Komatsu BR580JG-1 Crusher Operation and Maintenance Manual (EEAM026401)

This BR580JG-1 crusher manual is what I’d keep on hand any time the machine is working in a quarry, demolition site, or recycling yard. It helps you set up a steady maintenance rhythm so the crusher stays reliable under constant impact, dust, and vibration. When, for example, the machine starts feeding unevenly or you’re seeing more blockages than usual, this manual guides you through the basic checks and routine care steps before you start tearing into components or calling in major repairs.

Applications & Use Cases

Plan preventive maintenance so you can schedule greasing, filter changes, and inspections around production instead of during it.
Trace early wear on belts, liners, and guards by following the recommended inspection logic.
Verify operating practices for the crusher and travel systems to avoid overloading or abusing the machine.
Reduce unplanned downtime by using the manual to isolate simple faults on site before they become big failures.
Train new operators on daily walk-arounds and shutdown checks that keep the crusher in one piece.

FAQ

Q: Can I use this manual on a tablet in the field?

A: Yes, it’s well-suited to digital use; you can zoom diagrams and search terms while standing at the machine.

Q: Is it worth printing parts of it?

A: Many techs print the routine checklists and keep them in a binder on the service truck for quick reference.

Safety Note

Always follow the manual’s lockout, tagout, and guarding instructions before inspecting or servicing the crusher.

📘 Show Index

Komatsu BR580JG-1 Crusher Index:

FOREWORD
- BEFORE READING THIS MANUAL
- SAFETY INFORMATION
  - NOISE
- INTRODUCTION
  - INTRODUCTION
  - FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE
- NECESSARY INFORMATION
  - PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE
  - EPA REGULATIONS, ENGINE NUMBER PLATE
  - POSITION OF SERVICE METER
  - TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
  - MACHINE SERIAL NUMBER PLATE
  - MACHINE SERIAL NUMBER PLATE (according directive 2006/42/EC)
  - Declaration of conformity (Directive 2006/42/EC)
CONTENTS
- FOREWORD
- SAFETY
- OPERATION
- MAINTENANCE
- SPECIFICATIONS
- ATTACHMENTS, OPTIONS
- INDEX
- COLOPHON
SAFETY
- SAFETY
- SAFETY LABELS
  - POSITIONS OF SAFETY PICTOGRAMS
  - SAFETY LABELS
- GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE
  - PRECAUTIONS BEFORE STARTING OPERATION
  - PREPARATIONS FOR SAFE OPERATION
  - FIRE PREVENTION
  - PRECAUTIONS WHEN GETTING ON OR OFF MACHINE
  - DO NOT GET CAUGHT IN WORK EQUIPMENT
  - UNAUTHORIZED MODIFICATION
  - PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS
  - PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING
- PRECAUTIONS FOR OPERATION
  - PRECAUTIONS FOR JOBSITE
  - STARTING ENGINE
  - OPERATION
  - CRUSHING OPERATION
  - TRANSPORTATION
  - TOWING
  - MAGNETIC SEPARATOR
- PRECAUTIONS FOR MAINTENANCE
  - PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE
  - PRECAUTIONS FOR INSPECTION AND MAINTENANCE
OPERATION
- GENERAL VIEW
  - GENERAL VIEW OF MACHINE
  - GENERAL VIEW OF CONTROLS AND GAUGES
- EXPLANATION OF COMPONENTS
  - MACHINE MONITOR
  - SWITCHES
  - CONTROL LEVERS
  - OPTION-RELATED SWITCHES
  - OPERATION AND MAINTENANCE MANUAL STORING CASE
  - CAP, COVER WITH LOCK
  - REVOLVING WARNING LAMP
  - FUSIBLE LINK
  - CONTROLLERS
  - BATTERY DISCONNECT SWITCH (if installed)
  - FUSE
  - TOOL BOX
  - HANDLING MACHINES EQUIPPED WITH KOMTRAX
  - POSITIONS OF INSTRUCTION PICTOGRAMS
- 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
  - CHECK AND CONFIRMATION OF JAW CRUSHER AFTER WORK
  - CHECK AFTER FINISHING WORK
  - THE PROCEDURE WHICH HOUSES THE FOLDING HOPPER
  - LOCKING
  - RUN-IN OPERATION OF JAW CRUSHER
  - PRECAUTIONS WHEN OPERATING JAW CRUSHER
  - EFFICIENT USE OF JAW 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
  - STARTING MACHINE AFTER LONG-TERM STORAGE
- TROUBLESHOOTING
  - AFTER RUNNING OUT OF FUEL
  - PHENOMENA THAT ARE NOT FAILURES
  - METHOD OF TOWING MACHINE
  - IF BATTERY IS DISCHARGED
  - OTHER TROUBLE
MAINTENANCE
- GUIDE TO MAINTENANCE
- OUTLINE OF SERVICE
  - HANDLING AND PERFORMANCE OF OIL CLINIC FOR OIL, FUEL, COOLANT
  - RELATING TO ELECTRIC SYSTEM
  - OUTLINE OF HYDRAULIC EQUIPMENT
- WEAR PARTS
  - WEAR PARTS LIST
  - JAW CRUSHER RELATED PARTS
  - PRIMARY CONVEYOR RELATED PARTS
- RECOMMENDED FUEL, COOLANT AND LUBRICANTS
  - RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL
- STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
  - TORQUE LIST
  - TOOLS TO USE CHECK AND MAINTENANCE CRUSHER
- PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
  - SAFETY CRITICAL PARTS
- MAINTENANCE SCHEDULE CHART
  - MAINTENANCE SCHEDULE CHART
- SERVICE PROCEDURE
  - INITIAL 250 HOURS SERVICE (FIRST MAINTENANCE FOR NEW MACHINE ONLY)
  - INITIAL 1000 HOURS SERVICE (FIRST MAINTENANCE FOR NEW MACHINE ONLY)
  - WHEN REQUIRED
  - CHECK BEFORE STARTING
  - EVERY 10 HOURS SERVICE
  - 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
  - EVERY 8000 HOURS SERVICE
SPECIFICATIONS
- SPECIFICATIONS
ATTACHMENTS, OPTIONS
- GENERAL PRECAUTIONS
  - AUTHORIZED OPTIONAL EQUIPMENT
  - PRECAUTIONS RELATED TO SAFETY
  - PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT
- ATTACHMENTS, OPTIONS
  - ATTACHMENTS, OPTIONS CHART
- RADIO CONTROL UNIT
  - ON USE OF RADIO CONTROL UNIT
  - DIRECTIONS FOR USE
  - RADIO CONTROL OPERATION
- MAGNETIC SEPARATOR
  - CHECK AND ADJUSTMENT
  - GREASING MAGNETIC SEPARATOR
  - LIST OF CHECKPOINT
  - FAILURES AND CORRECTIVE ACTIONS
  - SPECIFICATIONS
  - WEARING PARTS
- MUCK DISCHARGE CONVEYOR
  - PROCEDURE FOR RAISING (BENDING) MUCK DISCHARGE CONVEYOR
  - PROCEDURE FOR LOWERING MUCK DISCHARGE CONVEYOR
  - GREASING MUCK DISCHARGE CONVEYOR
  - CHECK AND ADJUSTMENT OF MUCK DISCHARGE CONVEYOR
  - FAILURES AND CORRECTIVE ACTIONS
  - WEARING PARTS
  - SPECIFICATIONS
- BELT CONVEYOR PROTECTIVE PLATE
- SPRINKLER
  - EXPLANATIONS FOR COMPONENT PARTS
  - HOW TO USE SPRINKLER
  - INSPECTION AND MAINTENANCE
  - FAILURES AND CORRECTIVE ACTIONS
  - ADDITIONAL SPRINKLER NOZZLE
INDEX
INDEX
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COLOPHON