Komatsu BR500JG-1 Crusher Operation and Maintenance Manual (SEAM011303T)

This Komatsu BR500JG-1 crusher manual is what we lean on to keep a mobile crusher working steady in quarries, demo sites, and recycling yards. It helps you build a sensible service rhythm around how hard you actually run the machine, so you’re not guessing on greasing, filter changes, or crusher inspections. When you’ve got something like uneven crushing, blocked material flow, or vibration that feels “off,” this book walks you through the basic checks so you can trace the problem before it turns into a full breakdown.

Applications & Use Cases

Plan daily, weekly, and seasonal checks so wear parts and belts are inspected before they fail on a busy day.
Verify safe start-up and shutdown routines to avoid shock-loading the crusher and drivetrain.
Trace unusual noises or vibration back to mounts, guards, or loose fasteners using the manual’s inspection logic.
Align your cleaning and lubrication schedule with actual site conditions: dust, mud, and temperature swings.
Train new operators on what to watch, log, and report so maintenance can be scheduled instead of reacting.

FAQ

Q: Can I keep this manual on a tablet in the service truck?

A: Yes, it’s practical to use digitally; you can zoom diagrams and search text, then print only the pages you need.

Q: Is it worth printing a hard copy for the crusher itself?

A: Definitely; a bound or laminated copy in the site office or cab saves time when you’re diagnosing issues in bad weather.

Safety Note

Always lock out, tag out, and verify zero energy before inspecting or servicing any part of the crusher.

📘 Show Index

Komatsu BR500JG-1 Crusher Index:

COVER
1. FOREWORD
2. SAFETY INFORMATION
3. TO THE USER
4. LOCATION OF PLATES,TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
5. CONTENTS
SAFETY
- 1. GENERAL PRECAUTIONS
- 2. PRECAUTIONS DURING OPERATION
  - 2.1 BEFORE STARTING ENGINE
  - 2.2 AFTER STARTING ENGINE
  - 2.3 CRUSHER (CRUSHING) OPERATIONS
  - 2.4 BATTERY
  - 2.5 TOWING
- 3. PRECAUTIONS FOR MAINTENANCE
- 4. POSITION FOR ATTACHING SAFETY LABELS
OPERATION
- 1. GENERAL VIEW
- 2. EXPLANATION OF INSTRUMENTS
  - 2.1 VEHICLE MONITORING SYSTEM
  - 2.2 SWITCH UNIT
  - 2.3 CONTROL LEVER,DIAL,PATROL LIGHT
  - 2.4 CAP AND COVER WITH LOCK
  - 2.5 DUST INDICATOR
  - 2.6 FUSIBLE LINK
  - 2.7 FUSE
  - 2.8 ADDITIONAL LAMP CONNECTOR
  - 2.9 RADIO CONTROL
- 3.OPERATING PROCEDURES
  - 3.1 CHECK BEFORE STARTING
  - 3.2 STARTING THE ENGINE
  - 3.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE
  - 3.4 MOVING MACHINE OFF
  - 3.5 STEERING (CHANGING THE COURSE)
  - 3.6 STOPPING THE VEHICLE
  - 3.7 STARTING CRUSHER OPERATIONS
  - 3.8 OPERATIONS STARTING PROCEDURES OF (NEW) CRUSHER
  - 3.9 BASIC HANDLING OF GRIZZLY FEEDER (EFFECTIVE MUCK REMOVING METHOD)
  - 3.10 WATER SPRINKLER
  - 3.11 FINISHING OPERATIONS
  - 3.12 AFTER COMPLETING OPERATIONS
  - 3.13 STOPPING THE ENGINE
  - 3.14 CHECKS AFTER STOPPING ENGINE
  - 3.15 REVERSE ROTATION FUNCTION OF CRUSHER
  - 3.16 AUTOMATIC STOPPING OF BELT CONVEYOR
  - 3.17 PROHIBITED OPERATIONS
  - 3.18 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS
- 4. TRANSPORTATION
  - 4.1 PACKING STYLE FOR TRANSPORTATION
  - 4.2 LOADING,UNLOADING WORK
  - 4.3 PRECAUTIONS FOR LOADING
  - 4.4 PRECAUTIONS FOR TRANSPORTATION
- 5. LONG-TERM STORAGE
  - 5.1 BEFORE STORAGE
  - 5.2 DURING STORAGE
  - 5.3 AFTER STORAGE
- 6. TROUBLESHOOTING
  - 6.1 PHENOMENA THAT ARE NOT FAILURES
  - 6.2 METHOD OF TOWING MACHINE
- 7. WHEN THE BATTERY HAS DISCHARGED
  - 7.1 BATTERY REMOVAL AND INSTALLATION
  - 7.2 BATTERY CHARGES
  - 7.3 STARTING ENGINE WITH BOOSTER CABLES
MAINTENANCE
- 1. GENERAL INSTRUCTIONS ON MAINTENANCE OPERATIONS
- 2. AIR BLEEDING FROM CIRCUIT
  - 2.1 AIR BLEEDING IN THE MAIN PUMP
  - 2.2 STARTING THE ENGINE
  - 2.3 AIR BLEEDING IN THE CRUSHER MOTOR
  - 2.4 BLEEDING AIR FROM GRIZZLY FEEDER MOTOR
  - 2.5 AIR BLEEDING IN THE BELT CONVEYOR MOTOR
  - 2.6 AIR BLEEDING IN THE TRAVEL MOTOR (PERFORM THIS ONLY WHEN THE OIL IN THE TRAVEL MOTOR CASE IS DRAINED.)
  - 2.7 AIR BLEEDING IN THE CYLINDER
  - 2.8 STARTING OPERATIONS
- 3. OIL FILLER AND OIL LEVEL GAUGE
- 4. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
  - 4.1 INTRODUCTION OF NECESSARY TOOLS
  - 4.2 TORQUE LIST
- 5. MAINTENANCE TABLE
- 6. PERIODIC MAINTENANCE
  - 6.1 CHECK BEFORE STARTING
  - 6.2 EVERY 100 HOURS SERVICE
  - 6.3 EVERY 250 HOURS SERVICE
  - 6.4 EVERY 500 HOURS SERVICE
  - 6.5 EVERY 1000 HOURS SERVICE
  - 6.6 EVERY 2000 HOURS SERVICE
  - 6.7 EVERY 4000 HOURS SERVICE
  - 6.8 EVERY 5000 HOURS SERVICE
- 7. WHEN REQUIRED
  - 7.1 CHECK,CLEANING AND REPLACEMENT OF AIR CLEANER
  - 7.2 CLEANING OF THE INSIDE OF THE COOLING SYSTEM
  - 7.3 CHECK AND ADJUSTMENT FOR LOOSENESS OF TRACK SHOE BOLT
  - 7.4 TENSION CHECK AND ADJUSTMENT FOR THE TRACK SHOE
  - 7.5 CHECK,ADJUST,REPLACE CRUSHER
  - 7.6 CHECK,ADJUST BELT CONVEYOR
- 8. WEAR PARTS
  - 8.1 WEAR PARTS RELATED TO THE BODY
  - 8.2 WEAR PARTS RELATED TO THE CRUSHER
  - 8.3 WEAR PARTS RELATED TO THE BELT CONVEYOR
- 9. USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
- 10. PERIODIC REPLACEMENT OF IMPORTANT PARTS
- 11. TROUBLESHOOTING
  - 11.1 CRUSHER
  - 11.2 ELECTRICAL EQUIPMENT
  - 11.3 BODY
  - 11.4 ENGINE
  - 11.5 BELT CONVEYOR
SPECIFICATIONS AND CIRCUIT DIAGRAMS
- 1. EXTERNAL VIEWS
- 2. SPECIFICATIONS
OPTIONS,ATTACHMENTS
- 1. GENERAL PRECAUTIONS
  - 1.1 PRECAUTIONS RELATED TO SAFETY
- 2. HYDRAULIC MAGNETIC SEPARATOR
  - 2.1 SPECIFICATION (KMG900L)
  - 2.2 GENERAL VIEW (KMG900L)
  - 2.3 PRECAUTIONS ON SAFETY
  - 2.4 CONNECTING METHOD TO MACHINE BODY
  - 2.5 PRECAUTIONS FOR USE
  - 2.6 INSPECTION AND ADJUSTMENT
  - 2.7 TROUBLES AND CORRECTIVE ACTIONS
  - 2.8 MAINTENANCE SCHEDULE CHART
- 3. DEBRIS DISCHARGE CONVEYOR
  - 3.1 SPECIFICATION
  - 3.2 ASSEMBLY PROCEDURE
- 4. HYDRAULIC MAGNETIC SEPARATOR HYDRAULIC HOSE CONNECTING METHOD
- 5. MUCKING CONVEYOR HYDRAULIC HOSE CONNECTING METHOD