komatsu br500rg 1 series shop manual sebm012103 1

komatsu br500rg 1 series shop manual sebm012103 2

komatsu br500rg 1 series shop manual sebm012103 3

komatsu br500rg 1 series shop manual sebm012103 4

komatsu br500rg 1 series shop manual sebm012103 5

Komatsu BR500RG-1 Series Shop Manual SEBM012103

$40.00

Type Of Manual: Shop Manual
Manual ID: SEBM012103
Format: PDF
Size: 25.3MB
Number of Pages: 391

Category: Komatsu Shop Manual PDF

Model List:
- BR500RG-1 Series

0.1. TABLE OF OIL AND COOLANT CAPACITIES
1. STRUCTURE AND FUNCTION
1.1. PARTS RELATED TO ENGINE
1.2. RADIATOR, OIL COOLER
1.3. DRIVE SYSTEMS FOR EACH COMPONENT
1.4. FINAL DRIVE
1.5. TRACK FRAME, RECOIL SPRING
1.6. TRACK SHOE
1.7. HYDRAULIC TANK, HYDRAULIC FILTER
1.8. HYDRAULIC PUMP
1.9. CONTROL VALVE
1.10. SUCTION SAFETY VALVE
1.11. SELFREDUCING PRESSURE VALVE
1.12. CLSS
1.13. CRUSHER MOTOR
1.14. TRAVEL MOTOR
1.15. TRAVEL PPC VALVE
1.16. HYDRAULIC CYLINDER
1.17. ELECTRIC CIRCUIT DIAGRAM
1.18. ENGINE CONTROL SYSTEM
1.19. MACHINE MONITOR SYSTEM
1.20. BELT CONVEYOR MACHINERY
1.21. BELT CONVEYOR MOTOR
1.22. SOLENOID VALVE (6SPOOL)
1.23. SOLENOID VALVE (FOR CRUSHER MOTOR)
1.24. PPC VALVE
1.25. FIRST BELT CONVEYOR
1.26. GRIZZLY FEEDER
1.27. VIBRATOR
1.28. FLOW CONTROL VALVE
1.29. CRUSHER
2. TESTING AND ADJUSTING
2.1. STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
2.2. STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
2.3. TOOLS FOR TASTING, ADJUSTING, AND TROUBLESHOOTING
2.4. MEASURING ENGINE SPEED
2.5. MEASURING EXHAUST COLOR
2.6. ADJUSTING VALVE CLEARANCE
2.7. MEASURING COMPRESSION PRESSURE
2.8. MEASURING BLOWBY PRESSURE
2.9. TESTING AND ADJUSTING FUEL INJECTION TIMING
2.10. MEASURING ENGINE OIL PRESSURE
2.11. TESTING AND ADJUSTING FAN BELT TENSION
2.12. ADJUSTING ENGINE SPEED SENSOR
2.13. MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)
2.14. TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT AND TRAVEL CIRCUIT
2.15. TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE
2.16. TESTING SOLENOID VALVE OUTPUT PRESSURE
2.17. MEASURING PPC VALVE OUTPUT PRESSURE
2.18. TESTING TRAVEL DEVIATION
2.19. RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
2.20. TESTING AND ADJUSTING TRACK SHOE TENSION
2.21. BLEEDING AIR FROM HYDRAULIC CIRCUIT
2.22. ADJUSTING FUEL CONTROL LEVER
2.23. TESTING AND ADJUSTING CRUSHER
2.24. TROUBLESHOOTING
2.24.1. POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
2.24.2. CHECKS BEFORE TROUBLESHOOTING
2.24.2.1. FOR CHASSIS
2.24.2.2. FOR CRUSHER
2.24.2.3. FOR BELT CONVEYOR
2.24.3. CONNECTOR TYPES AND MOUNTING LOCATIONS
2.24.4. CONNECTOR ARRANGEMENT DIAGRAM
2.24.5. CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
2.24.6. METHOD OF PROCEEDING WITH TROUBLESHOOTING
2.24.7. METHOD OF USING TROUBLESHOOTING CHARTS
2.24.8. TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
2.24.8.1. E1 TRAVEL LOCK DOES NOT WORK NORMALLY
2.24.9. TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)
2.24.9.1. M1 WHEN STARTING SWITCH IS TURNED ON, NO DISPLAY IS GIVEN
2.24.9.2. M2 WHEN STARTING SWITCH IS TURNED ON, LAMPS LIGHT UP FOR 3 SECONDS, BUT THEN DO NOT GO OUT
2.24.9.3. M3 WHEN STARTING SWITCH IS TURNED ON, SOME LAMPS DO NOT LIGHT UP FOR 3 SECONDS
2.24.9.4. M4 WHEN POWER IS TURNED ON (BEFORE ENGINE IS STARTED), CHARGE CAUTION LAMP DOES NOT LIGHT UP
2.24.9.5. M5 WHEN POWER IS TURNED ON (BEFORE ENGINE IS STARTED), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP
2.24.9.6. M6 DURING PREHEATING, PREHEATING PILOT LAMP DOES NOT LIGHT UP
2.24.9.7. M7 WHEN SWITCH IS OPERATED, TRAVEL LOCK LAMP DOES NOT LIGHT UP
2.24.9.8. M8 ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING
2.24.9.9. M9 CHARGE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING
2.24.9.10. M10 ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE
2.24.9.11. M11 ABNORMALITY IN FUEL GAUGE
2.24.9.12. M12 DEFECTIVE OPERATION OF ALARM BUZZER
2.24.9.13. M13 ENGINE IS RUNNING, BUT SERVICE METER DOES NOT MOVE
2.24.9.14. M14 NIGHT LIGHTING DOES NOT LIGHT UP
3. DISASSEMBLY AND ASSEMBLY
3.1. METHOD OF USING MANUAL
3.2. PRECAUTIONS WHEN CARRYING OUT OPERATION
3.3. SPECIAL TOOL LIST
3.4. SKETCHES OF SPECIAL TOOLS
3.5. STARTING MOTOR ASSEMBLY
3.5.1. REMOVAL AND INSTALLATION
3.6. ALTERNATOR ASSEMBLY
3.6.1. REMOVAL AND INSTALLATION
3.7. ENGINE OIL COOLER ASSEMBLY
3.7.1. REMOVAL AND INSTALLATION
3.8. FUEL INJECTION PUMP ASSEMBLY
3.8.1. REMOVAL
3.8.2. INSTALLATION
3.9. WATER PUMP ASSEMBLY
3.9.1. REMOVAL AND INSTALLATION
3.10. NOZZLE HOLDER ASSEMBLY
3.10.1. REMOVAL AND INSTALLATION
3.11. TURBOCHARGER ASSEMBLY
3.11.1. REMOVAL AND INSTALLATION
3.12. THERMOSTAT ASSEMBLY
3.12.1. REMOVAL AND INSTALLATION
3.13. ENGINE FRONT SEAL
3.13.1. REMOVAL AND INSTALLATION
3.14. ENGINE REAR SEAL
3.14.1. REMOVAL
3.14.2. INSTALLATION
3.15. CYLINDER HEAD ASSEMBLY
3.15.1. REMOVAL
3.15.2. INSTALLATION
3.16. AFTERCOOLER CORE ASSEMBLY
3.16.1. REMOVAL AND INSTALLATION
3.17. HYDRAULIC COOLER ASSEMBLY
3.17.1. REMOVAL
3.17.2. INSTALLATION
3.18. RADIATOR, HYDRAULIC COOLER ASSEMBLY
3.18.1. REMOVAL
3.18.2. INSTALLATION
3.19. ENGINE, MAIN PUMP ASSEMBLY
3.19.1. REMOVAL
3.19.2. INSTALLATION
3.20. DAMPER ASSEMBLY
3.20.1. REMOVAL AND INSTALLATION
3.21. FUEL TANK ASSEMBLY
3.21.1. REMOVAL AND INSTALLATION
3.22. FINAL DRIVE ASSEMBLY
3.22.1. REMOVAL AND INSTALLATION
3.22.2. DISASSEMBLY
3.22.3. ASSEMBLY
3.23. SPROCKET
3.23.1. REMOVAL AND INSTALLATION
3.24. IDLER, RECOIL SPRING ASSEMBLY
3.24.1. REMOVAL AND INSTALLATION
3.25. IDLER ASSEMBLY
3.25.1. DISASSEMBLY
3.25.2. ASSEMBLY
3.26. RECOIL SPRING ASSEMBLY
3.26.1. DISASSEMBLY
3.26.2. ASSEMBLY
3.27. TRACK ROLLER ASSEMBLY
3.27.1. REMOVAL AND INSTALLATION
3.27.2. DISASSEMBLY
3.27.3. ASSEMBLY
3.28. CARRIER ROLLER ASSEMBLY
3.28.1. REMOVAL AND INSTALLATION
3.28.2. DISASSEMBLY
3.28.3. ASSEMBLY
3.29. TRACK SHOE ASSEMBLY
3.29.1. REMOVAL AND INSTALLATION
3.30. HYDRAULIC TANK ASSEMBLY
3.30.1. REMOVAL
3.30.2. INSTALLATION
3.31. CONTROL PUMP ASSEMBLY
3.31.1. REMOVAL AND INSTALLATION
3.32. MAIN PUMP ASSEMBLY
3.32.1. REMOVAL
3.32.2. INSTALLATION
3.33. MAIN PUMP INPUT SHAFT OIL SEAL
3.33.1. REMOVAL AND INSTALLATION
3.34. SERVO VALVE ASSEMBLY FOR FRONT PUMP
3.34.1. REMOVAL AND INSTALLATION
3.35. SERVO VALVE ASSEMBLY FOR REAR PUMP
3.35.1. REMOVAL AND INSTALLATION
3.36. TRAVEL PPC VALVE ASSEMBLY
3.36.1. DISASSEMBLY
3.36.2. ASSEMBLY
3.37. CONVEYOR MACHINERY, MOTOR ASSEMBLY
3.37.1. REMOVAL AND INSTALLATION
3.38. CONVEYOR MACHINERY ASSEMBLY
3.39. FIXED JAW PLATE
3.39.1. REMOVAL AND INSTALLATION
3.40. SWING JAW PLATE
3.40.1. REMOVAL AND INSTALLATION
3.41. FLYWHEEL AND V SHEAVE
3.41.1. REMOVAL AND INSTALLATION
3.42. FIXED JAW TEETH
3.42.1. TURNING AND REPLACEMENT
3.43. SWING JAW TEETH
3.43.1. TURNING AND REPLACEMENT
3.44. FLYWHEEL AND VPULLEY
4. MAINTENANCE STANDARD
4.1. ENGINE MOUNT
4.2. FINAL DRIVE
4.3. TRACK FRAME AND RECOIL SPRING
4.4. CONTROL PUMP AND RELIEF VALVE
4.5. SUCTIONSAFETY VALVE
4.6. SELFREDUCING PRESSURE VALVE
4.7. CRUSHER MOTOR
4.8. TRAVEL MOTOR
4.9. TRAVEL PPC VALVE
4.10. BELT CONVEYOR MACHINERY
4.11. BELT CONVEYOR MOTOR
4.12. CRUSHER
4.13. WEAR MEASUREMENT OF MAJOR CONSUMABLE PARTS
5. OTHERS
5.1. HYDRAULIC CIRCUIT DIAGRAM (SERIAL NO. 10061103)
5.2. HYDRAULIC CIRCUIT DIAGRAM (SERIAL NO. 1201 AND UP)
5.3. ELECTRIC CIRCUIT DIAGRAM (SERIAL NO. 10021006)
5.4. ELECTRIC CIRCUIT DIAGRAM (SERIAL NO. 10071103)
5.5. ELECTRIC CIRCUIT DIAGRAM (SERIAL NO. 1201 AND UP)

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