Komatsu Br580jg 1 Field Assembly Instruction

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 Preface

You are required to execute full inspection and maintenance before starting the engine and
assembling the work equipment. Since the work is often carried out in dangerous places and
positions by a team, hold a safety meeting in advance and appoint a crane director, work leader,
etc. so that the all members can work safely.

When the work is carried out in an overseas country, difference in language, customs, etc.
lowers safety. Accordingly, the field liaison man and work supervisor must examine the above
point and take necessary measures.

Instruction system
Work leader
Director
Work supervisor Crane director and
deputy director

Operator for assembly

Liaison man

Mechanics Sharing of work

Interpreter

We hope that the all members will cooperate with each other and assemble the work equipment
quickly in the field, observing the safety, quality, and delivery time.
 CONTENTS
SPECIFICATIONS............................................................................................................. 1
PRECAUTIONS FOR FIELD ASSEMBLY......................................................................... 2
OUTLINE OF WORK PROCESS ...................................................................................... 3
FLOW OF ASSEMBLY PROCEDURE .............................................................................. 4
KIT LAYOUT DRAWING ................................................................................................... 5
PACKING POSTURE FOR TRANSPORTATION ............................................................. 6
LIST OF TOOLS FOR FIELD ASSEMBLING.................................................................... 14
TIGHTENING TORQUE .................................................................................................... 15
COATING MATERIALS LIST ............................................................................................ 19
LIST OF SEPARATELY SHIPPED PARTS....................................................................... 21

A. ASSEMBLY PROCEDURE ........................................................................................... 29

A- 1. Preparation for installation of crusher assembly................................................... 30
A- 2. Installation of crusher assembly ........................................................................... 35
A- 3. Installation of steps ............................................................................................... 37
A- 4. Installation of handrails ......................................................................................... 38
A- 5. Installation of floor................................................................................................. 40
A- 6. Installation of crusher motor hoses....................................................................... 41
A- 7. Installation of lock cylinder hoses ......................................................................... 42
A- 8. Installation of crusher wiring ................................................................................. 44
A- 9. Installation of crusher covers ................................................................................ 45
A-10. Installation of guard assembly .............................................................................. 49
A-11. Installation of dust plate assembly........................................................................ 50
A-12. Installation of second chutes ................................................................................ 51
A-13. Installation of feeder motor ................................................................................... 54
A-14. Posture of open/close hopper............................................................................... 56
A-15. Installation of hopper (R.H.).................................................................................. 67
A-16. Installation of hopper (L.H.) .................................................................................. 71
A-17. Installation of hopper (REAR)............................................................................... 75
A-18. Installation of hopper pins..................................................................................... 80
A-19. Tightening of hopper mounting bolts .................................................................... 82
A-20. Greasing of hopper............................................................................................... 84
A-21. Installation of fixed hopper (if equipped)............................................................... 85
A-22. Installation of conveyor......................................................................................... 86
A-23. Installation of conveyor piping .............................................................................. 93
A-24. Posture of conveyor.............................................................................................. 94
A-25. Adjustment of conveyor tension ........................................................................... 100
A-26. Adjustment of conveyor snaking........................................................................... 101
A-27. Adjustment of conveyor scraper ........................................................................... 102
A-28. Adjustment of installation of return roller guard .................................................... 104
A-29. Adjustment of muck discharge conveyor scraper (if equipped)............................ 105
A-30. Installation of magnetic separator assembly ........................................................ 106
A-31. Installation of rear cover floor ............................................................................... 108
A-32. Installation of tail pipe ........................................................................................... 109
A-33. Installation of rotary lamp and working lamp assembly ........................................ 110
A-34. Installation of rotary lamp and working lamp wiring.............................................. 111
A-35. Adjustment of mirrors ........................................................................................... 112
A-36. Installation of reservoir tank cover........................................................................ 113
A-37. Installation of fuel tank cover ................................................................................ 114
M. CHECK AND MAINTENANCE PROCEDURES
AFTER COMPLETION OF ASSEMBLY ...................................................................... 115
M-1. Check fuel, coolant and lubricants......................................................................... 116
M-2. Air bleeding from hydraulic circuits........................................................................ 119
M-3. Replacement of return filter (Standard filter to flushing filter) ................................ 122
M-4. Flushing of hydraulic circuit ................................................................................... 125

FIELD ASSEMBLY INSPECTION REPORT

SPECIFICATIONS
Item Unit BR580JG-1
Weight
Operating weight (incl. fuel and coolant) kg 49,000
Dimensions
A Overall length [with open-close hopper] (for transport) mm 14,540 (A1 12,130/A2 A3 14,495)
B Overall height (for transport) mm 3,820 (A1 3,195/A2 3,395/A3 3,495)
C Overall width (for transport) mm 3,090 (2,995)
D Track shoe width mm 500
E Track gauge mm 2,480
F Length of track on ground mm 3,700
Engine
Type – KOMATSU SAA6D125E-5 Diesel engine
Flywheel horsepower kW{HP}/rpm 257/1,900 {350/1,900}

A1
A2
A3

1
PRECAUTIONS FOR FIELD ASSEMBLY
1. Selection of workplace
1) When selecting a workplace, consider the following items so that you can load and unload the machine.
• Width
• Hardness
• Flatness
• Access road, place for turn
2) Do not work in a place where dust, rainwater, etc. may enter the hydraulic circuit during assembling work.
3) Do not assemble while a strong wind is blowing or it is raining.

2. Preparation and check of slings and tools

1) Check each sling and tool thoroughly. When using wood blocks, etc., check that their inside is not rotten
or broken.

3. kCheck of actual work

1) Apply the parking brakes of the trailer and crane truck securely and put chocks under their wheels.
2) Before starting the work lower the temperature and pressure of the engine oil, hydraulic oil, cooling water,
etc.
3) When starting the engine, make an arranged sign such as sounding of the horn and check that the work
equipment control lever and travel lever are in neutral and the fuel control dial is at the low idling position.
4) When using the crane, balance the load.
5) Allow only the persons concerned into the workplace.

4. Before starting the work, read this manual thoroughly and keep the precautions in your mind.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text.
(For example: o (1))

5. The supervisor shall write down the precautions for each work process and explain them to the
workers.

6. Hold a meeting every morning to check today's work plan and safe work.

2
 Days

• Oil level and water level

checks
Assembly unit • Air bleeding from the
Machine body hydraulic circuits
(1) Crusher ass'y (4) Hopper ass'y (5) Conveyor
• Performance checks
(2) Guard ass'y (6) Exterior parts
(Disassembly to 27ton parts)

(3) Feeder
OUTLINE OF WORK PROCESS

Crane

45 t 25 t

3
Air compressor
Min. 15 m3/min

Stepladder
(Mobile elevating
work platform)

Workers

Group chief + 2 mechanics

Starting the assembly work Installation of unit of the

Assembly of
• Holding a meeting with machine body assemblies Final assembly work
the machine body
all the workers to the machine body
 Day 1 2
Detailed procedure A-1 A-1 A-2 A-3 – 5 A-9 A-10 A-13 A-14 – 18 A-22, 23 A-25 – 31
Machine
(Disassembly to 27ton parts)

Crusher

Crusher guard
FLOW OF ASSEMBLY PROCEDURE

Feeder

4
Unloading

Hopper

Conveyor

Setting and adjusting

Exterior parts
around crusher
Removal

Other exterior parts

Parts for getting on and off

Komatsu Br580jg 1 Field Assembly Instruction
Full download: http://manualplace.com/download/komatsu-br580jg-1-field-assembly-instruction/
KIT LAYOUT DRAWING
• The minimum necessary dimensions of each area and rough dimensions of each kit are shown in below.
• When selecting the working place, refer to “1. Selection of workplace” in Precautions for field assembly.
• The dimensions in the drawings are reference dimensions for installation in the following space (35 m × 25 m).
• If a wider work field is available, the shown dimensions should be increased.

Stepladder
Guard (Mobile elevating
work platform)
Hopper

Crusher

45t Crane Machine

Front

Skirt
Covers
Dust rubber Magnetic
separator
Front CW Motor (if equipped)

Number of
supervisors: 1
Tools and equipment Number of
workers: 2

5
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