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Komatsu GALEO BR550JG-1, Operation & Maintenance Manual

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Komatsu GALEO BR550JG-1 Operation & Maintenance Manual Download Page 168

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OPERATION

TROUBLESHOOTING

BELT CONVEYOR AND RELATED ACCESSORIES

Most of the troubles on the belt conveyor may be prevented beforehand, because they are often caused by
improper operation and maintenance. A simple inspection allows the belt conveyor to prolong the service life and
to demonstrate the performance to a maximum.

Abnormal Phenomenon

Major Cause

Corrective Action

Conveyor belt

Not operable

Electric circuit fault
Connection fault

Correct wiring.
Insert connection properly.

Snaky movement

Misalignment of rollers and
improper mounting
Debris transport direction

Debris stuck to rollers
(Likewise wire or string winding
about rollers)
Belt elongation
Belt bending, or not installed
properly in endless processing
Frame twisting and bending

Frame not poised evenly 
(Belt is deflected to lower side)

Belt too rigid
(Wrong belt chosen)

Adjust roller mounting angle.

Load debris evenly in the middle
of the belt, after making sure that
the machine is kept level on the
ground.
Clean roller periphery.

Adjust belt tension with take-up.
Retry endless processing, or
replace belt with new one.
Correct twisting and eccentricity
at time of assembly or machine
installation.
Correct twisting and eccentricity
at time of assembly or machine
installation.
a. Run in belt without load.
b. replace with softer (proper)
    belt.

Abnormal wear on backside

Slip on motor pulley (or driving
pulley) surface
Debris or foreign object stuck in
between belt and pulley
(Foreign objects stuck on pulley
surface)
Faulty rotation of rollers

Correct belt elongation with
take-up.
a. Remove foreign objects.
    (Remove sticking)
b. Improve loading conditions at
    loading part.
Replace faulty rollers.

Damage (fissure in vertical
direction)

Debris or foreign objects caught
where belt contacts hopper,
scraper, etc.
Rollers falling off from bracket
and bracket coming to direct
contact belt
Rollers of faulty rotation worn out
and perforated
Shock due to drop of large and
heavy mass
Edged debris

Remove foreign objects.

Insert rollers into bracket
correctly.

Replace faulty rollers.

Devise to alleviate shock, or
ensure right load.
Do not let such materials be
transported.

Abnormal elongation

Too strong take-up
Transport of hot materials
Abnormal load
End of service life

Return to normal tension.
Replace with heat-resistant belt.
Ensure proper load.
Replace with new belt.

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https://tractormanualz.com

Summary of Contents for GALEO BR550JG-1

Page 1: ...https tractormanualz com...

Page 2: ...1 1 https tractormanualz com...

Page 3: ...rstand them fully Keep this manual at the storage location for the operation and maintenance manual given below and have all personnel read it periodically If this manual has been lost or has become d...

Page 4: ...FOREWORD FOREWORD 1 3 https tractormanualz com...

Page 5: ...FOREWORD FOREWORD 1 4 https tractormanualz com...

Page 6: ...h if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury This word is used also to alert against...

Page 7: ...angle and the method of avoiding the hazardous condition is shown inside a circle Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance Therefore...

Page 8: ...ease refer to the section SCOPE OF WORKS USING MOBILE CRUSHER PAGE 3 86 FRONT REAR LEFT RIGHT DIRECTIONS OF MACHINE This manual indicates the right and left as well as the fore and aft sides of the ma...

Page 9: ...arts please inform your Komatsu distributor of the following items MACHINE SERIAL NO PLATE AND POSITION Provided at the rear on the right side of the frame ENGINE SERIAL NO PLATE AND POSITION Provided...

Page 10: ...TION OF SERVICE METER Provided above the machine monitors on the control panel TABLE OF ENTER SERIAL NO AND DISTRIBUTOR Machine serial No Engine serial No Distributor name Address Service Personnel Ph...

Page 11: ...ATION 2 24 TRANSPORTATION 2 27 BATTERY 2 28 TOWING 2 30 PRECAUTIONS FOR MAINTENANCE 2 31 OPERATION 3 1 GENERAL VIEW 3 2 GENERAL VIEW OF MACHINE 3 2 GENERAL VIEW OF CONTROLS AND GAUGES 3 3 EXPLANATION...

Page 12: ...ING STORAGE 3 110 AFTER STORAGE 3 110 STARTING MACHINE AFTER LONG TERM STORAGE 3 110 TROUBLESHOOTING 3 111 PHENOMENA THAT ARE NOT FAILURES 3 111 METHOD OF TOWING MACHINE 3 111 IF BATTERY IS DISCHARGED...

Page 13: ...N USE 6 3 CHECK AND INSPECTION 6 4 FAILURES AND CORRECTIVE ACTIONS 6 5 LIST OF CHECKPOINT 6 5 SPECIFICATIONS 6 6 LIST OF WEARING PARTS 6 7 MUCK DISCHARGE CONVEYOR 6 8 LIFTING PROCEDURES 6 8 ASSEMBLING...

Page 14: ...2 1 https tractormanualz com...

Page 15: ...LY LOCK WHEN LEAVING OPERATOR S PLATFORM 2 13 HANDRAILS AND STEPS 2 14 MOUNTING AND DISMOUNTING 2 14 NO PEOPLE ON ATTACHMENTS 2 14 PREVENTION OF BURNS 2 15 FIRE PREVENTION 2 15 ACTION IF FIRE OCCURS 2...

Page 16: ...LY ON SNOW 2 22 PARKING MACHINE 2 23 CRUSHER OPERATION 2 24 CHECKS AROUND MACHINE 2 24 TURN OPERATION MODE SELECTOR SWITCH TO WORK POSITION 2 24 ENSURE SAFETY WHILE OPERATING IN TANDEM WITH HYDRAULIC...

Page 17: ...SONNEL 2 33 PRECAUTIONS WHEN MOUNTING DISMANTLING AND STORING ATTACHMENTS 2 33 PRECAUTIONS FOR WORK UNDER MACHINEEQUIPMENT 2 33 NOISE 2 33 PRECAUTIONS WHEN USING HAMMER 2 34 REPAIR WELDING 2 34 REMOVI...

Page 18: ...e and always keep them clean When cleaning them do not use organic solvents or gasoline These may cause the labels to peel off There are also other labels in addition to the warning signs and safety l...

Page 19: ...SAFETY SAFETY LABELS POSITIONS OF SAFETY PICTOGRAMS 2 6 https tractormanualz com...

Page 20: ...ing the operator s platform 8295 93 1371 2 Watch out electric wires 8295 93 1580 3 Precautions for machine operation inspection and maintenance 09651 A0481 4 Precautions for machine operation inspecti...

Page 21: ...rating the machine 8221 93 1611 6 Precautions for oil at high temperature 09653 A0641 7 Warning the machine operator against falling off the machine 09805 C0881 8 Warning against machine rolling down...

Page 22: ...ine while running 09667 A0481 10 Precautions for the cooling water at high temperature 09653 A0481 11 Precautions when handling electric cables 09808 A0881 12 Warning when climbing up and down the mac...

Page 23: ...ing the crusher pulley 09667 A0641 14 Precautions when inspecting the crusher 09838 H1201 15 Warning against spattering debris 09826 A0881 16 Prohibition of unauthorized entry into Off Limit working a...

Page 24: ...perating belt conveyor 09828 H2321 18 Warning when inspecting the belt conveyor 09667 A0641 19 Precautions for access to the grizzly while in operation 09834 H1201 20 Precautions when tightening the t...

Page 25: ...h on control levers or other protruding parts If you have long hair and it hangs out from your hard hat there is a hazard that it may get caught up in the machine so tie your hair up and be careful no...

Page 26: ...t Make sure that no parts or tools are left around the operator s platform Never use a cellular phone on the operator s platform while operating the machine Never place any dangerous material like inf...

Page 27: ...Before getting on or off the machine check the handrails and steps including the track shoe If there is any oil grease or mud on the handrails or steps including the track shoe wipe it off immediatel...

Page 28: ...fail Never smoke nor use fire near any of them Stop the engine for refuelling and oiling Never leave the machine while refueling or oiling Tighten all the fuel and oil caps securely Do not spill fuel...

Page 29: ...that they catch fire and explode causing a serious injury or death ACTION IF FIRE OCCURS If a fire occurs escape from the machine as follows Turn the start switch OFF to stop the engine Use the handra...

Page 30: ...chine will cause the soil to collapse Before starting operations take steps to ensure that the ground is safe and to prevent the machine from rolling over or falling DO NOT GO CLOSE TO HIGH VOLTAGE CA...

Page 31: ...d position a signalman if necessary Operators should pay careful attention to the signs and follow the instructions from the signalman Only one signalman should give signals Make sure that all workers...

Page 32: ...the angle of the lights and working lamps and check that the control levers are all at the neutral position Before starting the engine make sure that the lock lever is in the LOCK position Adjust the...

Page 33: ...d this may lead to unexpected accidents If the battery electrolyte is frozen do not charge the battery or start the engine with a different power source There is a hazard that this will ignite the bat...

Page 34: ...machine is equipped with mirrors PRECAUTIONS WHEN TRAVELING On the uneven ground operate the machine at a low speed avoiding jerky operation so that the machine will not roll over Otherwise the machin...

Page 35: ...r starting the work When operating in tunnels under bridges under electric wires or other places where the height is limited be extremely careful not to let the work equipment hit anything To prevent...

Page 36: ...ongoing vehicles can readily spot the machine When parking the machine be sure to set the travel lever safety lock to the LOCK position and stop the engine by turning the mode selector switch to the...

Page 37: ...ions set forth in the section of Operation Jaw crusher operation in this manual ENSURE SAFETY WHILE OPERATING IN TANDEM WITH HYDRAULIC EXCAVATOR The operator of this machine is supposed to work in coo...

Page 38: ...ular Check the machine main frame whether there is no deformation or crack developed on it PRECAUTIONS FOR CRUSHING WORK While the machine is in operation do not allow any irrelevant person to come ne...

Page 39: ...SHING WORK An operator of this machine must take position near the emergency stop switch during the work and immediately press the switch to stop all the work equipment when he or she feels something...

Page 40: ...loading Never correct your steering on the ramps If necessary drive off the ramps correct the direction then enter the ramps again When the machine is on the ramps do not operate it other than travel...

Page 41: ...orking with batteries turn the starting switch to the OFF position As there is a hazard that sparks will be generated always do as follows Do not let tools or other metal objects make any contact betw...

Page 42: ...a hazard that the machine will move when the power is connected Be sure to connect the positive cable first when installing the booster cables Disconnect the negative cable ground side first when remo...

Page 43: ...ire rope Always wear leather gloves when handling wire rope Fix the wire rope to the track frame During the towing operation never stand between the towing machine and the machine being towed Never to...

Page 44: ...K PLACE CLEAN AND TIDY Do not leave hammers or other tools lying around in the work place Wipe up all grease oil or other substances that will cause you to slip Always keep the work place clean and ti...

Page 45: ...parts If it becomes necessary to clean the interior of the radiator with the engine running turn the mode selector switch A to the Work position Moreover make sure that the work will be carried out by...

Page 46: ...Place attachments that have been removed from the machine in a stable condition so that they do not fall And take steps to prevent unauthorized persons from entering the storage area PRECAUTIONS FOR...

Page 47: ...out welding REMOVING BATTERY TERMINAL When repairing the electrical system or when carrying out electrical welding remove the negative terminal of the battery to prevent the flow of current PRECAUTIO...

Page 48: ...oil or fuel leaks from high pressure hoses it may cause fire or defective operation which may lead to serious injury If any loose bolts are found stop work and tighten to the specified torque If any...

Page 49: ...cal parts See PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS PAGE 4 21 The material of these components naturally changes over time and repeated use causes deterioration wear and fatigue As a result th...

Page 50: ...3 1 https tractormanualz com...

Page 51: ...onveyor 3 Precleaner 4 Jaw crusher 5 Sprinkler 6 Hopper 7 Revolving warning lamp 8 Upper control box 9 Main control box 10 Sprocket 11 Tool box 12 Grizzly feeder vibrator case 13 Grizzly feeder 14 Deb...

Page 52: ...ion 16 Radio controller selector switch if equipped 17 Monitor 18 Fuel control dial 19 Starting switch 20 Horn switch 21 Crusher load setting switch 22 Primary belt conveyor starting switch 23 Primary...

Page 53: ...ter temperature monitor 5 Engine water temperature gauge 6 Clock cum defect condition display 7 Service meter 8 Fuel gauge 9 Fuel level monitor 10 Engine oil level monitor 11 Hydraulic oil level monit...

Page 54: ...or operating the machine To perform suitable operations correctly and safely it is important to completely understand methods of operating the equipment and the meanings of the displays MACHINE MONITO...

Page 55: ...the basic items that should be checked before starting the engine If there is any abnormality the appropriate monitor lamp will flash 1 Radiator water level monitor 2 Engine oil level monitor 3 Hydra...

Page 56: ...ed hydraulic oil level If the monitor lamp flashes check the hydraulic oil level and add oil REPLACEMENT OF ENGINE OIL For only set machine This monitor 4 gives warning when the predetermined time for...

Page 57: ...aired as soon as possible are displayed If there is any abnormality the appropriate monitor lamp will flash to indicate the location of the abnormality 1 Battery charging level monitor 2 Fuel level mo...

Page 58: ...mount of the remaining fuel in the fuel tank reaches approx 70 liter 18 49 US gal this monitor lamp begins to flash Lose no time in refueling AIR CLEANER CLOGGING MONITOR This monitor 3 warns that the...

Page 59: ...d the horn begins to sound If that happens take necessary actions at once 1 Engine water temperature monitor 2 Radiator cooling water level monitor 3 Engine hydraulic pressure monitor ENGINE COOLANT T...

Page 60: ...nitor 3 flashes if the engine lubricating oil pressure goes below the normal value If it flashes stop the engine and check the lubricating system and the level of the oil in the oil pan REMARK The mon...

Page 61: ...tch is ON the pilot display lights up when display items are functioning ENGINE PRE HEATING MONITOR This monitor 1 indicates the pre heating time required when starting the engine at an ambient temper...

Page 62: ...prevention system will be actuated The engine overheat prevention system works in the following manner Lighting up of red range A The engine cooling water temperature monitor lamp C flashes Lighting...

Page 63: ...ight fuel level for some time after the engine starting switch has been turned to the ON position This is not an abnormal phenomenon When the engine is stopped turn the starting switch ON and check th...

Page 64: ...mes 10 00 rounded off 10 45 becomes 11 00 rounded up If the set switch is pressed in time with a time signal or a standard clock the hour will be set X hours 00 minutes immediately 4 After setting the...

Page 65: ...9 Grizzly feeder stop switch 10 Grizzly feeder starting switch 11 Jaw crusher inching switch normal revolution 12 Jaw crusher inching switch reverse revolution 13 Emergency stop switch 14 Fuel control...

Page 66: ...tricity flows to the battery charging circuit and the lamp circuit START Position At this position the engine may be started Once the engine is started keep the hand off the starting switch key HEAT P...

Page 67: ...adjustment Q 8 Primary conveyor raising lowering Q Q Q 9 Debris discharging conveyor raising lowering if equipped Q Q Q 10 Foldable type hopper cylinder if equipped Q Q Q 11 Travel Q Machine does not...

Page 68: ...sounding for five seconds All work stopped due to abnormal load applied to crusher All work stopped due to abnormal load applied to side conveyor if equipped All work stopped due to abnormal load app...

Page 69: ...utlet of the jaw crusher When using this switch set the engine speed at low idling JAW CRUSHER INCHING SWITCH REVERSE REVOLUTION CAUTION While the crusher is in operation e g after the crusher startin...

Page 70: ...op the engine once bring the emergency switch back to the OFF position and try to restart them The emergency switch returns to the OFF position if it is depressed again FUEL CONTROL DIAL NOTICE Set th...

Page 71: ...Control Box This dial 15 is used to change the frequency of the grizzly feeder to adjust the debris and rock feeding speed a Stop feeding MIN Turn the dial to the left end b Maximum feeding speed MAX...

Page 72: ...u try to change the travel speed from the Hi to Lo position while the machine is traveling the machine may swerve from the straight path Change the travel speed after stopping machine once This switch...

Page 73: ...s raised Depress 2 The belt conveyor is lowered The belt conveyor raising and lowering cylinder works only while the switch is kept depressed EMERGENCY PUMP DRIVING SWITCH NOTICE The pump drive emerge...

Page 74: ...Push the control lever forward 2 Reverse Pull the lever toward yourself N Neutral The machine comes to a halt When you shift the travel control lever from Neutral to Forward or from Neutral to Revers...

Page 75: ...itch MUCK DISCHARGE CONVEYOR START SWITCH This switch 1 activates the debris discharging belt conveyor when depressed and sand and earth screened by the grizzly feeder will be taken out of the machine...

Page 76: ...h key when opening and closing the caps METHOD OF OPENING AND CLOSING CAP WITH LOCK Insert the key as far as it will go to the shoulder If the key is turned before it is inserted all the way it may br...

Page 77: ...K TO OPEN THE COVER 1 Insert the key into the key slot 2 Turn the key counterclockwise and open the cover by pulling the cover grip TO LOCK THE COVER 1 Close the cover and insert the key into the key...

Page 78: ...alities listed at left takes place When the cause is removed the lamps goes off Engine oil temperature abnormal Battery charging level abnormal Residual fuel amount abnormal below 70 liter 18 49 US ga...

Page 79: ...a working lamp When installing an additional lighting fixture on the machine use a connector A for an additional lighting provided beside the hopper frame Connector No FCN E21 FUSIBLE LINK When the st...

Page 80: ...ck and repair Do not open the door inside the main control box in a wet weather condition If it has to be opened by all means for some reason or other take care so that dust or rainwater will not get...

Page 81: ...ower source for LX controller and solenoid 4 30A Working lamp 5 10A Revolving working lamp 6 20A Horn 7 10A Optional equipment Radio control unit 8 10A Travel alarm 9 30A Optional appliance Power Sour...

Page 82: ...cylinders and hoses Check the work equipment the hydraulic cylinders and hoses for any damage wear and play If any of them is found fix it 2 Removing dust from the engine parts and the radiator Walk a...

Page 83: ...uges and monitors and if any abnormality is found replace it At the same time wipe out the smudges on their surface 11 Check and cleaning of the rear view mirrors Check the rear view mirrors for break...

Page 84: ...n using compressed air for cleaning blow it keeping some distance to avoid damaging the fins Damage on the fins can cause water leakage and overheating In a dusty job site check the fins every day reg...

Page 85: ...p loosen the cap slightly to relieve the internal pressure 1 Check with a water level sight gauge G provided on the fuel tank side cover on the left side of the machine that the cooling water level is...

Page 86: ...n remove it 4 The oil level should be between the H and L marks on dipstick G If the oil level is below the L mark add engine oil through oil filler F 5 If the engine oil level is higher than the H ma...

Page 87: ...fuel tank is not full add fuel through the fuel filler up until float gauge G reaches the highest point Fuel tank capacity 605 liters 159 84 US gal 4 When refueling hang a refueling gun on the hook o...

Page 88: ...e the H line This will damage the hydraulic equipment and cause the oil to spurt out 2 If the oil level is below the L line add oil through oil filler F on top of the hydraulic oil tank REMARK Since t...

Page 89: ...heck also for loose terminals and tighten any loosened ones Pay special attention to the wiring of the battery starter and alternator when checking Be sure to check that there are no piles of inflamma...

Page 90: ...nt temperature 40 C Stop and check if temperature is abnormally high Check greasing amount is proper 5 Abnorma noise from bearings Q Hearing check None If any abnormality is noticed stop and check Rep...

Page 91: ...age to the crusher main body For some time after an operation is started with load the locking force may be reduced on account of insufficient contact of the shims or fine foreign objects caught betwe...

Page 92: ...ning correct it by turning the adjusting bolts provided on the right and left sides of the belt as shown in the figures a and b at right In case the adjustment cannot be perfected by adjusting only th...

Page 93: ...OPERATION OPERATION CHECK OF JAW CRUSHER AND RELATED ACCESSORIES 3 44 https tractormanualz com...

Page 94: ...ur points 90 apart from each other on the periphery and that the spring is upright If the actual spring set length is longer than the specified dimension by more than 3 mm 0 118 in turn the spring to...

Page 95: ...er of the crusher Take measurement of V belt deflection l and load P using a designated potentiometer and adjust them to the specified tension Model BR550JG 1 Deflection l 1 17 0 mm 0 7 in Adjustment...

Page 96: ...ATION V belt tension adjusting method The V belt tension may be changed by adjusting the turnbuckle located behind the crusher motor After the adjustment be sure to tighten the lock nut 3 47 https tra...

Page 97: ...selector switch 1 is at the WORK position 2 Confirm that all the emergency switches are released They are located in the main control box upper control box and on the left and right sides of the mach...

Page 98: ...that the fuel control dial is at the low idling MIN position Do not crank the starting motor continuously for more than 20 seconds If the engine does not start wait for at least 2 minutes before tryin...

Page 99: ...tinuously If the engine does not start wait for about two minutes and begin with the step 2 again Follow the advices on the cold starting below in a low ambient temperature 1 Turn the fuel control dia...

Page 100: ...START position to start the engine Ambient temperature Preheating time Over 0 C 32 F 0 C to 10 C 32 F to 14 F Approx 20 seconds 10 C to 20 C 14 F to 4 F Approx 30 seconds 4 When the engine starts rel...

Page 101: ...for the inspection If you try to operate the work equipment without sufficient machine warming up the work equipment may respond to an activated control lever or switch only slowly or move against the...

Page 102: ...ing for about five minutes 2 After warm up run is completed check gauges in the following condition If any abnormality is found repair it Engine water temperature gauge 2 Check that it is in the green...

Page 103: ...switch key back to the OFF position stop the engine and pull out the key REMARK When the engine is overheated do not stop it on the spot but allow it to cool down gradually while running at a medium...

Page 104: ...angerous operate the travel control lever slowly and with good time allowance 1 Start the engine 2 Remove the belt conveyor bar off the mounting hook for work by depressing the belt conveyor raising s...

Page 105: ...selector switch 1 to the TRAVEL position and confirm that travel lock monitor 2 lamp is off 7 Raise the engine revolution by turning fuel control dial 3 in the direction of the full revolution 8 Rele...

Page 106: ...trol levers 4 in the following manner Push the levers forward slowly to start the machine MOVING MACHINE BACKWARD 1 Operate the right and left travel control levers 4 in the following manner Pull the...

Page 107: ...on Avoid to stop the machine abruptly Try to stop it with as much allowance as possible While the machine is at standstill be sure to set the travel control lever safety lock to the LOCK position and...

Page 108: ...sudden changes of direction as much as possible Especially when performing counter rotation spin turn stop the machine before turning Operate two travel levers 1 as follows CHANGING DIRECTION OF MACH...

Page 109: ...When turning to the right operate the right travel lever in the same way WHEN MAKING COUNTER ROTATION TURN SPIN TURN When using counter rotation spin turn to turn left pull the left travel lever back...

Page 110: ...moving 3 Turn crusher starting switch 2 to the ON position and confirm that the crusher is rotating 4 Turn grizzly feeder starting switch 3 to the ON position and confirm that the feeder is in motion...

Page 111: ...Minimum charge Turn the dial to the left end 2 Maximum charge Turn the dial to the right end The optimum charging rate for the crusher chamber is approx 60 considering the allowable work amount and w...

Page 112: ...an 60 adjust it by the crusher load setting dial 3 When crushing boulders or many big lumps contained in the debris reduce the grizzly feeder speed as well as the jaw crusher speed for attaining highe...

Page 113: ...N ABNORMAL LOAD IS APPLIED This function is provided to stop the primary belt conveyor the optional work equipment debris discharging conveyor A and magnetic selector B grizzly feeder and crusher auto...

Page 114: ...oreign oject is stuck or caught in the rollers or frame of the conveyor Remove excessive load causing the abnormality Abnormality occurred on magnetic selector 03 Abnormal load is applied to the magne...

Page 115: ...OPERATION WATER SPRINKLER The sprinkler may be put in service only by connecting a hose between a tap water faucet and the coupling 1 of the machine Hose inner diameter 14 mm 0 6 in 3 66 https tractor...

Page 116: ...ation radius of the hopper while opening and closing it If it becomes necessary to climb on the feeder for installing a hook when removing the wedges be sure to stop the engine first attach a safety b...

Page 117: ...OPERATION OPERATION UNIT OPERATOR S POSITION AT WORKSITE 3 68 https tractormanualz com...

Page 118: ...lever with a pin 10 Carry out the same works for the opposite side using left UP switch 3 and left DOWN switch 4 11 Stop the engine 12 Detach the hopper control box from the connector and store it in...

Page 119: ...ifting it up Store the removed pins in the tool box DETACHING REAR HOPPER 1 Insert two eyebolts M20 x 2 into the inside of the rear hopper and set a lifting hook to the eyebolts AGL height of loop 3 2...

Page 120: ...right and left 754 kg 1663 lb piece Dimensions Unit mm ft in A 4325 14 2 B 1185 3 11 C 3995 13 1 D 215 0 8 Rear hopper weight 344 kg 759 lb Dimensions Unit mm ft in F 1155 3 9 G 625 2 1 Dimensions Uni...

Page 121: ...in 2 pieces Dimensions Unit mm ft in A 250 0 10 B 545 1 9 C 940 3 1 D 250 0 10 E 240 0 9 Hopper support rear and weight 198 kg 437 lb in 2 pieces Dimensions Unit mm ft in A 250 0 10 B 545 1 9 C 940 3...

Page 122: ...ICATIONS Hopper when closed Working posture Dimensions Unit mm ft in A 13475 44 3 B 3640 11 11 B 3660 12 0 C 3115 10 3 2980 9 9 D 500 1 8 E 2480 8 2 F 3700 12 2 G 2770 9 1 Hydraulic excavator for load...

Page 123: ...posture Dimensions Unit mm ft in A 13475 44 3 B 3395 11 2 B 3690 12 1 C 2980 9 9 D 500 1 8 E 3700 12 0 SPECIFICATIONS Item Unit Foldable open close type hopper Hopper Capacity m3 cu yd 6 0 7 8 Weight...

Page 124: ...crusher has completely stopped and that there are no more crushed materials to be discharged with the belt conveyor depress primary belt conveyor stop switch 3 to stop the conveyor CHECK AFTER FINISHI...

Page 125: ...fresh debris to the jaw crusher after confirming that the crusher revolution stays steady and constant If the debris are found directly hitting the swing jaw protector after starting the feeding try t...

Page 126: ...plate wedge bolts M30 1716 2 175 0 1265 8 1520 0 to 1912 3 155 0 to 195 0 1121 1 to 1410 4 Slotted head nut of tension spring rod M36 2745 9 280 0 2025 2 2451 7 to 3040 1 250 0 to 310 0 1808 3 to 224...

Page 127: ...the crusher main body For some time after an operation is started with load the locking force may be reduced on account of insufficient contact of the shims or fine foreign objects caught between the...

Page 128: ...g parts 9 Retighten each bolt sufficiently 10 Use shim plates of the same dimensions on the right and left sides of the jaw crusher 11 When adjusting the clearance at the outlet of the crusher do so o...

Page 129: ...fixed jaw plate or its posture is judged as not proper make another inching operation using jaw crusher inching switch normal rotation 2 this time 5 If a sufficient clearance is created among the fore...

Page 130: ...s such a function that when some uncrushable material like an iron lump is fed into the crusher chamber it deforms itself to shield the shafts and the bearings from a large impact load The clearance b...

Page 131: ...ude stroke but cannot be adjusted in direction b crusher width or vertically Accordingly the grain size of crushed debris such as concrete which can be crushed to a cubic form like a dice is 0 to 40 m...

Page 132: ...debris or a concrete block containing many reinforcing bars toward the end of the day s operation because they are highly likely to disrupt the work by stopping the machine PREPARATION FOR DEBRIS AS R...

Page 133: ...LY FEEDER EFFECTIVE METHOD FOR REMOVING MUCK Grizzly feeder is installed to separate soils and sand from rocks and concrete blocks Pay attention to the conditions of the screen UNDESIRABLE USAGE DESIR...

Page 134: ...However do not forget to adjust the feeding amount watching the condition on the grizzly feeder STEP 2 Feeding the optimum amount assures that the screen separates soils and sand from concrete debris...

Page 135: ...case a debris exceeding the optimum feedable block dimensions has to be fed into the jaw crusher set the crusher load setting dial to the SOFT position and start the work This mode helps reduce the o...

Page 136: ...r than 13 mm 0 5 in in diameter and longer than 600 mm 23 6 in must not be crushed since it may damage the crusher 1 Start the engine 2 Depress belt conveyor raising and lowering control switch 1 to r...

Page 137: ...elt conveyor lowering switch to securely hang the belt conveyor bar on the mounting hook for work that was relocated to the lower part With this the machine is ready for crushing reinforced concrete d...

Page 138: ...are no reinforcing bars left around those spots every two to three hours Remove the remaining reinforcing bars in the following manner to prevent a damage on the machine 1 In order to secure working s...

Page 139: ...ch the earth spillage preventive rubber plates that were detached in Item 2 above NOTICE Be sure to push in the rubber part of the earth spillage preventive plates on to the primary conveyor frame sur...

Page 140: ...sher outlet in the range of 55 to 100 mm 2 2 to 3 9 in for fear of damages on the machine and premature wear of the fixed and swing jaw plates When crushing boulders collected in a riverbed set the cr...

Page 141: ...tes will interfere with each other and the toggle plate and the machine itself will be broken If you reduce the clearance at the crusher outlet below 50 mm 2 0 in by increasing the shim plate thicknes...

Page 142: ...ndercarriage under the primary belt conveyor the frame and belt of the conveyor may be damaged when the belt conveyor is set to a working posture Level the ground before parking the machine for work A...

Page 143: ...dial If a slope exceeds 10 when climbing down maintain the the machine posture shown in the figure at right while keeping a low engine rpm 2 When climbing up a slope exceeding 10 maintain the machine...

Page 144: ...g kg lb 1 1 Chassis parts 47445 104616 47445 104616 2 Removed parts 2 Patrol light Mirror A 15 33 08 16 35 28 50 110 51 112 3 Muffler 2 4 41 4 Pre cleaner A 12 26 46 5 Step 21 46 6 Option 3 Magnetic s...

Page 145: ...OPERATION TRANSPORTATION 3 96 https tractormanualz com...

Page 146: ...level ground 2 Fold the hopper For details see CHANGE OF MACHINE FROM OPERATION POSTURE TO TRANSPORTATION POSTURE PAGE 3 69 3 Remove 6 bolts then remove the rotating lamp and mirror A NOTICE There is...

Page 147: ...n fold it over NOTICE After folding it over tighten both the left and right covers securely with bolts to hold in position to prevent play during transportation 10 Remove the 4 steps installed to the...

Page 148: ...ter snow ice grease oil etc from the ramps too Never try to change the travel direction on the ramps Otherwise the machine will slip off them Return to the ground or the trailer bed once and then chan...

Page 149: ...tance from the edge of a road 2 Properly apply the brakes on the trailer and put blocks under the tires to ensure that the trailer does not move Make the slope of the ramps a maximum of 15 3 Turn fuel...

Page 150: ...belt conveyor raising and lowering operation panel 6 Raise the belt conveyor by depressing belt conveyor raising switch 1 again while holding up the belt conveyor stopper 7 When the belt conveyor has...

Page 151: ...chine SECURING MACHINE Load the machine onto a trailer as follows 1 Stop the machine when it takes a level posture right above the rear wheels on the trailer bed 2 Move the machine forward slowly on t...

Page 152: ...ns or wire ropes of sufficient strength Make sure particularly that the machine will not slip sideways UNLOADING 1 Load and unload on firm level ground only Maintain a safe distance from the edge of a...

Page 153: ...uel control dial 3 to the left end to slow down the the engine revolution 6 Set operation mode selector switch 1 to the TRAVEL position and check that the travel lock monitor 2 lamp is off 7 Release t...

Page 154: ...avel to them slowly Never operate any other lever than the travel control levers on the ramps 10 Stop the machine when it takes a level posture right above the rear wheels on the trailer 11 When climb...

Page 155: ...gravity Do not go under the lifted machine as that is dangerous When lifting the machine perform the operation on flat ground as follows Fixing machine and lifting posture without disassembly NOTICE F...

Page 156: ...nol based antifreeze Avoid using any leak preventing agent regardless if it is sold separately or in antifreeze Do not mix one brand of antifreeze with a different brand For the timing of engine cooli...

Page 157: ...and dry ground If a ground of such conditions is not available place wooden boards on the ground and park the machine on them That practice will prevent the undercarriage from being frozen keeping it...

Page 158: ...freeze cannot be used and an ethylene glycol base antifreeze winter one season type is used instead or if no antifreeze is used drain the cooling system completely Thoroughly flush out the cooling sys...

Page 159: ...conveyor storing cylinder Set the travel safety lock to the LOCK position DURING STORAGE WARNING If it is necessary to perform the rust prevention operation while the machine is indoors open the door...

Page 160: ...en towing the machine use a towing wire rope strong enough to withstand the machine weight When the machine gets stuck up in mud and cannot climb out on its own or when towing heavy materials tow them...

Page 161: ...ing the battery first disconnect the cable from the ground normally the negative terminal When installing install the positive terminal first If a tool touches the positive terminal and the chassis th...

Page 162: ...to explode Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line This may cause an explosion Check the battery electrolyte level periodically and add distill...

Page 163: ...normal machine 4 Connect the other clip of booster cable B to the engine block of the problem machine STARTING ENGINE CAUTION Check that the travel lever safety lock is set at the LOCK position irresp...

Page 164: ...Retighten Backlash at fixed jaw plate Retighten fixed jaw plate wedge bolts Wear or damage on bearings Check and replace Wear on toggle plate and toggle seat Replace with new one Wear on end plate at...

Page 165: ...ng amount shortage Wiring fault Starting motor fault Safety relay fault Charge battery Check and repair j Replace Replace The starting motor alternates engagement and disengagement Battery charging am...

Page 166: ...acking Replace monitor Repair The red range of the water temperature gauge lights up The engine cannot be started by turning the starting motor Insufficient fuel Air mixed in fuel system Fuel injectio...

Page 167: ...r rotating speed are slow Insufficient hydraulic oil Add oil up to specified level Hydraulic pump generates abnormal noise Clogged strainer element in hydraulic oil tank Clean element Hydraulic oil te...

Page 168: ...with new one Correct twisting and eccentricity at time of assembly or machine installation Correct twisting and eccentricity at time of assembly or machine installation a Run in belt without load b r...

Page 169: ...aper belt Wear and damage Debris caught a Remove caught in debris and correct scraper rubber mounting so as to evenly contact belt b Replace with new one Rollers Abnormal sound Breakage Faulty rotatio...

Page 170: ...nue Set machine in safe posture and receive inspection promptly Unable to operate the work equipment or turn the machine without display of an error code Ask for inspection promptly For how to use the...

Page 171: ...4 1 https tractormanualz com...

Page 172: ...Turn off the engine starting switch Do not apply more than 200 V continuously Connect grounding cable within 1 m 3 3 ft of the area to be welded If grounding cable is connected near instruments connec...

Page 173: ...face and replace with new parts When doing this be careful not to forget to assemble the O rings and gaskets When installing the hoses do not twist or bend them into loops with a small radius This wil...

Page 174: ...attributed to water or air entered the circuit Consult the Komatsu distributor in your territory When changing the oil always replace the related filters at the same time Komatsu oil analysis service...

Page 175: ...will also cause problems with corrosion due to air entering the coolant GREASE Grease is used to prevent seizure and noises at the joints Those grease fittings which are not shown in the chapter of MA...

Page 176: ...eep them outdoors exercise a good care for safe keeping by covering them with a tarpaulin Practice the first in first out rule when supplying oil in order to avoid the deteriolation in quality that is...

Page 177: ...rol system controller so before installing a radio receiver or other wireless equipment contact your Komatsu distributor When the machine is operated on a seaside take a good care of the electric acce...

Page 178: ...aulic oil filter elements or strainers are cleaned or replace or when any hydraulic component has been repaired or replaced or when a hydraulic piping has been disconnected bleed air from the hydrauli...

Page 179: ...08 60 61180 07000 05210 Element O ring 1 1 Every 500 hours of operation Fuel filter 600 311 8293 Cartridge 1 Every 500 hours of operation Hydraulic oil tank breather 20Y 60 21440 Element 1 Every 500 h...

Page 180: ...e lower right 8295 70 5140 1 72 0 159 17 Cheek plate upper left 8295 70 5110 1 106 0 234 18 Cheek plate lower left 8295 70 5130 1 72 0 159 19 Cheek plate bolt 8295 70 5190 6 20 Cheek plate nut 01580 1...

Page 181: ...MAINTENANCE WEAR PARTS 4 11 https tractormanualz com...

Page 182: ...raper rubber 8295 75 2780 1 0 75 1 65 13 Rubber 8295 75 2391 2 2 95 6 50 14 Rubber 8295 75 2381 2 3 95 8 71 15 Impact bar under crusher 8295 75 2730 9 7 00 15 44 16 Impact bar below shuter 8295 75 274...

Page 183: ...MAINTENANCE WEAR PARTS 4 13 https tractormanualz com...

Page 184: ...MAINTENANCE USE OF FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE USE OF FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 1 ASTM D975 No 1 4 14 https tractormanualz com...

Page 185: ...s above 0 5 When starting the engine with an atmospheric temperature of lower than 0 C 32 F be sure to use engine oil of SAE10W SAE10W 30 and SAE15W 40 even though the atmospheric temperature goes up...

Page 186: ...C3 Gear oil EP Hypogear EP Energrease LS EP2 Antifreeze 6 CALTEX RPM delo 400 RPM delo 450 Universal thuban Universal thuban EP Marfak all purpose 2 Ultra duty grease 2 AF engine coolant 7 CASTROL Tur...

Page 187: ...705 707L White bearing grease Anti freeze and summer coolant 15 PETROFIN A FINA kappa TD FINA potonic N FINA potonic NE FINA marson EPL2 FINA tamidor 16 SHELL Rimura X Spirax EP Spirax heavy duty Alb...

Page 188: ...k plate maintenance socket 8248 70 5770 1 M24 x 105L 10 Swing jaw plate maintenance socket 8295 70 5510 1 M24 x 320L 11 Ratchet handle 8242 70 5E30 1 500L 12 Extension pipe 8242 70 5E50 1 42 7 x 900L...

Page 189: ...MAINTENANCE STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4 19 https tractormanualz com...

Page 190: ...15 7 144 7 16 18 20 22 24 24 27 30 32 36 279 382 549 745 927 28 5 39 56 76 94 5 206 1 282 1 405 0 549 7 683 5 245 309 343 425 490 608 662 829 824 1030 25 0 31 5 35 0 43 5 50 0 62 0 67 5 84 5 84 0 105...

Page 191: ...full performance at all times Furthermore should anything abnormal be found on any of these parts replace it with a new one even if the periodic replacement time for the part has not yet arrived If a...

Page 192: ...adjustment of primary belt conveyor 4 57 CHECK BEFORE STARTING EVERY 100 HOURS SERVICE Greasing crusher bearingseat 4 60 Drain water sediment from fuel tank 4 60 Greasing primary belt conveyor 4 61 E...

Page 193: ...eplace crrosion resistor cartridge 4 77 Change of oil in conveyor motor machinery casE 4 78 EVERY 2000 HOURS SERVICE Change oil in final drive case 4 79 Check alternator starting motor 4 79 Check engi...

Page 194: ...the initial 250 hours of operation Replace fuel filter cartridge Replacement of oil in engine oil pan and engine oil filter cartridge Change of oil in grizzly feeder vibrator case Check engine valve c...

Page 195: ...not clean the air cleaner element until the air cleaner clogging monitor on the monitor panel flashes If the element is cleaned frequently before the clogging monitor flashes the air cleaner will not...

Page 196: ...en though it has not been cleaned 6 times 4 Check inner element mounting nuts for looseness and if necessary retighten 5 If seal washer 7 is found damaged or wing nut 5 is broken replace them with new...

Page 197: ...connector and tighten it with nuts NOTICE The inner element must not be used again even after cleaning When replacing the outer element replace the inner element at the same time 5 Set the outer eleme...

Page 198: ...ifreeze Cleaning of Cooling System and Replacement Replacement of Corrosion Resistor if equipped Super Coolant AF ACL Antifreeze Anti corrosive and all season type Every two years every other year and...

Page 199: ...If river water well water or other such water supply must be used contact your Komatsu distributor We recommend use of an antifreeze density gauge to control the mixing proportions Prepare a container...

Page 200: ...e watch on the water supply hose during supply lest it should come off the radiator water cap 10 Stop the engine after the cleaning work Stop supplying water and close drain valve 3 11 After drainage...

Page 201: ...engine at high idling for five minutes and at low idling for another five minutes to bleed air from the cooling system At that time keep the filler port open 19 Drain cooling water in the subtank cle...

Page 202: ...o the tightening torque of 392 39 2N m 40 4kgf m 289 3 28 9lbft andconfirmthatnuts A and B are in close contact with contact surface a of track link C 2 After checking further tighten to the tightenin...

Page 203: ...s thus necessary to continually inspect the track tension so as to maintain the standard tension Carry out the check and adjustment under the same conditions as when operating on jobsites where the tr...

Page 204: ...REASING TENSION WARNING Prepare a grease gun 1 Inject grease through grease fitting 2 using a grease gun 2 Move the machine back and forth a few times for a distance of 5 m 16 ft 5 in in order to conf...

Page 205: ...stributor for repairs 1 Loosen plug 1 gradually to release the grease 2 When loosening plug 1 turn it a maximum of one turn 3 If the grease does not come out smoothly move the machine forwards and bac...

Page 206: ...d the bottom of the swing jaw plate when the crusher outlet is most widely open In other words when a portion of the flywheel painted red matches a portion of the flywheel cover painted red as illustr...

Page 207: ...MAINTENANCE SERVICE PROCEDURE Below shown is the relation between the shim plate thickness t and outlet clearance when both fixed and swing jaw plates are brand new 4 37 https tractormanualz com...

Page 208: ...MAINTENANCE SERVICE PROCEDURE Attached plate t 6 4 plates t 9 4 plates t 12 16 plates 4 38 https tractormanualz com...

Page 209: ...ing tag to the starting switch in the control box For starting the engine see the sections of CHECKBEFORESTARTING ENGINE PAGE3 33 and STARTING ENGINE PAGE 3 49 in Operation of OPERATION in this manual...

Page 210: ...ush and discharge them making the chamber empty 5 Depress jaw crusher inching switch 3 in the upper control box and match both red painted portions of the flywheel and flywheel cover through an inchin...

Page 211: ...Should the shim plate thickness differ between the right and the left sides there would be a critical damage to the crusher main body For some time after an operation is started with load the locking...

Page 212: ...limit a serious damage will be inflicted on the jaw crusher main body itself Hatched area Area of virtual wear If the bottom tips of fixed and swing jaw plates have been worn off and reached the wear...

Page 213: ...sion reaches approx 65 mm 2 6 in wear amount 30 mm 1 2 in on the lower end of the wedge proceed with the replacement Replace a partially worn wedge too TOGGLE SEAT If the wear dimension reaches approx...

Page 214: ...aches approx 592 mm 23 3 in dismantle the toggle seat and toggle plate and measure their actual dimensions REMARK Use the above dimension as a guideline for the wear tolerance of the toggle seat and t...

Page 215: ...hanging hole of the lower cheek plate with compressed air or a wire brush then lift up the lower cheek plate with the special tool lower cheek plate weight 72 0 kg 159 lb 5 After removing all the chee...

Page 216: ...Ratchet handle Accessory Tool no 11 3 Extension pipe accessory Tool No 12 3 Lift up the fixed jaw plate with a wire rope When reversing the fixed jaw plate lower it on to a block once Then hook a wire...

Page 217: ...MAINTENANCE SERVICE PROCEDURE 7 Secure the fixed jaw plate wedge and fixed jaw plate wedge bolts Set the length A of the fixed jaw plate wedge bolt spring at 100 mm 3 9 in 8 Install the cheek plates...

Page 218: ...Tool No 11 3 Extension piping Accessory Tool No 12 4 2 shackles Accessory Tool No 17 5 Swing jaw stopper Accessory Tool No 20 6 2 wood chips Accesoory Tool No 26 45 x 45 x 250 mm 7 2 bars 8 Sledge ha...

Page 219: ...ch upper surface of swing jaw plate mount stopper and transverse stopper piece If not removed completely they may cause a backlash on the swing jaw plate When reversing the swing jaw plate lower it on...

Page 220: ...2 that is spread over the toggle plate M10 bolt x 10 pieces 4 Pass a wire rope through an eyebolt on the toggle plate 5 to lift it up provisionally Insert the eyebolt through a tap hole on the toggle...

Page 221: ...ep depressing crusher outlet clearance reduction switch 9 in the upper control box to advance the toggle block until the swing jaw plate comes to contact with the fixed jaw plate Remove all the insert...

Page 222: ...switch to the INSPECTION position 21 Attach a warning tag to the engine starting switch to announce to those concerned that the machine is now worked on 22 Depress the crusher outlet clearance reducti...

Page 223: ...rs on the toggle plate M10 bolt x 8 pieces 28 Install each working deck in the order of crusher front maintenance floor and crusher interior maintenance floor 29 Fix the swing jaw cover and rubber pla...

Page 224: ...AUTION The toggle seat has no parts interchangeability Hence take care to install it rightly Toggle seat on swing jaw side Protruding amount 25 mm 1 0 in and protruding downward Toggle seat on toggle...

Page 225: ...ionally taking care not to let it fall 7 When the work of lifting up the toggle seat provisionally has been completed proceed to remove a toggle seat holding plate on the opposite side 8 Screw in eyeb...

Page 226: ...machine 3 Open left flywheel cover 2 4 Open front cover 2 of the left flywheel cover 5 Loosen a turnbuckle on the crusher motor bracket and remove the V belts 6 Insert new V belts and fit them to V sh...

Page 227: ...bolts start with the work only after stopping the engine If the conveyor belt makes a snaky movement adjust the tension on the left and right sides by turning the adjust bolts ADJUSTMENT OF CONVEYOR S...

Page 228: ...ANCE SERVICE PROCEDURE DRIVEN PULLEY SIDE If the scraper rubber has been worn out replace it by loosening the securing bolts It is in even contact with the belt across the width 4 58 https tractormanu...

Page 229: ...level add water Check oil level in engine oil pan add oil Check fuel level add fuel Check oil level in hydraulic oil tank add oil Check air cleaner for clogging Check electric wiring Check function o...

Page 230: ...se trichloroethylene for cleaning the interior of the fuel tank 1 Carry out this procedure before operating the machine 2 Prepare a container to catch the fuel that is drained 3 Open drain valve 1 pro...

Page 231: ...MAINTENANCE SERVICE PROCEDURE GREASING PRIMARY CONVEYOR 1 Greasing pillow blocks of of head pulley 2 places 2 Greasing tail pulley bearings 2 places on both sides 4 61 https tractormanualz com...

Page 232: ...the battery box cover on the right side of the machine 2 Remove cap 1 and check that the battery electrolyte is up to the UPPER LEVEL line If the level is low add distilled water to the UPPER LEVEL li...

Page 233: ...tighten cap 1 securely Keep the top of the battery clean and with a damp cloth When adding distilled water wait until starting operations next morning in order to prevent the electrolyte from freezing...

Page 234: ...N 2 Tighten bolts and nuts 1 2 and 3 to secure alternator 5 Tightening torque Lock nut 1 and 4 137 2 53 9 N m 14 5 5kgf m 101 3 39 8 lbft Bolt 2 33 3 4 9N m 3 4 0 5kgf m 24 6 3 6 lbft Bolt 3 127 4 19...

Page 235: ...AW CRUSHER AND RELATED ACCESSORIES PAGE 3 44 in this manual ADJUSTMENT CAUTION V belts have a characteristic that their tension tends to lower by 20 30 in 24 hours after the engine start Hence measure...

Page 236: ...HER MOTOR BEARING CASE AND ADDING OIL 1 Unscrew oil filler plug F and loosen oil check port A If oil seeps out the oil level is normal 2 If oil is short add it through oil filler plug F until oil over...

Page 237: ...e undercover located direct under an extension hose for draining the engine oil and place a container beneath 5 Drain the engine oil by raising the drain valve lever slowly After all the oil has been...

Page 238: ...d engine oil through oil filler port F so that the oil level is between the H and L marks on dipstick G 10 Run the engine at low idling for some time and stop it Then referring to the section of CHECK...

Page 239: ...in cartridge until seal comes in contact with sealing surface then tighten approx 2 3 turn If the filter cartridge is tightened too far the packing will be damaged and this will lead to leakage of fue...

Page 240: ...the TOP mark at the top with the UP mark and plug P perpendicular to the ground surface 2 Remove plug F using the handle When the oil level reaches a point 10 mm 0 4 in below the bottom of the plug ho...

Page 241: ...n when removing the bolts 3 After removing spring 2 and valve 3 take out element 4 4 Clean the removed parts in diesel oil 5 Install the new element in the place where old element 4 was installed 6 Se...

Page 242: ...y compressed air from an appropriate distance Damaged fins may cause water leakage or overheating On dusty sites check the fins daily regardless of the maintenance interval Inspect and clean the radia...

Page 243: ...fter the engine is stopped and may cause burns Wait for the temperature to go down before starting the work When removing the oil filler cap turn it slowly to release the internal pressure then remove...

Page 244: ...N CRUSHER MOTOR BEARING CASE 1 Remove drain plug P to drain oil and screw it in after the drainage 2 Add engine oil through oil filler port F to the specified amount Replacement amount of engine oil 8...

Page 245: ...f the level gauge G Be sure to keep the oil amount at the optimum level since both excessive and insufficient amount of oil can cause failures CHANGE OF OIL Replace all the oil at the initial 250 hour...

Page 246: ...ug G and check the oil level if the oil level is near the bottom of the plug hole the oil amount is at a proper level If found short remove plug F and replenish oil through plug F filler port up to th...

Page 247: ...filter wrench turn cartridge 2 to the left to remove it 4 Install a new filter cartridge after coating engine oil on its sealing face In the installation turn the cartridge by two thirds of one turn...

Page 248: ...e 3 0 m 9 ft 10 in A container of capacity over 2 5 liters 0 66 US gal to receive drained oil Replacement amount of oil 2 5 liters 0 66 US gal 1 Set the container under the drain plug P 2 Unscrew drai...

Page 249: ...OP mark and plug P perpendicular to the ground surface 2 Place an oil receiving container under plug P 3 Remove plugs P and F using a handle to drain oil REMARK Check an O ring fitted to the plug for...

Page 250: ...trainer 4 into protruding part 5 of the tank and assemble 5 Install cover 1 with bolts CLEAN ENGINE BREATHER WARNING The parts and oil are at high temperature after the engine is stopped and may cause...

Page 251: ...ntenance work of every 100 250 500 1000 and 2000 hours of operation at the same time CHECK WATER PUMP Check the pulley for play and water leakage If anything unusual is found ask the Komatsu distribut...

Page 252: ...er port F at the top of the hydraulic tank 2 Set a container direct under the drain plug located on the machine s underside to catch oil that is drained Remove drain plug P and drain the oil Check an...

Page 253: ...air bleed plug 1 and install the drain hose NOTICE If the drain hose is installed first oil will spurt out from plug hole 1 If the pump is operated without filling the pump case with hydraulic oil abn...

Page 254: ...AIR FROM CONVEYOR MOTOR NOTICE For replacing oil in the conveyor motor machinery case prepare a suitable scaffold for safety and commence the work AGL height of conveyor motor machinery case 3 0 m 9...

Page 255: ...case has been drained 1 Run the engine at low idling loosen air bleeder 1 and check that oil flows out OPERATION After completing air bleeding stop the engine Wait for more than five minutes before s...

Page 256: ...5 1 https tractormanualz com...

Page 257: ...rsepower kw HP rpm 228 306 2050 Feeding device Method Grizzly feeder with vibration controller Trough dimensions width x length excluding grizzly bar mm ft in 1125 3 8 x 3955 12 12 2050 6 9 Crusher Ja...

Page 258: ...SPECIFICATIONS SPECIFICATIONS 5 3 https tractormanualz com...

Page 259: ...6 1 https tractormanualz com...

Page 260: ...ing or installing attachments observe the following precautions for safety work Carry out dismantling and installation works on the flat and solid ground When a work is carried out by two workers or m...

Page 261: ...card may be disrupted by strong magnetism CAUTION When conduction a trial run of the machine be sure to run the motor at low speed and check that the conveyor belt does not make a snaky movement If m...

Page 262: ...p unit referring to the figure at right The take up unit consists of a base plate a pillow block and a tap bolt Loosen the lock bolt on the base plate and adjust the position of the take up unit with...

Page 263: ...h take up bolt Remove foreign objects Breakage of belt Perforation wear fatigue or attraction of metal pieces on attractive surface Remove metal pieces Replace belt with new one depending on hole size...

Page 264: ...ULIC TYPE MAGNETIC SELECTOR SPECIFICATIONS KMG900S Type KMG900S 62A HPK903B Belt rotating speed 95 m min Conveyor belt width 700 mm Driving method Hydraulic gear motor Weight 900 kg 1985 lb KMG900L 6...

Page 265: ...side 19 Bearing MFK0000301 1 On driven side 23 Belt MFK0000401 1 Ultra wear resistant conveyor belt 500kgf cm Width 900 mm x overall thickness 11 8t Scraper MFK0000411 8 Rubber lug 24 Bar MFK0000421...

Page 266: ...enter of gravity of the debris discharging conveyor is at position A two point lifting is possible It is recommended however to lift it at four points fixing another wire rope 2 to position B too unti...

Page 267: ...er a hydraulic cylinder bracket and an in transport conveyor fixing bracket on the side of the machine where the debris discharging conveyor is inserted DISMANTLING PROCEDURES FOR INSTALLING HYDRAULIC...

Page 268: ...M16 x 8 bolts 3 Insert pin 3 at the hydraulic cylinder head to connect with the debris discharging belt conveyor 4 Connect with the machine piping for the hydraulic cylinder and belt conveyor as well...

Page 269: ...scharging conveyor rasing switch 3 to fold up the conveyor 5 Insert a pin into the in transport conveyor fixing bracket to secure the conveyor 6 Stop the engine GREASING MUCK DISCHARGE CONVEYOR NOTICE...

Page 270: ...he revolving parts of the conveyor while inspecting or cleaning it Be sure to stop the engine before starting the work IS THE BELT NOT SLACKENED CAUTION Stop the engine first and start to work on the...

Page 271: ...tc that are stuck at the backside of the belt conveyor or in between the rollers and belt or inside the hopper rubber and belt DO THE TAIL PULLEY AND ROLLERS TURN SMOOTHLY OR IS THERE ANY PART IN THE...

Page 272: ...side Slip on motor pulley or driving pulley surface Debris or foreign object stuck in between belt and pulley Foreign objects stuck on pulley surface Faulty rotation of rollers Correct belt elongation...

Page 273: ...ntact belt b Replace with new one Rollers Abnormal sound Breakage Faulty rotation of rollers Wire or string winding about shafts Shock due to fall of large and heavy mass Replace with new one Remove f...

Page 274: ...90 10 80 8 Rubber 8295 75 5211 2 0 31 0 68 9 Rubber 8295 75 5261 2 0 29 0 64 10 Impact carrier roller 8295 75 5470 15 1 80 3 94 11 Rubber 8295 75 5311 2 0 65 1 43 12 Rubber 8295 75 5341 1 0 55 1 21 13...

Page 275: ...ATTACHMENTS OPTIONS MUCK DISCHARGE CONVEYOR 6 17 https tractormanualz com...

Page 276: ...YOR SPECIFICATIONS Komatsu Part No 8295 75 5000 Belt width x machine length 60 cm x 4 m 1 ft 12 in x 13 ft 1 in Max gradeability degree 13 Motor rotation rpm 153 Belt travel speed m min 130 weight kg...

Page 277: ...D 8 R FORWARD 9 L BACK 10 R BACK 11 FEEDER ON 12 FEEDER OFF 13 CRUSHER ON 14 CRUSHER OFF SWITCH NOTICE The following switches may be operated by setting the operation mode selector switch to the TRAVE...

Page 278: ...pm at one touch TRAVELING CAUTION When the machine travels under the raio control the travel speed is regulated to 1 8 km h 1 1 MPH for a safety reason NOTICE The following switches may be operated by...

Page 279: ...surrounding conditions like noises from neighboring plants This unit is so designed as to turn off transmission output by virtue of various safety circuits in place and stop all the work when receivin...

Page 280: ...r away from an operator be sure to turn POWER switch 1 off and pull out the key Confirm then that the switch is at the OFF 0 position When installing the unit somewhere or when carrying out maintenanc...

Page 281: ...ollowing methods If transmission is topped the revolving working lamp blue will be switched off Depress TRANSMISSION STOP switch 2 located on top of the transmitter control panel Set POWER switch 1 to...

Page 282: ...automatically that the batteries have been fully charged When batteries are fully charged the battery charger switches a charging mode to light charging Then the battery charger automatically begins...

Page 283: ...mes on With this the unit is ready for operation NOTICE As long as the TRANSMISSION STOP switch remains depressed the work equipment cannot be started Release the switch by depressing it again and sta...

Page 284: ...PROTECTIVE PLATE BELT CONVEYOR PROTECTIVE PLATE CONVEYOR PROTECTIVE BELT When crushing mainly reinforcedconcrete debris a conveyor protection plate is effective at preventingthe conveyor belt from bre...

Page 285: ...CONNECTING OPTIONAL ATTACHMENTS When using the debris discharging conveyor and the magnetic selector individually or in tandem install hydraulic hoses and electric connectors in the following manner L...

Page 286: ...ind plug fitted to the machine and connect a hydraulic hose by the conventional way of screwing in Both debris discharging conveyor and magnetic selector can discharge crushed debris to either side of...

Page 287: ...rged to the side of the hydraulic oil tank by connecting magnetic selector relay block B 3 and Bv port B REMARK Install reinforcing bar discharging guide 1 to the side of the hydraulic oil tank if dis...

Page 288: ...RAL VIEW 3 2 GENERAL VIEW OF CONTROLS AND GAUGES 3 3 GENERAL VIEW OF MACHINE 3 2 GUIDE TO MAINTENANCE 4 2 H HANDLING OIL FUEL COOLANT AND PERFORMING OIL CLINIC 4 4 HYDRAULIC TYPE MAGNETIC SELECTOR 6 3...

Page 289: ...ATTACHMENTS 6 27 PROCEDURES FOR CONNECTING OPTIONAL ATTACHMENTS 6 28 PROHIBITIONS FOR OPERATION 3 92 R RADIO CONTROL UNIT 6 19 DIRECTIONS FOR USE 6 19 ON USE OF RADIO CONTROL UNIT 6 22 OVERVIEW 6 21 R...

Page 290: ...OF TOWING MACHINE 3 111 OTHER TROUBLE 3 115 PHENOMENA THAT ARE NOT FAILURES 3 111 U USE OF FUEL COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4 14 W WATER SPRINKLER 3 66 WEAR PARTS 4 9 WEAR...

Page 291: ...BR550JG 1 GALEO MOBILE CRUSHER Form No PEN00020 00 2004 KOMATSU All Rights Reserved Printed in Japan 11 04 https tractormanualz com...

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