Complete Operation & Maintenance Manuals for Komatsu Mobile Crusher GALEO BR380JG, with all the service information to maintain & operate your crusher.
SEAM059001T – Mobile Crusher GALEO BR380JG-1 Operation & Maintenance Manual (SN1001&up).pdf
TEN00006-03 – Mobile Crusher GALEO BR380JG-1 Operation & Maintenance Manual (SN1201&up).pdf
TEN00168-03 – Mobile Crusher GALEO BR380JG-1E0 Operation & Maintenance Manual (SN2001&up).pdf
TEN00358-01 – Mobile Crusher GALEO BR380JG-1E0 Operation & Maintenance Manual (SN2609&up).pdf
TEN00476-01 – Mobile Crusher GALEO BR380JG-1E0 Operation & Maintenance Manual (SN2621&up).pdf
Total Pages: 1,857 pages
File Format: PDF
Language: English
TABLE OF CONTENTS
FOREWORD
BEFORE READING THIS MANUAL
SAFETY INFORMATION
INTRODUCTION
INTRODUCTION
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE
NECESSARY INFORMATION
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE
EPA REGULATIONS, ENGINE NUMBER PLATE
POSITION OF SERVICE METER
TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR
SAFETY
SAFETY
SAFETY LABELS
POSITIONS OF SAFETY PICTOGRAMS
SAFETY LABELS
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE
PRECAUTIONS BEFORE STARTING OPERATION
PREPARATIONS FOR SAFE OPERATION
FIRE PREVENTION
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE
DO NOT GET CAUGHT IN WORK EQUIPMENT
UNAUTHORIZED MODIFICATION
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING
PRECAUTIONS FOR OPERATION
PRECAUTIONS FOR JOBSITE
STARTING ENGINE
OPERATION
CRUSHING OPERATION
TRANSPORTATION
TOWING
MAGNETIC SEPARATOR
PRECAUTIONS FOR MAINTENANCE
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE
PRECAUTIONS FOR INSPECTION AND MAINTENANCE
OPERATION
GENERAL VIEW
GENERAL VIEW OF MACHINE
GENERAL VIEW OF CONTROLS AND GAUGES
EXPLANATION OF COMPONENTS
MACHINE MONITOR
SWITCHES
CONTROL LEVERS
OPTION-RELATED SWITCHES
CAP, COVER WITH LOCK
REVOLVING WARNING LAMP
ELECTRIC POWER TAKEOFF
FUSIBLE LINK
CONTROLLERS
FUSE
TOOL BOX
OPERATION
CHECK BEFORE STARTING ENGINE
STARTING ENGINE
OPERATIONS AND CHECKS AFTER STARTING ENGINE
STOPPING ENGINE
CHECK AFTER STOPPING ENGINE
MACHINE OPERATION
STEERING MACHINE
OPERATION OF WORK EQUIPMENT
CHECK AND CONFIRMATION OF JAW CRUSHER AFTER WORK
CHECK AFTER FINISHING WORK
LOCKING
RUN-IN OPERATION OF JAW CRUSHER
PRECAUTIONS WHEN OPERATING JAW CRUSHER
EFFICIENT USE OF JAW CRUSHER
SCOPE OF WORKS USING MOBILE CRUSHER
PROHIBITIONS FOR OPERATION
PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS
TRANSPORTATION
TRANSPORTATION PROCEDURE
LOADING, UNLOADING WORK
LIFTING MACHINE
COLD WEATHER OPERATION
PRECAUTIONS FOR LOW TEMPERATURE
AFTER COMPLETION OF WORK
AFTER COLD WEATHER
LONG-TERM STORAGE
BEFORE STORAGE
DURING STORAGE
AFTER STORAGE
STARTING MACHINE AFTER LONG-TERM STORAGE
TROUBLESHOOTING
AFTER RUNNING OUT OF FUEL
PHENOMENA THAT ARE NOT FAILURES
METHOD OF TOWING MACHINE
IF BATTERY IS DISCHARGED
OTHER TROUBLE
MAINTENANCE
GUIDE TO MAINTENANCE
OUTLINE OF SERVICE
HANDLING AND PERFORMANCE OF OIL CLINIC FOR OIL, FUEL, COOLANT
RELATING TO ELECTRIC SYSTEM
OUTLINE OF HYDRAULIC EQUIPMENT
AIR-BLEEDING FROM HYDRAULIC CIRCUIT
WEAR PARTS
WEAR PARTS LIST
JAW CRUSHER RELATED PARTS
PRIMARY CONVEYOR RELATED PARTS
RECOMMENDED FUEL, COOLANT AND LUBRICANTS
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN
KOMATSU GENUINE OIL
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
TORQUE LIST
TOOLS TO USE CHECK AND MAINTENANCE CRUSHER
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
SAFETY CRITICAL PARTS
MAINTENANCE SCHEDULE CHART
MAINTENANCE SCHEDULE CHART
SERVICE PROCEDURE
INITIAL 250 HOURS SERVICE (FIRST MAINTENANCE FOR NEW MACHINE ONLY)
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)
WHEN REQUIRED
CHECK BEFORE STARTING
EVERY 10 HOURS SERVICE
EVERY 100 HOURS SERVICE
EVERY 250 HOURS SERVICE
EVERY 500 HOURS SERVICE
EVERY 1000 HOURS SERVICE
EVERY 2000 HOURS SERVICE
EVERY 4000 HOURS SERVICE
EVERY 5000 HOURS SERVICE
EVERY 8000 HOURS SERVICE
SPECIFICATIONS
SPECIFICATIONS
ATTACHMENTS, OPTIONS
GENERAL PRECAUTIONS
PRECAUTIONS RELATED TO SAFETY
ATTACHMENTS, OPTIONS
ATTACHMENTS, OPTIONS CHART
METHOD FOR CONNECTING HYDRAULIC HOSES FOR OPTIONS
RADIO CONTROL UNIT
ON USE OF RADIO CONTROL UNIT
DIRECTIONS FOR USE
RADIO CONTROL OPERATION
MUCK DISCHARGE CONVEYOR
PROCEDURE FOR RAISING (BENDING) MUCK DISCHARGE CONVEYOR
PROCEDURE FOR LOWERING (EXTEND) MUCK DISCHARGE CONVEYOR
GREASING MUCK DISCHARGE CONVEYOR
CHECK AND ADJUSTMENT OF MUCK DISCHARGE CONVEYOR
FAILURES AND CORRECTIVE ACTIONS
WEARING PARTS
SPECIFICATIONS
M-TYPE CHUTE
METHOD OF OPERATION
GRIZZLY BAR OPENING
HANDLING MACHINES EQUIPPED WITH KOMTRAX
BASIC PRECAUTIONS
MACHINES THAT CAN INSTALL ATTACHMENTS
NAMES OF CONTROL PANEL SWITCHES
HYDRAULIC POWER TAKEOFF PORT
ATTACHMENT PORT
PROCEDURE FOR CONNECTING OPTIONS
SPRINKLER
EXPLANATIONS FOR COMPONENT PARTS
HOW TO USE SPRINKLER
INSPECTION AND MAINTENANCE
ADDITIONAL SPRINKLER NOZZLE
INDEX
SEAM059001T – Mobile Crusher GALEO BR380JG-1 Operation & Maintenance Manual (SN1001&up)…2
COVER…2
FOREWORD…3
FOREWORD…4
SAFETY INFORMATION…7
INTRODUCTION…9
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE…9
NECESSARY INFORMATION…10
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…10
ENGINE SERIAL NO. PLATE AND POSITION…10
POSITION OF SERVICE METER…11
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…11
CONTENTS…12
SAFETY…16
SAFETY…17
SAFETY LABELS…20
POSITIONS OF SAFETY PICTOGRAMS…21
SAFETY LABELS…22
GENERAL PRECAUTIONS…31
SAFETY RULES…31
IF ABNORMALITIES ARE FOUND…31
CLOTHING AND PERSONAL PROTECTIVE ITEMS…31
FIRE EXTINGUISHER AND FIRST AID KIT…31
SAFETY FEATURES…31
KEEP MACHINE CLEAN…32
ON OPERATOR'S PLATFORM…32
ALWAYS APPLY LOCK WHEN LEAVING UPPER OPERATION DECK…32
HANDRAILS AND STEPS…33
MOUNTING AND DISMOUNTING…33
NO PEOPLE ON ATTACHMENTS…33
CRUSHING OR CUTTING PREVENTION…33
PREVENTION OF BURNS…34
FIRE PREVENTION…34
ACTION IF FIRE OCCURS…35
PRECAUTIONS FOR ATTACHMENTS…35
UNAUTHORIZED MODIFICATION…35
SAFETY AT WORKSITE…35
WORKING ON LOOSE GROUND…36
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES…36
ENSURE GOOD VISIBILITY…36
VENTILATION FOR ENCLOSED AREAS…37
CHECKING SIGNALMAN'S SIGNALS AND SIGNS…37
BE CAREFUL ABOUT ASBESTOS DUST…37
PRECAUTIONS FOR OPERATION…38
STARTING ENGINE…38
CHECKS BEFORE STARTING ENGINE…38
PRECAUTIONS WHEN STARTING…38
PRECAUTIONS IN COLD AREAS…39
OPERATION…40
CHECKS BEFORE OPERATION…40
PRECAUTIONS WHEN CHANGING DIRECTION…40
PRECAUTIONS WHEN TRAVELING…40
TRAVELING ON SLOPES…41
OPERATIONS ON SLOPES…41
PRECAUTIONS WHILE IN OPERATION…41
OPERATE CAREFULLY ON SNOW…41
PARKING MACHINE…42
CRUSHING OPERATION…43
CHECKS AROUND MACHINE…43
TURN MODE SELECTOR SWITCH TO WORK POSITION…43
ENSURE SAFETY WHILE OPERATING IN TANDEM WITH HYDRAULIC EXCAVATOR…44
CHECKS OF CRUSHER BEFORE STARTING OPERATION…44
PRECAUTIONS FOR CRUSHING WORK…44
EMERGENCY STOP TO WARD OFF DANGERS WHILE IN CRUSHING WORK…45
REMOVE FOREIGN MATERIAL FROM INSIDE CRUSHER…45
MAGNETIC SEPARATOR…46
HYDRAULIC MAGNETIC SEPARATOR (HANGING TYPE)…46
TRANSPORTATION…47
LOADING AND UNLOADING…47
SHIPPING…47
BATTERY…48
BATTERY HAZARD PREVENTION…48
STARTING WITH BOOSTER CABLE…49
TOWING…50
WHEN TOWING…50
PRECAUTIONS FOR MAINTENANCE…51
WARNING TAG…51
KEEP WORK PLACE CLEAN AND TIDY…51
APPOINT LEADER WHEN WORKING WITH OTHERS…51
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…51
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…52
PRECAUTIONS FOR CONVEYOR MAINTENANCE…52
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE OF FEEDER, CRUSHER…53
PROPER TOOLS…53
PERSONNEL…53
PRECAUTIONS WHEN MOUNTING, DISMANTLING AND STORING ATTACHMENTS…53
PRECAUTIONS FOR WORK UNDER MACHINE…53
NOISE…54
PRECAUTIONS WHEN USING HAMMER…54
REPAIR WELDING…54
REMOVING BATTERY TERMINAL…54
PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…54
DO NOT DISASSEMBLE RECOIL SPRING…55
PRECAUTIONS WITH HIGH-PRESSURE OIL…55
HANDLING HIGH-PRESSURE HOSES…55
WASTE MATERIAL…55
COMPRESSED AIR…56
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…56
OPERATION…57
GENERAL VIEW…58
GENERAL VIEW OF MACHINE…58
GENERAL VIEW OF CONTROLS AND GAUGES…59
EXPLANATION OF COMPONENTS…63
MACHINE MONITOR…63
SWITCHES…87
CONTROL LEVERS…96
OPTION-RELATED SWITCHES…97
CAP, COVER WITH LOCK…99
REVOLVING WARNING LAMP…101
ELECTRIC POWER TAKEOFF…102
FUSIBLE LINK…104
CONTROLLERS…104
FUSE…104
TOOL BOX…105
OPERATION…106
CHECK BEFORE STARTING ENGINE…106
STARTING ENGINE…124
OPERATIONS AND CHECKS AFTER STARTING ENGINE…128
STOPPING ENGINE…133
CHECK AFTER STOPPING ENGINE…133
MACHINE OPERATION…134
STEERING MACHINE…140
OPERATION OF WORK EQUIPMENT…142
CHECK AND CONFIRMATION OF JAW CRUSHER AFTER WORK…151
CHECK AFTER FINISHING WORK…151
LOCKING…152
RUN-IN OPERATION OF JAW CRUSHER…153
PRECAUTIONS WHEN OPERATING JAW CRUSHER…155
SCOPE OF WORKS USING MOBILE CRUSHER…163
PROHIBITIONS FOR OPERATION…171
PRECAUTIONS WHEN TRAVELING UP OR DOWNHILLS…173
TRANSPORTATION…174
TRANSPORTATION PROCEDURE…174
LOADING, UNLOADING WORK…174
LIFTING MACHINE…180
COLD WEATHER OPERATION…181
PRECAUTIONS FOR LOW TEMPERATURE…181
AFTER COMPLETION OF WORK…183
AFTER COLD WEATHER…184
LONG-TERM STORAGE…185
BEFORE STORAGE…185
DURING STORAGE…185
AFTER STORAGE…185
STARTING MACHINE AFTER LONG-TERM STORAGE…185
TROUBLESHOOTING…186
AFTER RUNNING OUT OF FUEL…186
PHENOMENA THAT ARE NOT FAILURES…186
METHOD OF TOWING MACHINE…186
IF BATTERY IS DISCHARGED…187
OTHER TROUBLE…190
MAINTENANCE…199
GUIDES TO MAINTENANCE…200
OUTLINE OF SERVICE…202
HANDLING AND PERFORMANCE OF OIL CLINIC FOR OIL, FUEL, COOLANT…202
RELATING TO ELECTRIC SYSTEM…205
OUTLINE OF HYDRAULIC EQUIPMENT…205
AIR-BLEEDING FROM HYDRAULIC CIRCUIT…206
WEAR PARTS…207
WEAR PARTS LIST…207
JAW CRUSHER RELATED PARTS…208
PRIMARY CONVEYOR RELATED PARTS…210
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…211
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…215
CRUSHER ACCESSORY TOOLS…215
TORQUE LIST…217
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…218
SAFETY CRITICAL PARTS…218
MAINTENANCE SCHEDULE CHART…219
MAINTENANCE SCHEDULE CHART…219
SERVICE PROCEDURE…221
INITIAL 250 HOURS SERVICE (FIRST MAINTENANCE FOR NEW MACHINE ONLY)…221
INITIAL 1000 HOURS SERVICE (FIRST MAINTENANCE FOR NEW MACHINE ONLY)…221
WHEN REQUIRED…222
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…222
CLEAN INSIDE OF COOLING SYSTEM…227
CHECK AND TIGHTEN TRACK SHOE BOLT…229
CHECK AND ADJUST TRACK TENSION…230
INSPECTION OF ELECTRIC HEATER…232
CHECK AND ADJUSTMENT OF JAW CRUSHER…233
CHECK AND ADJUSTMENT OF PRIMARY CONVEYOR…254
INSPECTION AND MAINTENANCE OF MAGNETIC SEPARATOR…259
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT…261
CHECK BEFORE STARTING…263
EVERY 100 HOURS SERVICE…264
GREASING CRUSHER BEARING SEAT…264
GREASING PRIMARY CONVEYOR…265
EVERY 250 HOURS SERVICE…266
CHECK LEVEL OF BATTERY ELECTROLYTE…266
CHECK AND ADJUSTMENT OF JAW CRUSHER V-BELT…268
CHECK OF OIL LEVEL IN CRUSHER MOTOR BEARING CASE AND ADDING OIL…268
EVERY 500 HOURS SERVICE…269
REPLACE FUEL FILTER CARTRIDGE…269
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…270
CLEAN, INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS…271
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…272
REPLACE HYDRAULIC TANK BREATHER ELEMENT…273
GREASE CRUSHER LINK…273
EVERY 1000 HOURS SERVICE…274
CHANGE OF OIL IN CRUSHER MOTOR BEARING CASE…274
CHANGE OF OIL IN GRIZZLY FEEDER VIBRATOR CASE…274
CHANGE OIL IN DAMPER CASE…275
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…275
CHECK PLAY OF TURBOCHARGER ROTOR…275
CHECK AND REPLACE OF FAN BELT TENSION…275
REPLACE HYDRAULIC FILTER ELEMENT…276
EVERY 2000 HOURS SERVICE…277
CHANGE OIL IN FINAL DRIVE CASE…277
CLEAN HYDRAULIC TANK STRAINER…278
CLEAN, CHECK TURBOCHARGER…278
CHECK ALTERNATOR, STARTING MOTOR…278
CHECK ENGINE VALVE CLEARANCE, ADJUST…278
CHECK VIBRATION DAMPER…278
EVERY 4000 HOURS SERVICE…279
CHECK WATER PUMP…279
EVERY 5000 HOURS SERVICE…280
CHANGE OIL IN HYDRAULIC TANK AND CLEAN STRAINER…280
SPECIFICATIONS…281
SPECIFICATIONS…282
ATTACHMENTS, OPTIONS…284
GENERAL PRECAUTIONS…285
PRECAUTIONS RELATED TO SAFETY…285
ATTACHMENTS, OPTIONS…286
ATTACHMENTS, OPTIONS CHART…286
METHOD FOR CONNECTING HYDRAULIC HOSES FOR OPTIONS…286
RADIO CONTROL UNIT…287
ON USE OF RADIO CONTROL UNIT…287
DIRECTIONS FOR USE…290
REMOTE CONTROL OPERATION…294
MUCK DISCHARGE CONVEYOR…303
PROCEDURE FOR RAISING (BENDING) MUCK DISCHARGE CONVEYOR…303
PROCEDURE FOR LOWERING MUCK DISCHARGE CONVEYOR…305
GREASING MUCK DISCHARGE CONVEYOR…306
CHECK AND ADJUSTMENT OF MUCK DISCHARGE CONVEYOR…307
FAILURES AND CORRECTIVE ACTIONS…309
WEARING PARTS…311
SPECIFICATIONS…312
M-TYPE CHUTE…313
METHOD OF OPERATION…313
BELT CONVEYOR PROTECTIVE PLATE…314
GRIZZLY BAR OPENING…316
MACHINES THAT CAN INSTALL ATTACHMENTS…317
NAMES OF CONTROL PANEL SWITCHES…317
HYDRAULIC POWER TAKEOFF PORT…317
PROCEDURE FOR CONNECTING OPTIONS…318
HYDRAULIC VIBRATORY SIEVE…319
SPECIFICATION…319
GENERAL VIEW…319
CAUTIONS TO BE NOTED FOR SAFETY…320
CONNECTING METHOD TO MACHINE BODY…320
PRECAUTIONS DURING OPERATION…320
HYDRAULIC SECONDARY CONVEYOR…321
SPECIFICATIONS…321
GENERAL VIEW…321
INCLINED LEG CONNECTING METHOD…323
LIFTING METHOD…324
CONNECTING METHOD TO MACHINE BODY…324
PRECAUTIONS ON OPERATION…324
INSPECTION, MAINTENANCE AND ADJUSTMENT…325
TROUBLES AND CORRECTIVE ACTIONS…327
CONSUMABLE PARTS OF HYDRAULIC SECONDARY CONVEYOR…329
INDEX…331
TEN00006-03 – Mobile Crusher GALEO BR380JG-1 Operation & Maintenance Manual (SN1201&up)…335
COVER…335
FOREWORD…336
FOREWORD…337
SAFETY INFORMATION…340
INTRODUCTION…342
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE…342
BREAKING IN THE NEW MACHINE…342
NECESSARY INFORMATION…343
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…343
ENGINE SERIAL NO. PLATE AND POSITION…343
POSITION OF SERVICE METER…344
TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR…344
CONTENTS…345
SAFETY…349
SAFETY…350
SAFETY LABELS…353
POSITIONS OF SAFETY PICTOGRAMS…354
SAFETY LABELS…355
GENERAL PRECAUTIONS…363
SAFETY RULES…363
IF ABNORMALITIES ARE FOUND…363
CLOTHING AND PERSONAL PROTECTIVE ITEMS…363
FIRE EXTINGUISHER AND FIRST AID KIT…363
SAFETY FEATURES…363
KEEP MACHINE CLEAN…364
ON OPERATOR'S PLATFORM…364
ALWAYS APPLY LOCK WHEN LEAVING UPPER OPERATOR'S PLATFORM…364
HANDRAILS AND STEPS…365
PRECAUTIONS WHEN WORKING IN HIGH PLACES…365
MOUNTING AND DISMOUNTING…365
NO PEOPLE ON ATTACHMENTS…365
CRUSHING OR CUTTING PREVENTION…365
PREVENTION OF BURNS…366
FIRE PREVENTION…366
ACTION IF FIRE OCCURS…367
PRECAUTIONS FOR ATTACHMENTS…367
UNAUTHORIZED MODIFICATION…367
SAFETY AT WORKSITE…367
WORKING ON LOOSE GROUND…368
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES…368
ENSURE GOOD VISIBILITY…368
VENTILATION FOR ENCLOSED AREAS…369
CHECKING SIGNALMAN'S SIGNALS AND SIGNS…369
BE CAREFUL ABOUT ASBESTOS DUST…369
MAGNETIC SEPARATOR…370
PRECAUTIONS FOR OPERATION…371
STARTING ENGINE…371
CHECKS BEFORE STARTING ENGINE…371
PRECAUTIONS WHEN STARTING…371
PRECAUTIONS IN COLD AREAS…371
OPERATION…373
CHECK BEFORE OPERATION…373
PRECAUTIONS WHEN CHANGING DIRECTION…373
PRECAUTIONS WHEN TRAVELING…373
TRAVELING ON SLOPES…374
OPERATIONS ON SLOPES…374
PRECAUTIONS WHILE IN OPERATION…374
OPERATE CAREFULLY ON SNOW…374
PARKING MACHINE…375
CRUSHING OPERATION…376
CHECKS AROUND MACHINE…376
TURN MODE SELECTOR SWITCH TO WORK POSITION…376
ENSURE SAFETY WHILE OPERATING IN TANDEM WITH HYDRAULIC EXCAVATOR…377
CHECKS OF CRUSHER BEFORE STARTING OPERATION…377
PRECAUTIONS FOR CRUSHING WORK…377
EMERGENCY STOP TO WARD OFF DANGERS WHILE IN CRUSHING WORK…378
REMOVE FOREIGN MATERIAL FROM INSIDE CRUSHER…378
TRANSPORTATION…379
LOADING AND UNLOADING…379
SHIPPING…379
BATTERY…380
BATTERY HAZARD PREVENTION…380
STARTING WITH BOOSTER CABLE…381
TOWING…382
WHEN TOWING…382
PRECAUTIONS FOR MAINTENANCE…383
WARNING TAG…383
KEEP WORK PLACE CLEAN AND TIDY…383
APPOINT LEADER WHEN WORKING WITH OTHERS…383
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE…383
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…384
PRECAUTIONS FOR CONVEYOR MAINTENANCE…384
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE OF FEEDER, CRUSHER…385
PROPER TOOLS…385
PERSONNEL…385
PRECAUTIONS WHEN MOUNTING, DISMANTLING AND STORING ATTACHMENTS…385
PRECAUTIONS FOR WORK UNDER MACHINE…385
NOISE…386
PRECAUTIONS WHEN USING HAMMER…386
REPAIR WELDING…386
REMOVING BATTERY TERMINAL…386
PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…386
DO NOT DISASSEMBLE RECOIL SPRING…387
PRECAUTIONS WITH HIGH-PRESSURE OIL…388
HANDLING HIGH-PRESSURE HOSES…388
WASTE MATERIAL…388
COMPRESSED AIR…388
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…389
OPERATION…390
GENERAL VIEW…391
GENERAL VIEW OF MACHINE…391
GENERAL VIEW OF CONTROLS AND GAUGES…392
EXPLANATION OF COMPONENTS…396
MACHINE MONITOR…396
SWITCHES…421
CONTROL LEVERS…430
OPTION-RELATED SWITCHES…431
CAP, COVER WITH LOCK…433
REVOLVING WARNING LAMP…435
ELECTRIC POWER TAKEOFF…436
FUSIBLE LINK…438
CONTROLLERS…438
FUSE…438
TOOL BOX…439
OPERATION…440
CHECK BEFORE STARTING ENGINE…440
STARTING ENGINE…459
OPERATIONS AND CHECKS AFTER STARTING ENGINE…463
STOPPING ENGINE…468
CHECK AFTER STOPPING ENGINE…468
MACHINE OPERATION…469
STEERING MACHINE…475
OPERATION OF WORK EQUIPMENT…477
CHECK AND CONFIRMATION OF JAW CRUSHER AFTER WORK…486
CHECK AFTER FINISHING WORK…486
LOCKING…487
RUN-IN OPERATION OF JAW CRUSHER…488
PRECAUTIONS WHEN OPERATING JAW CRUSHER…490
EFFICIENT USE OF JAW CRUSHER…494
SCOPE OF WORKS USING MOBILE CRUSHER…500
PROHIBITIONS FOR OPERATION…508
PRECAUTIONS WHEN TRAVELING UP OR DOWNHILLS…510
TRANSPORTATION…511
TRANSPORTATION PROCEDURE…511
LOADING, UNLOADING WORK…511
LIFTING MACHINE…517
COLD WEATHER OPERATION…518
PRECAUTIONS FOR LOW TEMPERATURE…518
AFTER COMPLETION OF WORK…520
AFTER COLD WEATHER…520
LONG-TERM STORAGE…521
BEFORE STORAGE…521
DURING STORAGE…521
AFTER STORAGE…521
STARTING MACHINE AFTER LONG-TERM STORAGE…521
TROUBLESHOOTING…522
AFTER RUNNING OUT OF FUEL…522
PHENOMENA THAT ARE NOT FAILURES…522
METHOD OF TOWING MACHINE…523
IF BATTERY IS DISCHARGED…524
OTHER TROUBLE…527
MAINTENANCE…536
GUIDE TO MAINTENANCE…537
OUTLINE OF SERVICE…539
HANDLING AND PERFORMANCE OF OIL CLINIC FOR OIL, FUEL, COOLANT…539
RELATING TO ELECTRIC SYSTEM…542
OUTLINE OF HYDRAULIC EQUIPMENT…542
AIR-BLEEDING FROM HYDRAULIC CIRCUIT…543
WEAR PARTS…544
WEAR PARTS LIST…544
JAW CRUSHER RELATED PARTS…545
PRIMARY CONVEYOR RELATED PARTS…547
RECOMMENDED FUEL, COOLANT AND LUBRICANTS…548
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN…550
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…551
CRUSHER ACCESSORY TOOLS…551
TORQUE LIST…553
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…554
SAFETY CRITICAL PARTS…554
MAINTENANCE SCHEDULE CHART…555
MAINTENANCE SCHEDULE CHART…555
SERVICE PROCEDURE…557
INITIAL 250 HOURS SERVICE (FIRST MAINTENANCE FOR NEW MACHINE ONLY)…557
INITIAL 1000 HOURS SERVICE (FIRST MAINTENANCE FOR NEW MACHINE ONLY)…557
WHEN REQUIRED…558
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…558
CLEAN INSIDE OF COOLING SYSTEM…563
CHECK AND TIGHTEN TRACK SHOE BOLT…566
CHECK AND ADJUST TRACK TENSION…567
INSPECTION OF ELECTRIC HEATER…569
CHECK AND ADJUSTMENT OF JAW CRUSHER…570
CHECK AND ADJUSTMENT OF PRIMARY CONVEYOR…592
INSPECTION AND MAINTENANCE OF MAGNETIC SEPARATOR…596
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT…599
CHECK BEFORE STARTING…601
EVERY 10 HOURS SERVICE…602
GREASING CRUSHER BEARING SEAT…602
GREASING CRUSHER LINK…602
EVERY 100 HOURS SERVICE…603
GREASING CRUSHER LOCK CYLINDER SECURING POINT…603
GREASING PRIMARY CONVEYOR…604
EVERY 250 HOURS SERVICE…605
CHECK LEVEL OF BATTERY ELECTROLYTE…605
CHECK AND ADJUSTMENT OF JAW CRUSHER V-BELT…608
CHECK OF OIL LEVEL IN CRUSHER MOTOR BEARING CASE AND ADDING OIL…608
EVERY 500 HOURS SERVICE…609
REPLACE FUEL FILTER CARTRIDGE…609
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…610
CLEAN, INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS…611
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…612
REPLACE HYDRAULIC TANK BREATHER ELEMENT…613
EVERY 1000 HOURS SERVICE…614
CHANGE OF OIL IN CRUSHER MOTOR BEARING CASE…614
CHANGE OF OIL IN GRIZZLY FEEDER VIBRATOR CASE…615
CHANGE OIL IN DAMPER CASE…616
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…616
CHECK PLAY OF TURBOCHARGER ROTOR…616
CHECK AND REPLACE OF FAN BELT TENSION…616
REPLACE HYDRAULIC FILTER ELEMENT…617
EVERY 2000 HOURS SERVICE…618
CHANGE OIL IN FINAL DRIVE CASE…618
CLEAN HYDRAULIC TANK STRAINER…619
CLEAN, CHECK TURBOCHARGER…619
CHECK ALTERNATOR, STARTING MOTOR…619
CHECK ENGINE VALVE CLEARANCE, ADJUST…619
CHECK VIBRATION DAMPER…619
EVERY 4000 HOURS SERVICE…620
CHECK WATER PUMP…620
EVERY 5000 HOURS SERVICE…621
CHANGE OIL IN HYDRAULIC TANK AND CLEAN STRAINER…621
SPECIFICATIONS…622
SPECIFICATIONS…623
ATTACHMENTS, OPTIONS…625
GENERAL PRECAUTIONS…626
PRECAUTIONS RELATED TO SAFETY…626
ATTACHMENTS, OPTIONS…627
ATTACHMENTS, OPTIONS CHART…627
METHOD FOR CONNECTING HYDRAULIC HOSES FOR OPTIONS…627
RADIO CONTROL UNIT…628
ON USE OF RADIO CONTROL UNIT…628
DIRECTIONS FOR USE…631
REMOTE CONTROL OPERATION…635
MUCK DISCHARGE CONVEYOR…643
PROCEDURE FOR RAISING (BENDING) MUCK DISCHARGE CONVEYOR…643
PROCEDURE FOR LOWERING MUCK DISCHARGE CONVEYOR…644
GREASING MUCK DISCHARGE CONVEYOR…647
CHECK AND ADJUSTMENT OF MUCK DISCHARGE CONVEYOR…648
FAILURES AND CORRECTIVE ACTIONS…650
WEARING PARTS…652
SPECIFICATIONS…653
M-TYPE CHUTE…654
METHOD OF OPERATION…654
BELT CONVEYOR PROTECTIVE PLATE…655
GRIZZLY BAR OPENING…657
HANDLING MACHINES EQUIPPED WITH KOMTRAX…658
BASIC PRECAUTIONS…658
MACHINES THAT CAN INSTALL ATTACHMENTS…659
NAMES OF CONTROL PANEL SWITCHES…659
HYDRAULIC POWER TAKEOFF PORT…659
ATTACHMENT PORT…660
PROCEDURE FOR CONNECTING OPTIONS…661
HYDRAULIC VIBRATORY SIEVE…663
SPECIFICATION…663
GENERAL VIEW…663
CAUTIONS TO BE NOTED FOR SAFETY…664
CONNECTING METHOD TO MACHINE BODY…664
PRECAUTIONS DURING OPERATION…664
HYDRAULIC SECONDARY CONVEYOR…665
SPECIFICATIONS…665
GENERAL VIEW…665
INCLINED LEG CONNECTING METHOD…667
LIFTING METHOD…668
CONNECTING METHOD TO MACHINE BODY…668
PRECAUTIONS ON OPERATION…668
INSPECTION, MAINTENANCE AND ADJUSTMENT…669
TROUBLES AND CORRECTIVE ACTIONS…671
CONSUMABLE PARTS OF HYDRAULIC SECONDARY CONVEYOR…673
SPRINKLER…675
EXPLANATIONS FOR COMPONENT PARTS…675
HOW TO USE SPRINKLER…676
INSPECTION AND MAINTENANCE…679
INDEX…681
TEN00168-03 – Mobile Crusher GALEO BR380JG-1E0 Operation & Maintenance Manual (SN2001&up)…685
COVER…685
FOREWORD…686
BEFORE READING THIS MA…687
SAFETY INFORMATION…688
INTRODUCTION…689
INTRODUCTION…689
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE…689
NECESSARY INFORMATION…690
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…690
EPA REGULATIONS, ENGINE NUMBER PLATE…690
POSITION OF SERVICE METER…691
TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR…691
CONTENTS…692
SAFETY…696
SAFETY…697
SAFETY LABELS…700
POSITIONS OF SAFETY PICTOGRAMS…701
SAFETY LABELS…702
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…712
PRECAUTIONS BEFORE STARTING OPERATION…712
PREPARATIONS FOR SAFE OPERATION…712
FIRE PREVENTION…714
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…715
DO NOT GET CAUGHT IN WORK EQUIPMENT…717
UNAUTHORIZED MODIFICATION…717
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…717
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…717
PRECAUTIONS FOR OPERATION…718
PRECAUTIONS FOR JOBSITE…718
STARTING ENGINE…720
OPERATION…723
CRUSHING OPERATION…726
TRANSPORTATION…729
TOWING…730
MAGNETIC SEPARATOR…731
PRECAUTIONS FOR MAINTENANCE…732
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…732
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…736
OPERATION…742
GENERAL VIEW…743
GENERAL VIEW OF MACHINE…743
GENERAL VIEW OF CONTROLS AND GAUGES…744
EXPLANATION OF COMPONENTS…748
MACHINE MONITOR…748
SWITCHES…775
CONTROL LEVERS…787
OPTION-RELATED SWITCHES…788
CAP, COVER WITH LOCK…789
REVOLVING WARNING LAMP…791
ELECTRIC POWER TAKEOFF…792
FUSIBLE LINK…794
CONTROLLERS…794
FUSE…794
TOOL BOX…795
OPERATION…796
CHECK BEFORE STARTING ENGINE…796
STARTING ENGINE…821
OPERATIONS AND CHECKS AFTER STARTING ENGINE…823
STOPPING ENGINE…829
CHECK AFTER STOPPING ENGINE…829
MACHINE OPERATION…830
STEERING MACHINE…835
OPERATION OF WORK EQUIPMENT…837
CHECK AND CONFIRMATION OF JAW CRUSHER AFTER WORK…845
CHECK AFTER FINISHING WORK…845
LOCKING…846
RUN-IN OPERATION OF JAW CRUSHER…847
PRECAUTIONS WHEN OPERATING JAW CRUSHER…849
EFFICIENT USE OF JAW CRUSHER…853
SCOPE OF WORKS USING MOBILE CRUSHER…860
PROHIBITIONS FOR OPERATION…868
PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…871
TRANSPORTATION…872
TRANSPORTATION PROCEDURE…872
LOADING, UNLOADING WORK…873
LIFTING MACHINE…880
COLD WEATHER OPERATION…881
PRECAUTIONS FOR LOW TEMPERATURE…881
AFTER COMPLETION OF WORK…883
AFTER COLD WEATHER…883
LONG-TERM STORAGE…884
BEFORE STORAGE…884
DURING STORAGE…884
AFTER STORAGE…884
STARTING MACHINE AFTER LONG-TERM STORAGE…884
TROUBLESHOOTING…885
AFTER RUNNING OUT OF FUEL…885
PHENOMENA THAT ARE NOT FAILURES…885
METHOD OF TOWING MACHINE…886
IF BATTERY IS DISCHARGED…887
OTHER TROUBLE…891
MAINTENANCE…900
GUIDE TO MAINTENANCE…901
OUTLINE OF SERVICE…903
HANDLING AND PERFORMANCE OF OIL CLINIC FOR OIL, FUEL, COOLANT…903
RELATING TO ELECTRIC SYSTEM…907
OUTLINE OF HYDRAULIC EQUIPMENT…907
AIR-BLEEDING FROM HYDRAULIC CIRCUIT…908
WEAR PARTS…910
WEAR PARTS LIST…910
JAW CRUSHER RELATED PARTS…911
PRIMARY CONVEYOR RELATED PARTS…913
RECOMMENDED FUEL, COOLANT AND LUBRICANTS…914
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…916
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…917
TORQUE LIST…917
TOOLS TO USE CHECK AND MAINTENANCE CRUSHER…918
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…920
SAFETY CRITICAL PARTS…920
MAINTENANCE SCHEDULE CHART…921
MAINTENANCE SCHEDULE CHART…921
SERVICE PROCEDURE…923
INITIAL 250 HOURS SERVICE (FIRST MAINTENANCE FOR NEW MACHINE ONLY)…923
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)…923
WHEN REQUIRED…924
CHECK BEFORE STARTING…986
EVERY 10 HOURS SERVICE…987
EVERY 100 HOURS SERVICE…988
EVERY 250 HOURS SERVICE…989
EVERY 500 HOURS SERVICE…993
EVERY 1000 HOURS SERVICE…1001
EVERY 2000 HOURS SERVICE…1008
EVERY 4000 HOURS SERVICE…1010
EVERY 5000 HOURS SERVICE…1012
EVERY 8000 HOURS SERVICE…1013
SPECIFICATIONS…1014
SPECIFICATIONS…1015
ATTACHMENTS, OPTIONS…1018
GENERAL PRECAUTIONS…1019
PRECAUTIONS RELATED TO SAFETY…1019
ATTACHMENTS, OPTIONS…1020
ATTACHMENTS, OPTIONS CHART…1020
METHOD FOR CONNECTING HYDRAULIC HOSES FOR OPTIONS…1020
RADIO CONTROL UNIT…1021
ON USE OF RADIO CONTROL UNIT…1021
DIRECTIONS FOR USE…1024
RADIO CONTROL OPERATION…1030
MUCK DISCHARGE CONVEYOR…1043
PROCEDURE FOR RAISING (BENDING) MUCK DISCHARGE CONVEYOR…1043
PROCEDURE FOR LOWERING (EXTEND) MUCK DISCHARGE CONVEYOR…1045
GREASING MUCK DISCHARGE CONVEYOR…1048
CHECK AND ADJUSTMENT OF MUCK DISCHARGE CONVEYOR…1049
FAILURES AND CORRECTIVE ACTIONS…1051
WEARING PARTS…1053
SPECIFICATIONS…1054
M-TYPE CHUTE…1055
METHOD OF OPERATION…1055
GRIZZLY BAR OPENING…1056
HANDLING MACHINES EQUIPPED WITH KOMTRAX…1057
BASIC PRECAUTIONS…1057
MACHINES THAT CAN INSTALL ATTACHMENTS…1058
NAMES OF CONTROL PANEL SWITCHES…1058
HYDRAULIC POWER TAKEOFF PORT…1059
ATTACHMENT PORT…1060
PROCEDURE FOR CONNECTING OPTIONS…1062
SPRINKLER…1063
EXPLANATIONS FOR COMPONENT PARTS…1063
HOW TO USE SPRINKLER…1064
INSPECTION AND MAINTENANCE…1067
ADDITIONAL SPRINKLER NOZZLE…1068
INDEX…1072
TEN00358-01 – Mobile Crusher GALEO BR380JG-1E0 Operation & Maintenance Manual (SN2609&up)…1076
COVER…1076
FOREWORD…1077
BEFORE READING THIS MANUAL…1078
SAFETY INFORMATION…1079
INTRODUCTION…1080
INTRODUCTION…1080
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE…1080
NECESSARY INFORMATION…1081
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…1081
EPA REGULATIONS, ENGINE NUMBER PLATE…1081
POSITION OF SERVICE METER…1082
TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR…1082
CONTENTS…1083
SAFETY…1087
SAFETY…1088
SAFETY LABELS…1091
POSITIONS OF SAFETY PICTOGRAMS…1092
SAFETY LABELS…1093
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…1103
PRECAUTIONS BEFORE STARTING OPERATION…1103
PREPARATIONS FOR SAFE OPERATION…1103
FIRE PREVENTION…1105
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…1106
DO NOT GET CAUGHT IN WORK EQUIPMENT…1108
UNAUTHORIZED MODIFICATION…1108
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…1108
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…1108
PRECAUTIONS FOR OPERATION…1109
PRECAUTIONS FOR JOBSITE…1109
STARTING ENGINE…1111
OPERATION…1114
CRUSHING OPERATION…1117
TRANSPORTATION…1120
TOWING…1121
MAGNETIC SEPARATOR…1122
PRECAUTIONS FOR MAINTENANCE…1123
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…1123
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…1127
OPERATION…1133
GENERAL VIEW…1134
GENERAL VIEW OF MACHINE…1134
GENERAL VIEW OF CONTROLS AND GAUGES…1135
EXPLANATION OF COMPONENTS…1139
MACHINE MONITOR…1139
SWITCHES…1166
CONTROL LEVERS…1178
OPTION-RELATED SWITCHES…1179
CAP, COVER WITH LOCK…1180
REVOLVING WARNING LAMP…1182
ELECTRIC POWER TAKEOFF…1183
FUSIBLE LINK…1185
CONTROLLERS…1185
FUSE…1185
TOOL BOX…1186
OPERATION…1187
CHECK BEFORE STARTING ENGINE…1187
STARTING ENGINE…1212
OPERATIONS AND CHECKS AFTER STARTING ENGINE…1214
STOPPING ENGINE…1220
CHECK AFTER STOPPING ENGINE…1220
MACHINE OPERATION…1221
STEERING MACHINE…1226
OPERATION OF WORK EQUIPMENT…1228
CHECK AND CONFIRMATION OF JAW CRUSHER AFTER WORK…1236
CHECK AFTER FINISHING WORK…1236
LOCKING…1237
RUN-IN OPERATION OF JAW CRUSHER…1238
PRECAUTIONS WHEN OPERATING JAW CRUSHER…1240
EFFICIENT USE OF JAW CRUSHER…1244
SCOPE OF WORKS USING MOBILE CRUSHER…1251
PROHIBITIONS FOR OPERATION…1259
PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…1262
TRANSPORTATION…1263
TRANSPORTATION PROCEDURE…1263
LOADING, UNLOADING WORK…1264
LIFTING MACHINE…1271
COLD WEATHER OPERATION…1272
PRECAUTIONS FOR LOW TEMPERATURE…1272
AFTER COMPLETION OF WORK…1274
AFTER COLD WEATHER…1274
LONG-TERM STORAGE…1275
BEFORE STORAGE…1275
DURING STORAGE…1275
AFTER STORAGE…1275
STARTING MACHINE AFTER LONG-TERM STORAGE…1275
TROUBLESHOOTING…1276
AFTER RUNNING OUT OF FUEL…1276
PHENOMENA THAT ARE NOT FAILURES…1276
METHOD OF TOWING MACHINE…1277
IF BATTERY IS DISCHARGED…1278
OTHER TROUBLE…1282
MAINTENANCE…1291
GUIDE TO MAINTENANCE…1292
OUTLINE OF SERVICE…1294
HANDLING AND PERFORMANCE OF OIL CLINIC FOR OIL, FUEL, COOLANT…1294
RELATING TO ELECTRIC SYSTEM…1298
OUTLINE OF HYDRAULIC EQUIPMENT…1298
AIR-BLEEDING FROM HYDRAULIC CIRCUIT…1299
WEAR PARTS…1301
WEAR PARTS LIST…1301
JAW CRUSHER RELATED PARTS…1302
PRIMARY CONVEYOR RELATED PARTS…1304
RECOMMENDED FUEL, COOLANT AND LUBRICANTS…1305
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…1307
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…1308
TORQUE LIST…1308
TOOLS TO USE CHECK AND MAINTENANCE CRUSHER…1309
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…1311
SAFETY CRITICAL PARTS…1311
MAINTENANCE SCHEDULE CHART…1312
MAINTENANCE SCHEDULE CHART…1312
SERVICE PROCEDURE…1314
INITIAL 250 HOURS SERVICE (FIRST MAINTENANCE FOR NEW MACHINE ONLY)…1314
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)…1314
WHEN REQUIRED…1315
CHECK BEFORE STARTING…1377
EVERY 10 HOURS SERVICE…1378
EVERY 100 HOURS SERVICE…1379
EVERY 250 HOURS SERVICE…1380
EVERY 500 HOURS SERVICE…1384
EVERY 1000 HOURS SERVICE…1392
EVERY 2000 HOURS SERVICE…1398
EVERY 4000 HOURS SERVICE…1400
EVERY 5000 HOURS SERVICE…1402
EVERY 8000 HOURS SERVICE…1403
SPECIFICATIONS…1405
SPECIFICATIONS…1406
ATTACHMENTS, OPTIONS…1409
GENERAL PRECAUTIONS…1410
PRECAUTIONS RELATED TO SAFETY…1410
ATTACHMENTS, OPTIONS…1411
ATTACHMENTS, OPTIONS CHART…1411
METHOD FOR CONNECTING HYDRAULIC HOSES FOR OPTIONS…1411
RADIO CONTROL UNIT…1412
ON USE OF RADIO CONTROL UNIT…1412
DIRECTIONS FOR USE…1415
RADIO CONTROL OPERATION…1421
MUCK DISCHARGE CONVEYOR…1434
PROCEDURE FOR RAISING (BENDING) MUCK DISCHARGE CONVEYOR…1434
PROCEDURE FOR LOWERING (EXTEND) MUCK DISCHARGE CONVEYOR…1436
GREASING MUCK DISCHARGE CONVEYOR…1439
CHECK AND ADJUSTMENT OF MUCK DISCHARGE CONVEYOR…1440
FAILURES AND CORRECTIVE ACTIONS…1442
WEARING PARTS…1444
SPECIFICATIONS…1445
M-TYPE CHUTE…1446
METHOD OF OPERATION…1446
GRIZZLY BAR OPENING…1447
HANDLING MACHINES EQUIPPED WITH KOMTRAX…1448
BASIC PRECAUTIONS…1448
MACHINES THAT CAN INSTALL ATTACHMENTS…1449
NAMES OF CONTROL PANEL SWITCHES…1449
HYDRAULIC POWER TAKEOFF PORT…1450
ATTACHMENT PORT…1451
PROCEDURE FOR CONNECTING OPTIONS…1453
SPRINKLER…1454
EXPLANATIONS FOR COMPONENT PARTS…1454
HOW TO USE SPRINKLER…1455
INSPECTION AND MAINTENANCE…1458
ADDITIONAL SPRINKLER NOZZLE…1459
INDEX…1463
TEN00476-01 – Mobile Crusher GALEO BR380JG-1E0 Operation & Maintenance Manual (SN2621&up)…1467
COVER…1467
FOREWORD…1468
BEFORE READING THIS MANUAL…1469
SAFETY INFORMATION…1470
INTRODUCTION…1471
INTRODUCTION…1471
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE…1471
NECESSARY INFORMATION…1472
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…1472
EPA REGULATIONS, ENGINE NUMBER PLATE…1472
POSITION OF SERVICE METER…1473
TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR…1473
CONTENTS…1474
SAFETY…1478
SAFETY…1479
SAFETY LABELS…1482
POSITIONS OF SAFETY PICTOGRAMS…1483
SAFETY LABELS…1484
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…1494
PRECAUTIONS BEFORE STARTING OPERATION…1494
PREPARATIONS FOR SAFE OPERATION…1494
FIRE PREVENTION…1496
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…1497
DO NOT GET CAUGHT IN WORK EQUIPMENT…1499
UNAUTHORIZED MODIFICATION…1499
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…1499
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…1499
PRECAUTIONS FOR OPERATION…1500
PRECAUTIONS FOR JOBSITE…1500
STARTING ENGINE…1502
OPERATION…1505
CRUSHING OPERATION…1508
TRANSPORTATION…1511
TOWING…1512
MAGNETIC SEPARATOR…1513
PRECAUTIONS FOR MAINTENANCE…1514
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…1514
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…1518
OPERATION…1524
GENERAL VIEW…1525
GENERAL VIEW OF MACHINE…1525
GENERAL VIEW OF CONTROLS AND GAUGES…1526
EXPLANATION OF COMPONENTS…1530
MACHINE MONITOR…1530
SWITCHES…1557
CONTROL LEVERS…1569
OPTION-RELATED SWITCHES…1570
CAP, COVER WITH LOCK…1571
REVOLVING WARNING LAMP…1573
ELECTRIC POWER TAKEOFF…1574
FUSIBLE LINK…1576
CONTROLLERS…1576
FUSE…1576
TOOL BOX…1577
OPERATION…1578
CHECK BEFORE STARTING ENGINE…1578
STARTING ENGINE…1603
OPERATIONS AND CHECKS AFTER STARTING ENGINE…1605
STOPPING ENGINE…1611
CHECK AFTER STOPPING ENGINE…1611
MACHINE OPERATION…1612
STEERING MACHINE…1617
OPERATION OF WORK EQUIPMENT…1619
CHECK AND CONFIRMATION OF JAW CRUSHER AFTER WORK…1627
CHECK AFTER FINISHING WORK…1627
LOCKING…1628
RUN-IN OPERATION OF JAW CRUSHER…1629
PRECAUTIONS WHEN OPERATING JAW CRUSHER…1631
EFFICIENT USE OF JAW CRUSHER…1635
SCOPE OF WORKS USING MOBILE CRUSHER…1642
PROHIBITIONS FOR OPERATION…1650
PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…1653
TRANSPORTATION…1654
TRANSPORTATION PROCEDURE…1654
LOADING, UNLOADING WORK…1655
LIFTING MACHINE…1662
COLD WEATHER OPERATION…1663
PRECAUTIONS FOR LOW TEMPERATURE…1663
AFTER COMPLETION OF WORK…1665
AFTER COLD WEATHER…1665
LONG-TERM STORAGE…1666
BEFORE STORAGE…1666
DURING STORAGE…1666
AFTER STORAGE…1666
STARTING MACHINE AFTER LONG-TERM STORAGE…1666
TROUBLESHOOTING…1667
AFTER RUNNING OUT OF FUEL…1667
PHENOMENA THAT ARE NOT FAILURES…1667
METHOD OF TOWING MACHINE…1668
IF BATTERY IS DISCHARGED…1669
OTHER TROUBLE…1673
MAINTENANCE…1682
GUIDE TO MAINTENANCE…1683
OUTLINE OF SERVICE…1685
HANDLING AND PERFORMANCE OF OIL CLINIC FOR OIL, FUEL, COOLANT…1685
RELATING TO ELECTRIC SYSTEM…1689
OUTLINE OF HYDRAULIC EQUIPMENT…1689
AIR-BLEEDING FROM HYDRAULIC CIRCUIT…1690
WEAR PARTS…1692
WEAR PARTS LIST…1692
JAW CRUSHER RELATED PARTS…1693
PRIMARY CONVEYOR RELATED PARTS…1695
RECOMMENDED FUEL, COOLANT AND LUBRICANTS…1696
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…1698
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…1699
TORQUE LIST…1699
TOOLS TO USE CHECK AND MAINTENANCE CRUSHER…1700
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…1702
SAFETY CRITICAL PARTS…1702
MAINTENANCE SCHEDULE CHART…1703
MAINTENANCE SCHEDULE CHART…1703
SERVICE PROCEDURE…1705
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…1705
INITIAL 500 HOURS SERVICE (ONLY AFTER THE FIRST 500 HOURS)…1705
WHEN REQUIRED…1706
CHECK BEFORE STARTING…1768
EVERY 10 HOURS SERVICE…1769
EVERY 100 HOURS SERVICE…1770
EVERY 250 HOURS SERVICE…1771
EVERY 500 HOURS SERVICE…1775
EVERY 1000 HOURS SERVICE…1783
EVERY 2000 HOURS SERVICE…1789
EVERY 4000 HOURS SERVICE…1791
EVERY 5000 HOURS SERVICE…1793
EVERY 8000 HOURS SERVICE…1794
SPECIFICCATIONS…1796
SPECIFICATIONS…1797
ATTACHMENTS, OPTIONS…1800
GENERAL PRECAUTIONS…1801
PRECAUTIONS RELATED TO SAFETY…1801
ATTACHMENTS, OPTIONS…1802
ATTACHMENTS, OPTIONS CHART…1802
METHOD FOR CONNECTING HYDRAULIC HOSES FOR OPTIONS…1802
RADIO CONTROL UNIT…1803
ON USE OF RADIO CONTROL UNIT…1803
DIRECTIONS FOR USE…1806
RADIO CONTROL OPERATION…1812
MUCK DISCHARGE CONVEYOR…1825
PROCEDURE FOR RAISING (BENDING) MUCK DISCHARGE CONVEYOR…1825
PROCEDURE FOR LOWERING (EXTEND) MUCK DISCHARGE CONVEYOR…1827
GREASING MUCK DISCHARGE CONVEYOR…1830
CHECK AND ADJUSTMENT OF MUCK DISCHARGE CONVEYOR…1831
FAILURES AND CORRECTIVE ACTIONS…1833
WEARING PARTS…1835
SPECIFICATIONS…1836
M-TYPE CHUTE…1837
METHOD OF OPERATION…1837
GRIZZLY BAR OPENING…1838
HANDLING MACHINES EQUIPPED WITH KOMTRAX…1839
BASIC PRECAUTIONS…1839
MACHINES THAT CAN INSTALL ATTACHMENTS…1840
NAMES OF CONTROL PANEL SWITCHES…1840
HYDRAULIC POWER TAKEOFF PORT…1841
ATTACHMENT PORT…1842
PROCEDURE FOR CONNECTING OPTIONS…1844
SPRINKLER…1845
EXPLANATIONS FOR COMPONENT PARTS…1845
HOW TO USE SPRINKLER…1846
INSPECTION AND MAINTENANCE…1849
ADDITIONAL SPRINKLER NOZZLE…1850
INDEX…1854
Komatsu Mobile Crusher GALEO BR380JG Operation & Maintenance Manuals