Komatsu BR480RG-1 Crusher Operation and Maintenance Manual (SEAM047100T)

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Komatsu BR480RG-1 Crusher Index:

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FOREWORD
- FOREWORD
- SAFETY INFORMATION
- INTRODUCTION
  - FRONT/REAR,LEFT/RIGHT DIRECTIONS OF MAHCINE
- NECESSARY INFORMATION
  - MACHINE SERIAL NO. PLATE AND POSITION
  - ENGINE SERIAL NO. PLATE AND POSITION
  - POSITION OF SERVICE METER
  - TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR
CONTENTS
SAFETY
- SAFETY
- SAFETY LABELS
  - POSITIONS OF SAFETY PICTOGRAMS
  - SAFETY LABELS
- GENERAL PRECAUTIONS
  - SAFETY RULES
  - IF ABNORMALITIES ARE FOUND
  - CLOTHING AND PERSONAL PROTECTIVE ITEMS
  - FIRE EXTINGUISHER AND FIRST AID KIT
  - SAFETY FEATURES
  - KEEP MACHINE CLEAN
  - PRECAUTIONS TO BE FOLLOWED IN UPPER OPERATION DECK
  - ALWAYS APPLY LOCK WHEN LEAVING OPERATOR’S PLATFROM
  - HANDRAILS AND STEPS
  - MOUNTING AND DISMOUNTING
  - NO PEOPLE ON ATTACHMENTS
  - CRUSHING OR CUTTING PREVENTION
  - PREVENTION OF BURNS
  - FIRE PREVENTION
  - ACTION IF FIRE OCCURS
  - PRECAUTIONS FOR ATTACHMENTS
  - UNAUTHORIZED MODIFICATION
  - SAFETY AT WORKSITE
  - WORKING ON LOOSE GROUND
  - DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES
  - ENSURE GOOD VISIBILITY
  - VENTILATION FOR ENCLOSED AREAS
  - CHECKING SIGNALMAN’S SIGNALS AND SIGNS
  - BE CAREFUR ABOUT ASBESTOS DUST
- PRECAUTIONS FOR OPERATION
  - STARTING ENGINE
  - OPERATION
  - CRUSHING OPERATION
  - TRANSPORTATION
  - BATTERY
  - TOWING
- PRECAUTIONS FOR MAINTENANCE
  - WARNING TAG
  - KEEP WORK PLACE CLEAN AND TIDY
  - APPOINT LEADER WHEN WORKING WITH OTHERS
  - STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE
  - TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING
  - PRECAUTIONS FOR CONVEYOR MAINTENANCE
  - PROPER TOOLS
  - PERSONNEL
  - PRECAUTIONS WHEN MOUNTING,DISMANTLING AND STORING ATTACHMENTS
  - PRECAUTIONS FOR WORK UNDER MACHINE
  - NOISE
  - PRECAUTIONS WHEN USING HAMMER
  - REPAIR WELDING
  - REMOVING BATTERY TERMINAL
  - PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION
  - DO NOT DISASSEMBLE RECOIL SPRING
  - PRECAUTIONS WITH HIGH-PRESSURE OIL
  - HANDLING HIGH-PRESSURE HOSES
  - WASTE MATERIAL
  - COMPRESSED AIR
  - PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
OPERATION
- GENERAL VIEW
  - GENERAL VIEW OF MACHINE
  - GENERAL VIEW OF IMPACT CRUSHER
  - GENERAL VIEW OF CONTROLS AND GAUGES
- EXPLANATION OF COMPONENTS
  - MACHINE MONITOR
  - SWITCHES
  - CONTROL LEVERS
  - CAP,COVER WITH LOCK
  - REVOLVING WARNING LAMP
  - ADDITIONAL WORKING LAMP
  - FUSIBLELINK
  - CONTROLLERS
  - FUSE
- 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
  - WATER SPRINKLER
  - HYDRAULIC TYPE MAGNETIC SELECTOR
  - CHECK AND CONFIRMATION OF IMPACT CRUSHER AFTER WORK
  - CHECK AFTER FINISHING WORK
  - LOCKING
  - PRECAUTIONS WHEN OPERATING IMPACT CRUSHER
  - EFFICIENT USE OF IMPACT 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
  - STRTING MACHINE AFTER LONG-TERM STORAGE
- TROUBLESHOOTING
  - PHENOMENA THAT ARE NOT FAILURES
  - METHOD OF TOWING MACHINE
  - IF BATTERY IS DISCHARGED
  - OTHER TROUBLE
MAINTENANCE
- GUIDE TO MAINTENANCE
- OUTLINE OF SERVICE
  - HANDLING OIL,FUEL,COOLANT,AND PERFORMING OIL CLINIC
  - RELATING TO ELECTRIC SYSTEM
  - OUTLINE OF HYDRAULIC EQUIPMENT
- WEAR PARTS
  - WEAR PARTS LIST
  - IMPACT CRUSHER RELATED PARTS
  - PRIMARY BELT CONVEYOR RELATED PARTS
  - DEBRIS DISCHARGING BELT CONVEYOR RELATED PARTS
- USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
- STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
  - TORQUE LIST
- PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
  - SAFETY CRITICAL PARTS
- MAINTENANCE SCHEDULE CHART
  - MAINTENANCE SCHEDULE CHART
- SERVICE PROCEDURE
  - INITIAL 250 HOURS MAINTENANCE(ONLY AFTER THE FIRST 250 HOURS)
  - WHEN REQUIRED
  - CHECK BEFORE STARTING
  - 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
SPECIFICATIONS
- SPECIFICATIONS
ATTACHMENTS,OPTIONS
- GENERAL PRECAUTIONS
  - PRECAUTIONS RELATED TO SAFETY
- SPRINKLER
  - EXPLANATIONS FOR COMPONENT PARTS
  - HOW TO USE SPRINKLER
  - INSPECTION AND MAINTENANCE
- RADIO CONTROL UNIT
  - DIRECTIONS FOR USE
  - OVERVIEW
  - ON USE OF RADIO CONTROL UNIT
INDEX
COVER
TABLE OF CONTENTS
PART Ⅰ INTRODUCTION
- 1. FOREWORD
PART ⅡSAFETY
- 1. SAFETY INFORMATION
- 2. QUALIFICATION FOR OPERATING THE MACHINE
  - 2.1 QUALIFICATION REQUIREED FOR OPERATING CRANES
- 3. BASIC RULES
- 4. RULES FOR OPERATION
  - 4.1 BEFORE SATRTING UP ENGINE
  - 4.2 AFTER THE ENGINE HAS STARTED
  - 4.3 DURING CRANE OPERATION
- 5. RULES FOR HANDLING THE BATTERY
- 6. RULES TO OBSERVE IN CONNECTION WITH SERVICE
  - 6.1 BEFORE STARTING THE SERVICE WORK
  - 6.2 DURING SERVICE WORK
- 7. LOCATION FOR AFFIXING CAUTION PLATES
- 8. CAUTION PLATES AND OPERATION MANUAL ORDERING PROCEDURES
PART Ⅲ OPERATION
- 1. NOMENCLATURE OF COMPONENTS
- 2. CRANE OVERVIEW
  - 2.1 KEY SPECIFICATIONS
  - 2.2 GLOSSARY
  - 2.3 HOW TO READ WORKING RADIUS AND LIFTING HEIGHT DIAGRAM
  - 2.4 HOW TO READ TOTAL RATED LOAD CHART(DS100C-MC053)
  - 2.5 HOW TO READ LOAD INDICATOR AND MOMENT METER
  - 2.6 HOOK OVER-HOIST PREVENTIVE DEVICE
- 3. CRANE OPERATION PROCEDURE(FROM REMOTE CONTROL SWITCHES)
  - 3.1 NOMENCLATURE OF COMPONENTS ON REMOTE CONTROL DEVICE
  - 3.2 NOMENCLATURE OF COMPONENTS ON CONTROL CASE
  - 3.3 PREPARATIONS FOR OPERATION
  - 3.4 USING THE REMOTE CONTROL SWITCHES
  - 3.5 ENDING THE CRANE OPERATION
- 4. PRECAUTIONS ON USE OF REMOTE CONTROL SWITHCES
  - 4.1 BEFORE STARTING THE OPERATION
  - 4.2 DURING THE OPERATION
  - 4.3 AFTER THE OPERATION
  - 4.4 OTHERS
- 5. REMOTE CONTROL DEVICE CHECK POINTS
  - 5.1 TROUBLESHOOTING GUIDE-WHEN THE CRANE IS INOPERABLE FROM THE REMOTE CONTROL DEVICE
- 6. PRECAUTIONS ON USE
  - 6.1 BEFORE STARTING THE OPERATION
  - 6.2 HANDLING OF TARGET CARGO OF LIFT
  - 6.3 HANDLING OF WIRE ROPE
  - 6.4 AFTER USING THE CRANE
  - 6.5 OTHERS
- 7. CHECK ITEMS
  - 7.1 INSPECTION OF THE SWING BEARING MOUNTING BOLT
- 8. WIRE ROPE REPLACEMENT PROCEDURE
  - 8.1 PRECAUTIONS ON HANDLING WIRE ROPES
  - 8.2 WIRE ROPE REPLACEMENT PROCEDURE
- 9. BOOM TELESCOPING WIRE ROPE ADJUSTING PROCEDURE
  - 9.1 ADJUSTING PROCEDURE
- 10. REPLACEMENT OF DRY CELL ON THE OVER-HOIST PREVENTIVE DEVICE
- 11. HYDRAULIC OIL
- 12. LUBRICATING OIL
  - 12.1 LUBRICATING POINTS
  - 12.2 CHECK AND REFILLING OF LUBRICATING OIL ON THE SWING GEARBOX
  - 12.3 LUBRICATING POINTS,LUBRICATING OILS USED AND LUBRICATION INTERVALS
- 13. REPLACEMENT OF CONSUMABLE PARTS
- 14. DESCRIPTION OF THE DEVICES EMPLOYED FOR THE CRANE
  - 14.1 ALARM SWITCH
  - 14.2 OVER-HOIST PREVENTIVE DEVICE
  - 14.3 LOAD INDICATOR
  - 14.4 MOMENT METER
  - 14.5 AUTOMATIC OIL PRESSURE LOCK DEVICE