3KY] Short circuit in crusher reverse EPC valve ............................................... 45 Failure code [7RF4KA] Disconnection in feeder forward EPC valve ............................................. 46 Failure code [7RF4KB] Short circuit in feeder forward EPC valve ................................................. 47 Failure code [7RF4KY] Short circuit in feeder forward EPC valve ................................................. 48 Failure code [7RF8KA] Disconnection in accessory 2 EPC valve ................................................. 49 Failure code [7RF8KB] Short circuit in accessory 2 EPC valve ..................................................... 50 Failure code [7RF8KY] Short circuit in accessory 2 EPC solenoid ................................................ 51 Troubleshooting by failure code, Part 2 SEN03159-00 Failure code [7RFAKY] Short circuit in engine stop relay ................................................................ 4 Failure code [7RFAKZ] Disconnection or short circuit in engine stop relay ..................................... 6 Failure code [7RFBKB] Short circuit in muck conveyor solenoid ..................................................... 8 Failure code [7RFBKZ] Disconnection or short circuit in muck conveyor solenoid .......................... 9 Failure code [7RFHKA] Disconnection in conveyor forward EPC valve ........................................ 10 Failure code [7RFHKB] Short circuit in conveyor forward EPC valve ............................................ 11 Failure code [7RFHKY] Short circuit in conveyor forward EPC valve ............................................ 12 Failure code [7RFKKB] Short circuit in lock cylinder pull relay ...................................................... 14 Failure code [7RFKKY] Short circuit in lock cylinder pull relay ...................................................... 16 Failure code [7RFLKA] Disconnection in accessory 1 EPC solenoid ............................................ 18 Failure code [7RFLKB] Short circuit in accessory 1 EPC solenoid ................................................ 19 Failure code [7RFLKY] Short circuit in accessory 1 EPC solenoid ................................................ 20 Failure code [7RFMKY] Short circuit in abnormal pressure relay .................................................. 22 Failure code [7RFMKZ] Disconnection or short circuit in abnormal pressure relay ....................... 24 Failure code [7RFNKA] Disconnection in lock cylinder unlock solenoid valve ............................... 26 Failure code [7RFNKB] Short circuit in lock cylinder unlock solenoid valve .................................. 27 Failure code [7RFNKY] Short circuit in lock cylinder unlock solenoid valve .................................. 28 Failure code [7RFPKB] Short circuit in lock cylinder push relay .................................................... 30 Failure code [7RFPKY] Short circuit in lock cylinder push relay .................................................... 32 Failure code [7RGAMA] Abnormality in 2nd conveyor pressure sensor ........................................ 34 Failure code [7RJAKA] Disconnection in travel lock EPC solenoid valve ...................................... 36 Failure code [7RJAKB] Short circuit in travel lock EPC solenoid valve.......................................... 38 Failure code [7RJAKY] Short circuit in travel lock EPC solenoid valve.......................................... 40 Failure code [7RJDMA] Abnormality in crusher forward pressure sensor ..................................... 42 Failure code [7RJEMA] Abnormality in crusher reverse pressure sensor...................................... 44 Failure code [7RJLKA] Disconnection in magnetic separator EPC valve ...................................... 46 Failure code [7RJLKB] Short circuit in magnetic separator EPC valve .......................................... 47 Failure code [7RJLKY] Short circuit in magnetic separator EPC valve .......................................... 48 Failure code [7RJMMW] Lock cylinder slipping ............................................................................. 50 Failure code [7RJPKB] Short circuit in radio control work-mode switch ........................................ 52 Failure code [7RJQKB] Short circuit in radio control travel-mode switch ....................................... 54 Failure code [7RJRKB] Short circuit on travel signal ..................................................................... 56 Failure code [7RJSMA] Abnormality in magnetic separator pressure sensor ................................ 58 Failure code [AA10NX] Air cleaner Clogging ................................................................................. 60 Failure code [AB00KE] Charge voltage too low ............................................................................. 62 Troubleshooting by failure code, Part 3 SEN03160-01 Failure code [B@BAZG] Engine oil pressure too low ...................................................................... 3 Failure code [B@BAZK] Engine oil level reduction .......................................................................... 4 Failure code [B@BCNS] Engine coolant overheat........................................................................... 5 Failure code [B@BCZK] Radiator coolant level reduction ............................................................... 6 Failure code [B@HANS] Hydraulic Oil Overheat ............................................................................. 7 Failure code [CA111] ECM Critical Internal Failure .......................................................................... 8 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ........................................................... 10 Failure code [CA122] Chg Air Press Sensor High Error ................................................................ 11 Failure code [CA123] Chg Air Press Sensor Low Error ................................................................. 13 Failure code [CA131] Throttle Sensor High Error .......................................................................... 14 Failure code [CA132] Throttle Sensor Low Error ........................................................................... 16 BR580JG-1
7
SEN02604-08
00 Index and foreword
Failure code [CA135] Eng Oil Press Sensor High Error................................................................. 17 Failure code [CA141] Eng Oil Press Sensor Low Error.................................................................. 19 Failure code [CA144] Coolant Temp Sens High Error.................................................................... 20 Failure code [CA145] Coolant Temp Sens Low Error..................................................................... 22 Failure code [CA153] Chg Air Temp Sensor High Error ................................................................. 23 Failure code [CA154] Chg Air Temp Sensor Low Error.................................................................. 25 Failure code [CA187] Sens Supply 2 Volt Low Error...................................................................... 25 Failure code [CA221] Ambient Press Sens High Error................................................................... 26 Failure code [CA222] Ambient Press Sens Low Error ................................................................... 28 Failure code [CA227] Sens Supply 2 Volt High Error ..................................................................... 29 Failure code [CA234] Eng Overspeed............................................................................................ 31 Failure code [CA238] Ne Speed Sens Supply Volt Error................................................................ 32 Failure code [CA263] Fuel Temp Sensor High Error ...................................................................... 34 Failure code [CA265] Fuel Temp Sensor Low Error....................................................................... 36 Failure code [CA273] PCV2 Short Error......................................................................................... 37 Failure code [CA274] PCV2 Open Error ........................................................................................ 38 Failure code [CA322] Inj #1 (L#1) Open/Short Error ...................................................................... 40 Failure code [CA323] Inj #5 (L#5) Open/Short Error ...................................................................... 42 Failure code [CA324] Inj #3 (L#3) Open/Short Error ...................................................................... 44 Failure code [CA325] Inj #6 (L#6) Open/Short Error ...................................................................... 46 Failure code [CA331] Inj #2 (L#2) Open/Short Error ...................................................................... 48 Failure code [CA332] Inj #4 (L#4) Open/Short Error ...................................................................... 50 Troubleshooting by failure code, Part 4 SEN03161-00 Failure code [CA342] Calibration Code Incompatibility .................................................................... 3 Failure code [CA351] INJ. Drive Circuit Error................................................................................... 4 Failure code [CA352] Sens Supply 1 Volt Low Error........................................................................ 6 Failure code [CA386] Sens Supply 1 Volt High Error ....................................................................... 8 Failure code [CA441] Battery Voltage Low Error............................................................................ 10 Failure code [CA442] Battery Voltage High Error ........................................................................... 12 Failure code [CA449] Rail Press Very High Error........................................................................... 13 Failure code [CA451] Rail Press Sensor High Error ...................................................................... 14 Failure code [CA452] Rail Press Sensor Low Error ....................................................................... 16 Failure code [CA553] Rail Press High Error................................................................................... 16 Failure code [CA554] Rail Press Sensor In Range Error ............................................................... 17 Failure code [CA559] Rail Press Low Error.................................................................................... 18 Failure code [CA689] Eng Ne Speed Sensor Error ........................................................................ 22 Failure code [CA731] Eng Bkup Speed Sens Phase Error ............................................................ 24 Failure code [CA757] All Persistent Data Lost Error ...................................................................... 25 Failure code [CA778] Eng Bkup Speed Sensor Error .................................................................... 26 Failure code [CA1228] EGR Valve Servo Error 1........................................................................... 28 Failure code [CA1625] EGR Valve Servo Error 2........................................................................... 29 Failure code [CA1633] CAN Communication Error (engine controller) .......................................... 30 Failure code [CA2185] Throt Sens Sup Volt High Error ................................................................. 32 Failure code [CA2186] Throt Sens Sup Volt Low Error .................................................................. 34 Failure code [CA2249] Rail Press Very Low Error ......................................................................... 35 Failure code [CA2271] EGR Valve Lift Position Sens High Error ................................................... 36 Failure code [CA2272] EGR Valve Lift Position Sens Low Error.................................................... 38 Failure code [CA2351] EGR Valve Sol Current High Error ............................................................ 39 Failure code [CA2352] EGR Valve Sol Current Low Error ............................................................. 41 Failure code [CA2555] Grid Heater Relay Open Error ................................................................... 42 Failure code [CA2556] Grid Heater Relay Short Error ................................................................... 44 Troubleshooting by failure code, Part 5 SEN03162-00 Failure code [D162KY] Short circuit in horn relay ............................................................................ 4 Failure code [D162KZ] Disconnection or short circuit in horn relay ................................................. 6 Failure code [DA22KK] Solenoid power source too low................................................................... 8 Failure code [DA25KP] Abnormality in pressure sensor power source.......................................... 10 Failure code [DA2RMC] CAN communication error (work equipment and pump controller) ......... 14 Failure code [DA2SKQ] Abnormality in model code input.............................................................. 16
8
BR580JG-1
00 Index and foreword
SEN02604-08
Failure code [DAFRMC] CAN communication error (monitor controller) ....................................... 18 Failure code [DDA6KA] Disconnection in engine stop switch ........................................................ 20 Failure code [DGH2KB] Short circuit in hydraulic oil temperature sensor...................................... 22 Failure code [DHPAMA] Abnormality in F pump pressure sensor.................................................. 24 Failure code [DHPBMA] Abnormality in R pump pressure sensor................................................. 26 Failure code [DUB0KY] Short circuit in beacon solid state relay ................................................... 28 Failure code [DUB0KZ] Disconnection or short circuit in beacon solid state relay......................... 30 Failure code [DXA0KA] Disconnection in PC-EPC Solenoid ......................................................... 32 Failure code [DXA0KB] Short circuit in PC-EPC Solenoid ............................................................. 33 Failure code [DXA0KY] Short circuit in PC-EPC Solenoid ............................................................. 34 Failure code [DXE0KA] Disconnection in LS-EPC solenoid .......................................................... 35 Failure code [DXE0KB] Short circuit in LS-EPC solenoid .............................................................. 36 Failure code [DXE0KY] Short circuit in LS-EPC solenoid .............................................................. 37 Troubleshooting of electrical system (E-mode) SEN03163-01 Information in troubleshooting table ................................................................................................. 3 E-1 Engine does not start (Engine does not turn) ............................................................................ 4 E-2 The engine stops while it is running .......................................................................................... 8 E-3 Automatic warming-up does not operate................................................................................. 10 E-4 Preheater does not operate..................................................................................................... 12 E-5 The whole work equipment stops suddenly............................................................................. 14 E-6 The red mark of emergency stop is indicated just after the engine is started.......................... 18 E-7 The machine monitor does not display any item ..................................................................... 22 E-8 Some items are not displayed on the machine monitor........................................................... 24 E-9 Contents of display by machine monitor are different from applicable machine...................... 24 E-10 Fuel level monitor was lighted in red while engine running ................................................... 25 E-11 Engine coolant temperature gauge does not indicate normally ............................................. 26 E-12 The fuel level gauge does not display normally. .................................................................... 28 E-13 The hydraulic oil temperature gauge does not display normally ........................................... 29 E-14 The travel, work, and inspection modes do not change. ....................................................... 30 E-15 The crusher clearance adjustment mode does not change................................................... 32 E-16 The crusher rotation direction does not change .................................................................... 34 E-17 Machine does not travel ........................................................................................................ 36 E-18 Travel cannot be controlled by radio control.......................................................................... 38 E-19 The feeder cannot be turned ON and OFF by radio control .................................................. 42 E-20 One-touch start, stop switch cannot be operated by radio control ........................................ 46 E-21 The monitor switches do not work ......................................................................................... 49 E-22 The crusher cannot be operated with the crusher manual FORWARD/REVERSE switch on the monitor ................................................................................................................. 50 E-23 The conveyor cannot be operated with the conveyor manual FORWARD/REVERSE switch on the monitor....................................................................................................... 51 E-24 KOMTRAX system does not operate normally...................................................................... 52 Troubleshooting of hydraulic and mechanical system (H-mode) SEN03164-00 System chart for hydraulic and mechanical systems ....................................................................... 4 Information contained in troubleshooting table................................................................................. 6 H-1 The speed or power of the whole work equipment and travel is low......................................... 8 H-2 The engine speed lowers extremely or the engine stalls ........................................................ 10 H-3 The work equipment and travel systems do not work ............................................................. 11 H-4 Abnormal sound comes out from around the hydraulic pump................................................. 11 H-5 Fine control performance or response is low .......................................................................... 12 H-6 The conveyor does not operate............................................................................................... 13 H-7 The speed or power of the conveyor is low............................................................................. 14 H-8 The crusher does not operate ................................................................................................. 15 H-9 The speed or power of crusher is low ..................................................................................... 16 H-10 The feeder does not operate ................................................................................................. 16 H-11 The feeder does not feed smoothly (Vibration frequency is low)........................................... 17 H-12 The magnetic separator does not operate ............................................................................ 17 H-13 The speed of magnetic separator belt is low ......................................................................... 18 H-14 The muck discharge conveyor does not operate .................................................................. 18 BR580JG-1
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SEN02604-08
00 Index and foreword
H-15 The speed or power of the muck discharge conveyor is low................................................. 19 H-16 The primary conveyor does not move up and down.............................................................. 19 H-17 The muck discharge conveyor does not move up and down ................................................ 20 H-18 The open and close hopper does not move up and down..................................................... 21 H-19 The machine deviates during travel....................................................................................... 22 H-20 The travel speed is low.......................................................................................................... 24 H-21 The machine is not steered well or steering power is low ..................................................... 26 H-22 The travel motor does not work (only one side) .................................................................... 27 H-23 When the travel switch of the wired remote control or radio controller is depressed, the machine does not travel ............................................................................................ 28 H-24 The crusher clearance cannot be adjusted ........................................................................... 29 Troubleshooting of engine (S-mode) SEN03165-01 Method of using troubleshooting chart ............................................................................................. 4 S-1 Starting performance is poor...................................................................................................... 8 S-2 Engine does not start............................................................................................................... 10 S-3 Engine does not pick up smoothly ...........................................................................................14 S-4 Engine stops during operations ............................................................................................... 15 S-5 Engine does not rotate smoothly ............................................................................................. 16 S-6 Engine lacks output (or lacks power)....................................................................................... 17 S-7 Exhaust smoke is black (incomplete combustion) ................................................................... 18 S-8 Oil consumption is excessive (or exhaust smoke is blue) ....................................................... 20 S-9 Oil becomes contaminated quickly .......................................................................................... 21 S-10 Fuel consumption is excessive .............................................................................................. 22 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)..................................... 23 S-12 Oil pressure drops ................................................................................................................. 24 S-13 Oil level rises (Entry of coolant or fuel) .................................................................................. 25 S-14 Coolant temperature becomes too high (overheating) .......................................................... 27 S-15 Abnormal noise is made ........................................................................................................ 28 S-16 Vibration is excessive ............................................................................................................ 29 50 Disassembly and assembly General information on disassembly and assembly SEN03441-03 How to read this manual................................................................................................................... 2 Coating materials list ........................................................................................................................ 4 Special tool list.................................................................................................................................. 8 Sketches of special tools................................................................................................................ 11 Engine and cooling system SEN03442-01 Removal and installation of fuel supply pump assembly .................................................................. 2 Removal and installation of fuel injector assembly........................................................................... 6 Removal and installation of engine front seal................................................................................. 13 Removal and installation of engine rear seal ................................................................................. 16 Removal and installation of cylinder head assembly...................................................................... 21 Removal and installation of engine and hydraulic pump assembly ................................................ 32 Removal and installation of radiator assembly............................................................................... 39 Removal and installation of hydraulic oil cooler assembly ............................................................. 41 Removal and installation of aftercooler assembly .......................................................................... 43 Removal and installation of fuel tank assembly ............................................................................. 45 Power train SEN03443-00 Removal and installation of final drive assembly.............................................................................. 2 Disassembly and assembly of final drive assembly ......................................................................... 4 Undercarriage and frame SEN03444-01 Disassembly and assembly of track roller assembly ........................................................................ 2 Disassembly and assembly of idler assembly.................................................................................. 3 Disassembly and assembly of recoil spring ..................................................................................... 6 Removal and installation of sprocket................................................................................................ 8 Repair of guide plate with wear plates ............................................................................................. 9 Spreading and installation of track shoe assembly ........................................................................ 11
10
BR580JG-1
00 Index and foreword
SEN02604-08
Hydraulic system SEN03445-00 Removal and installation of hydraulic tank assembly....................................................................... 2 Removal and installation of hydraulic pump assembly .................................................................... 6 Removal and installation of control valve assembly......................................................................... 9 Disassembly and assembly of control valve assembly .................................................................. 16 Removal and installation of crusher motor assembly..................................................................... 20 Removal and installation of crusher lock cylinder assembly .......................................................... 21 Disassembly and assembly of crusher lock cylinder assembly...................................................... 24 Bleeding air from crusher lock cylinder .......................................................................................... 28 Removal and installation of primary belt conveyor motor .............................................................. 30 Removal and installation of feeder vibrator motor assembly ......................................................... 33 Removal and installation of muck discharge conveyor motor assembly ........................................ 35 Removal and installation of magnetic separator motor assembly .................................................. 36 Work equipment SEN03446-01 Removal and installation of cheek plates ......................................................................................... 3 Removal and installation of fixed tooth ............................................................................................ 7 Removal and installation of swing tooth ......................................................................................... 11 Removal and installation of toggle plate ........................................................................................ 16 Removal and installation of fixing link ............................................................................................ 21 Removal and installation of swing jaw assembly ........................................................................... 25 Removal and installation of crusher main bearing ......................................................................... 28 Removal and installation of crusher motor and motor housing assembly ...................................... 33 Removal and installation of crusher motor V-sheave ..................................................................... 35 Removal and installation of V-sheave and balance weight ............................................................ 38 Removal and installation of potentiometer ..................................................................................... 42 Removal and installation of fixing link lifting spring assembly ........................................................ 43 Removal and installation of link pin dust cover .............................................................................. 45 Removal and installation of crusher assembly ............................................................................... 47 Removal and installation of primary belt conveyor assembly ........................................................ 56 Removal and installation of primary belt conveyor head pulley frame ........................................... 60 Removal and installation of muck discharge conveyor assembly (if equipped) ............................. 67 Removal and installation of muck discharge conveyor head pulley (if equipped) .......................... 70 Removal and installation of muck discharge conveyor tail pulley (if equipped) ............................. 75 Removal and installation of magnetic separator assembly ............................................................ 77 Electrical system SEN03447-00 Removal and installation of engine controller assembly .................................................................. 2 Removal and installation of work equipment and pump controller assembly................................... 3 90 Diagrams and drawings Hydraulic diagrams and drawings SEN02618-01 Hydraulic circuit diagram (1/2) ......................................................................................................... 3 Hydraulic circuit diagram (2/2) ......................................................................................................... 5 Electrical diagrams and drawings SEN02619-02 Electrical circuit diagram (1/4).......................................................................................................... 3 Electrical circuit diagram (2/4).......................................................................................................... 5 Electrical circuit diagram (3/4).......................................................................................................... 7 Electrical circuit diagram (4/4).......................................................................................................... 9 Connector arrangement diagram (1/2)........................................................................................... 11 Connector arrangement diagram (2/2)........................................................................................... 13
BR580JG-1
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SEN02604-08
BR580JG-1 Mobile crusher Form No. SEN02604-08
© 202 KOMATSU All Rights Reserved Printed in Japan -2
12
SEN02605-02
MOBILE CRUSHER 1SHOP MANUAL
BR580JG-1
Machine model
Serial number
BR580JG-1
1001 and up
00 Index and foreword
1
Foreword and general information Safety notice ................................................................................................................................................... 2 How to read the shop manual ......................................................................................................................... 7 Explanation of terms for maintenance standard ............................................................................................. 9 Handling of electric equipment and hydraulic component .............................................................................11 Handling of connectors newly used for engines ........................................................................................... 20 How to read electric wire code ...................................................................................................................... 23 Precautions when carrying out operation...................................................................................................... 26 Method of disassembling and connecting push-pull type coupler................................................................. 29 Standard tightening torque table ................................................................................................................... 32 Conversion table ........................................................................................................................................... 36
BR580JG-1
1
This is the sample of the manual Click on the download link for complete manual
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