Komatsu GALEO BR550JG-1 Manual

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FOREWORD
FOREWORD
FOREWORD
This manual provides rules and guidelines which will help you use this machine safely and effectively. The
precautions in this manual must be followed at all times when performing operation and maintenance. Most
accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of
machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when
performing operation and maintenance.
WARNING
Operators and maintenance personnel must always do as follows before beginning operation or maintenance.
Always be sure to read and understand this manual thoroughly before performing operation and maintenance.
Read the safety messages given in this manual and the safety labels affixed to the machine thoroughly and be sure that you
understand 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 dirty and cannot be read, request a replacement manual immediately from Komatsu
or your Komatsu distributor.
If you sell the machine, be sure to give this manual to the new owners together with the machine.
Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped.
If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety
devices and specifications that are necessary for use in your country. If there is any question about whether your product
complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before
operating the machine.
Storage location for the Operation and Maintenance Manual:
Main Control Box
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FOREWORD FOREWORD
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FOREWORD
FOREWORD
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FOREWORD SAFETY INFORMATION
SAFETY INFORMATION
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such
situations.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to
personal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, 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 unsafe practices that may cause
property damage.
Example of safety message using signal word
WARNING
When standing up from the operator's seat, always place the lock lever in
the LOCK position.
If you accidentally touch the control levers when they are not locked, this
may cause a serious injury or death.
Other signal words
In addition to the above, the following signal words are used to indicate precautions that should be followed to
protect the machine or to give information that is useful to know.
This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
This word is used for information that is useful to know.
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FOREWORD
SAFETY INFORMATION
Safety labels
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying out
operation or maintenance of the machine that may involve hazard.
This machine uses "Safety labels using words" and "Safety labels using pictograms" to indicate safety procedures.
Example of safety label using words
Safety labels using pictogram
Safety pictograms use a picture to express a level of hazardous
condition equivalent to the signal word. These safety pictograms
use pictures in order to let the operator or maintenance worker
understand the level and type of hazardous condition at all times.
Safety pictograms show the type of hazardous condition at the top
or left side, and the method of avoiding the hazardous condition at
the bottom or right side. In addition, the type of hazardous
condition is displayed inside a triangle 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, the safety messages in this manual and on the machine may not include all possible safety precautions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsibility
to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your
machine or for questions regarding information in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: 1-> (1))
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FOREWORD INTRODUCTION
INTRODUCTION
This Komatsu machine is designed to be used mainly for the following work:
Crushing Operation
For details on operations, please 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 machine, as viewed from the operator's
platform in the foreward traveling direction and with the sprockets turned to the front side.
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FOREWORD
NECESSARY INFORMATION
NECESSARY INFORMATION
When requesting service or ordering replacement parts, 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 at the side of the engine cylinder head cover (under the suction manifold).
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FOREWORD NECESSARY INFORMATION
POSITION 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
Phone/Fax
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FOREWORD
CONTENTS
CONTENTS
FOREWORD 1- 1
FOREWORD 1- 2
SAFETY INFORMATION 1- 5
INTRODUCTION 1- 7
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE 1- 7
NECESSARY INFORMATION 1- 8
MACHINE SERIAL NO. PLATE AND POSITION 1- 8
ENGINE SERIAL NO. PLATE AND POSITION 1- 8
POSITION OF SERVICE METER 1- 9
TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR 1- 9
SAFETY 2- 1
SAFETY 2- 2
SAFETY LABELS 2- 5
POSITIONS OF SAFETY PICTOGRAMS 2- 6
SAFETY LABELS 2- 7
GENERAL PRECAUTIONS 2- 12
PRECAUTIONS FOR OPERATION 2- 19
STARTING ENGINE 2- 19
OPERATION 2- 21
CRUSHING OPERATION 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 OF COMPONENTS 3- 5
MACHINE MONITOR 3- 5
SWITCHES 3- 16
CONTROL LEVERS 3- 25
OPTION-RELATED SWITCHES 3- 26
CAP, COVER WITH LOCK 3- 27
REVOLVING WARNING LAMP 3- 29
ADDITIONAL WORKING LAMP 3- 30
FUSIBLE LINK 3- 30
CONTROLLERS 3- 31
FUSE 3- 31
TOOL BOX 3- 32
OPERATION 3- 33
CHECK BEFORE STARTING ENGINE 3- 33
STARTING ENGINE 3- 49
OPERATIONS AND CHECKS AFTER STARTING ENGINE 3- 52
STOPPING ENGINE 3- 54
CHECK AFTER STOPPING ENGINE 3- 54
MACHINE OPERATION 3- 55
STEERING MACHINE 3- 59
OPERATION OF WORK EQUIPMENT 3- 61
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FOREWORD CONTENTS
WATER SPRINKLER 3- 66
OPENING-CLOSING TYPE HOPPER 3- 67
CHECK AND CONFIRMATION OF JAW CRUSHER AFTER WORK 3- 75
CHECK AFTER FINISHING WORK 3- 75
LOCKING 3- 75
RUN-IN OPERATION OF JAW CRUSHER 3- 76
PRECAUTIONS WHEN OPERATING JAW CRUSHER 3- 79
EFFICIENT USE OF JAW CRUSHER 3- 81
SCOPE OF WORKS USING MOBILE CRUSHER 3- 86
PROHIBITIONS FOR OPERATION 3- 92
PRECAUTIONS WHEN TRAVELING UP OR DOWNHILLS 3- 94
TRANSPORTATION 3- 95
TRANSPORTATION PROCEDURE 3- 95
PROCEDURE FOR DISASSEMBLY AND FOLDING 3- 97
LOADING, UNLOADING WORK 3- 99
LIFTING MACHINE 3-106
COLD WEATHER OPERATION 3-107
PRECAUTIONS FOR LOW TEMPERATURE 3-107
AFTER COMPLETION OF WORK 3-108
AFTER COLD WEATHER 3-108
LONG-TERM STORAGE 3-110
BEFORE STORAGE 3-110
DURING 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 3-112
OTHER TROUBLE 3-115
MAINTENANCE 4- 1
GUIDE TO MAINTENANCE 4- 2
OUTLINE OF SERVICE 4- 4
HANDLING OIL, FUEL, COOLANT,AND PERFORMING OIL CLINIC 4- 4
RELATING TO ELECTRIC SYSTEM 4- 7
OUTLINE OF HYDRAULIC EQUIPMENT 4- 7
AIR-BLEEDING FROM HYDRAULIC CIRCUIT 4- 8
WEAR PARTS 4- 9
WEAR PARTS LIST 4- 9
JAW CRUSHER RELATED PARTS 4- 10
PRIMARY CONVEYOR RELATED PARTS 4- 12
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 14
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 18
CRUSHER ACCESSORY TOOLS 4- 18
TORQUE LIST 4- 20
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 4- 21
SAFETY CRITICAL PARTS 4- 21
MAINTENANCE SCHEDULE CHART 4- 22
MAINTENANCE SCHEDULE CHART 4- 22
SERVICE PROCEDURE 4- 24
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FOREWORD
CONTENTS
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) 4- 24
WHEN REQUIRED 4- 25
CHECK BEFORE STARTING 4- 59
EVERY 100 HOURS SERVICE 4- 60
EVERY 250 HOURS SERVICE 4- 62
EVERY 500 HOURS SERVICE 4- 69
EVERY 1000 HOURS SERVICE 4- 74
EVERY 2000 HOURS SERVICE 4- 79
EVERY 4000 HOURS SERVICE 4- 81
EVERY 5000 HOURS SERVICE 4- 82
SPECIFICATIONS 5- 1
SPECIFICATIONS 5- 2
ATTACHMENTS, OPTIONS 6- 1
GENERAL PRECAUTIONS 6- 2
PRECAUTIONS RELATED TO SAFETY 6- 2
HYDRAULIC TYPE MAGNETIC SELECTOR 6- 3
SAFETY PRECAUTIONS 6- 3
PROCEDURES FOR CONNECTION WITH CRUSHER 6- 3
PRECAUTIONS IN 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 PROCEDURES 6- 9
PROCEDURES FOR FOLDING DEBRIS DISCHARGING CONVEYOR 6- 10
GREASING MUCK DISCHARGE CONVEYOR 6- 11
CHECK AND ADJUSTMENT OF MUCK DISCHARGE CONVEYOR 6- 12
FAILURES AND CORRECTIVE ACTIONS 6- 14
WEARING PARTS 6- 16
SPECIFICATIONS 6- 18
RADIO CONTROL UNIT 6- 19
DIRECTIONS FOR USE 6- 19
OVERVIEW 6- 21
ON USE OF RADIO CONTROL UNIT 6- 22
BELT CONVEYOR PROTECTIVE PLATE 6- 26
PROCEDURES FOR CONNECTING OPTIONAL ATTACHMENTS 6- 27
LOCATION OF PORTS FOR CONNECTING OPTIONAL ATTACHMENTS 6- 27
PROCEDURES FOR CONNECTING OPTIONAL ATTACHMENTS 6- 28
INDEX 7- 1
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SAFETY
SAFETY
SAFETY
SAFETY LABELS 2- 5
POSITIONS OF SAFETY PICTOGRAMS 2- 6
SAFETY LABELS 2- 7
GENERAL PRECAUTIONS 2- 12
SAFETY RULES 2- 12
IF ABNORMALITIES ARE FOUND 2- 12
CLOTHING AND PERSONAL PROTECTIVE ITEMS 2- 12
FFIRE EXTINGUISHER AND FIRST AID KIT 2- 12
SAFETY FEATURES 2- 12
KEEP MACHINE CLEAN 2- 13
ON OPERATOR'S PLATFORM 2- 13
ALWAYS APPLY 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- 16
PRECAUTIONS FOR ATTACHMENTS 2- 16
UNAUTHORIZED MODIFICATION 2- 16
SAFETY AT WORKSITE 2- 17
WORKING ON LOOSE GROUND 2- 17
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES 2- 17
ENSURE GOOD VISIBILITY 2- 18
VENTILATION FOR ENCLOSED AREAS 2- 18
CHECKING SIGNALMAN'S SIGNALS AND SIGNS 2- 18
BE CAREFUR ABOUT ASBESTOS DUST 2- 18
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SAFETY SAFETY
PRECAUTIONS FOR OPERATION 2- 19
STARTING ENGINE 2- 19
CCHECKS BEFORE STARTING ENGINE 2- 19
PRECAUTIONS WHEN STARTING 2- 19
PRECAUTIONS IN COLD AREAS 2- 22
OPERATION 2- 21
CHECK BEFORE OPERATION 2- 21
PRECAUTIONS WHEN CHANGING DIRECTION 2- 21
PRECAUTIONS WHEN TRAVELING 2- 21
TRAVELING ON SLOPES 2- 22
PRECAUTIONS WHILE IN OPERATION 2- 22
OPERATE CAREFULLY 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 EXCAVATOR 2- 24
CHECKS OF CRUSHER BEFORE STARTING OPERATION 2- 25
PRECAUTIONS FOR CRUSHING WORK 2- 25
EMERGENCY STOP TO WARD OFF DANGERS WHILE IN CRUSHING WORK 2- 26
TRANSPORTATION 2- 27
LOADING AND UNLOADING 2- 27
SHIPPING 2- 27
BATTERY 2- 28
BATTERY HAZARD PREVENTION 2- 28
STARTING WITH BOOSTER CABLE 2- 29
TOWING 2- 30
WHEN TOWING 2- 30
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SAFETY
SAFETY
PRECAUTIONS FOR MAINTENANCE 2- 31
WARNING TAG 2- 31
KEEP WORK PLACE CLEAN AND TIDY 2- 31
APPOINT LEADER WHEN WORKING WITH OTHERS 2- 31
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE 2- 31
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING 2- 32
PRECAUTIONS FOR CONVEYOR MAINTENANCE 2- 32
PROPER TOOLS 2- 33
PERSONNEL 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
REMOVING BATTERY TERMINAL 2- 34
PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION 2- 34
DO NOT DISASSEMBLE RECOIL SPRING 2- 34
PRECAUTIONS WITH HIGH-PRESSURE OIL 2- 35
HANDLING HIGH-PRESSURE HOSES 2- 35
WASTE MATERIAL 2- 35
COMPRESSED AIR 2- 35
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 2- 36
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SAFETY SAFETY LABELS
SAFETY LABELS
The following warning signs and safety labels are used on this machine.
Be sure that you fully understand the correct position and content of labels.
To ensure that the content of labels can be read properly, be sure that they are in the correct place 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 labels. Handle those labels in the same
way.
If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part
numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.
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SAFETY
SAFETY LABELS
POSITIONS OF SAFETY PICTOGRAMS
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SAFETY SAFETY LABELS
SAFETY LABELS
(1)Precautions when leaving 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, inspection and
maintenance (09651-A0461)
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