Komatsu BR500RG-1 Series Shop Manual SEBM012103
Komatsu BR500RG-1 Series Shop Manual SEBM012103 - Image 2
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Komatsu BR500RG-1 Series Shop Manual SEBM012103 - Image 5

Komatsu BR500RG-1 Series Shop Manual SEBM012103

$50.00

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

Description

  • 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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