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Komatsu BR580JG-1 Mobile Crusher Service Manual

1,068 pages · Publication SEN02602-06

$109.51
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Models
BR580JG-1
Serial coverage
1001 and up
Manual type
Service Manual
Pages
1,068
Publication
SEN02602-06
Condition
Brand new
Komatsu BR580JG-1 Mobile Crusher Service Manual, publication SEN02602-06

What's inside

From the manual's own table of contents: 187 sections, 387 entries. See sample pages (PDF, 875 KB)

Composition of shop manual
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table
Specification dimension drawings
Specifications
Weight table
Table of fuel, coolant and lubricants
Engine mount, damper
Radiator, oil cooler and aftercooler
Power train
Drive system for components
Final drive
Sprocket
Track frame and recoil spring
Idler
Guide plate
Show all 187 sections
Track roller
Track shoe
Hydraulic piping drawing
Hydraulic tank and hydraulic oil filter
Hydraulic pump
Control valve
Self pressure reducing valve
CLSS
Functions and operation by valve48 topics
  • Crusher motor
  • Grizzly feeder motor
  • Conveyor motor
  • Travel motor
  • Valve control
  • Solenoid valve
  • 8-spool EPC valve
  • Solenoid valve for travel
  • PPC shuttle valve (if equipped)
  • Electromagnetic selector valve
  • Hydraulic cylinder
  • Grizzly feeder semiautomatic system
  • Abnormal load stop system
  • Primary belt conveyor
  • Grizzly feeder
  • Crusher
  • Crusher tooth tip adjustment system
  • Vibrator
  • Engine control
  • Work equipment and pump controller
  • Electronic control system
  • Machine monitor system
  • Sensor
  • KOMTRAX system
  • Standard value table for engine
  • Standard value table for chassis
  • Tools for testing, adjusting and troubleshooting
  • Measuring engine speed
  • Measuring intake air pressure (boost pressure)
  • Measuring exhaust temperature
  • Checking exhaust gas color
  • Adjusting valve clearance
  • Measuring compression pressure
  • Measuring blow-by pressure
  • Measuring engine oil pressure
  • Testing EGR valve and bypass valve drive oil pressure
  • Handling fuel system parts
  • Releasing residual pressure from fuel system
  • Measuring fuel pressure
  • Handling during cylinder cut-out operation
  • Handling during no injection cranking operation
  • Measuring fuel return rate and leakage
  • Bleeding air from fuel circuit
  • Checking fuel circuit for leakage
  • Checking and adjusting fan belt and alternator belt
  • Checking and adjusting track shoe tension
  • Measuring and adjusting oil pressure in work equipment and travel circuits
  • Measuring control circuit basic pressure
Measuring and adjusting oil pressure in pump PC control circuit
Measuring and adjusting oil pressure in pump LS control circuit
Measuring solenoid valve output pressure
Measuring PPC valve output pressure
Measuring oil leakage
Bleeding air from each part
Testing travel deviation
Adjusting mirrors
Special functions of machine monitor
Check and adjustment of jaw crusher
Check and adjustment of outlet clearance
Testing and adjusting tension of crusher drive V-belt
Check and adjustment of primary conveyor
Inspection and maintenance of magnetic separator
Check and adjustment of muck discharge conveyor
List of companies which handles radio controllers
Handling voltage circuit of engine controller
Procedure for turning on KOMTRAX terminal
KOMTRAX terminal lamp indications
Preparation work for troubleshooting for electrical system
Procedure for testing diodes
Failure code table
Fuse locations
Points to remember when troubleshooting
Sequence of events in troubleshooting
Checks before troubleshooting
Classification and procedures of troubleshooting
Contents of troubleshooting table
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Failure code [7RC1KB] Short circuit conveyor ON switch
Failure code [7RC2KA] Disconnection in conveyor OFF switch
Failure code [7RC5KB] Short circuit in feeder ON switch
Failure code [7RD2KB] Short circuit in discharge conveyor reverse solenoid
Failure code [7RD2KZ] Disconnection or short circuit in discharge conveyor reverse solenoid
Failure code [7RE1KB] Short circuit in crusher ON switch
Failure code [7RE2KA] Disconnection in crusher OFF switch
Failure code [7RE6KB] Short circuit in muck discharge conveyor ON switch
Failure code [7RE7KA] Disconnection in muck discharge conveyor OFF switch
Failure code [7RE8KB] Short circuit in magnetic separator ON switch
Failure code [7RE9KA] Disconnection in magnetic separator OFF switch
Failure code [7REAKB] Short circuit in accessory input circuit 1
Failure code [7REDMA] Abnormality in conveyor pressure sensor
Failure code [7REEMA] Abnormality in muck conveyor pressure sensor
Failure code [7REHKB] Short circuit in accessory input circuit 2
Failure code [7RENKZ] Abnormality in clearance potentiometer
Failure code [7REPKA] Disconnection in feeder OFF switch
Failure code [7RESKB] Short circuit in one-touch start switch
Failure code [7RETKA] Disconnection in one-touch stop switch
Failure code [7RF2KA] Disconnection in crusher forward EPC valve56 topics
  • Failure code [7RF2KB] Short circuit in crusher forward EPC valve
  • Failure code [7RF2KY] Short circuit in crusher forward EPC valve
  • Failure code [7RF3KA] Disconnection in crusher reverse EPC valve
  • Failure code [7RF3KB] Short circuit in crusher reverse EPC valve
  • Failure code [7RF3KY] Short circuit in crusher reverse EPC valve
  • Failure code [7RF4KA] Disconnection in feeder forward EPC valve
  • Failure code [7RF4KB] Short circuit in feeder forward EPC valve
  • Failure code [7RF4KY] Short circuit in feeder forward EPC valve
  • Failure code [7RF8KA] Disconnection in accessory 2 EPC valve
  • Failure code [7RF8KB] Short circuit in accessory 2 EPC valve
  • Failure code [7RF8KY] Short circuit in accessory 2 EPC solenoid
  • Failure code [7RFAKY] Short circuit in engine stop relay
  • Failure code [7RFAKZ] Disconnection or short circuit in engine stop relay
  • Failure code [7RFBKB] Short circuit in muck conveyor solenoid
  • Failure code [7RFBKZ] Disconnection or short circuit in muck conveyor solenoid
  • Failure code [7RFHKA] Disconnection in conveyor forward EPC valve
  • Failure code [7RFHKB] Short circuit in conveyor forward EPC valve
  • Failure code [7RFHKY] Short circuit in conveyor forward EPC valve
  • Failure code [7RFKKB] Short circuit in lock cylinder pull relay
  • Failure code [7RFKKY] Short circuit in lock cylinder pull relay
  • Failure code [7RFLKA] Disconnection in accessory 1 EPC solenoid
  • Failure code [7RFLKB] Short circuit in accessory 1 EPC solenoid
  • Failure code [7RFLKY] Short circuit in accessory 1 EPC solenoid
  • Failure code [7RFMKY] Short circuit in abnormal pressure relay
  • Failure code [7RFMKZ] Disconnection or short circuit in abnormal pressure relay
  • Failure code [7RFNKA] Disconnection in lock cylinder unlock solenoid valve
  • Failure code [7RFNKB] Short circuit in lock cylinder unlock solenoid valve
  • Failure code [7RFNKY] Short circuit in lock cylinder unlock solenoid valve
  • Failure code [7RFPKB] Short circuit in lock cylinder push relay
  • Failure code [7RFPKY] Short circuit in lock cylinder push relay
  • Failure code [7RGAMA] Abnormality in 2nd conveyor pressure sensor
  • Failure code [7RJAKA] Disconnection in travel lock EPC solenoid valve
  • Failure code [7RJAKB] Short circuit in travel lock EPC solenoid valve
  • Failure code [7RJAKY] Short circuit in travel lock EPC solenoid valve
  • Failure code [7RJDMA] Abnormality in crusher forward pressure sensor
  • Failure code [7RJEMA] Abnormality in crusher reverse pressure sensor
  • Failure code [7RJLKA] Disconnection in magnetic separator EPC valve
  • Failure code [7RJLKB] Short circuit in magnetic separator EPC valve
  • Failure code [7RJLKY] Short circuit in magnetic separator EPC valve
  • Failure code [7RJMMW] Lock cylinder slipping
  • Failure code [7RJPKB] Short circuit in radio control work-mode switch
  • Failure code [7RJQKB] Short circuit in radio control travel-mode switch
  • Failure code [7RJRKB] Short circuit on travel signal
  • Failure code [7RJSMA] Abnormality in magnetic separator pressure sensor
  • Failure code [AA10NX] Air cleaner Clogging
  • Failure code [AB00KE] Charge voltage too low
  • Failure code [B@BAZG] Engine oil pressure too low
  • Failure code [B@BAZK] Engine oil level reduction
  • Failure code [B@BCNS] Engine coolant overheat
  • Failure code [B@BCZK] Radiator coolant level reduction
  • Failure code [B@HANS] Hydraulic Oil Overheat
  • Failure code [CA111] ECM Critical Internal Failure
  • Failure code [CA115] Eng Ne and Bkup Speed Sens Error
  • Failure code [CA122] Chg Air Press Sensor High Error
  • Failure code [CA123] Chg Air Press Sensor Low Error
  • Failure code [CA131] Throttle Sensor High Error
Failure code [CA132] Throttle Sensor Low Error
Failure code [CA135] Eng Oil Press Sensor High Error
Failure code [CA141] Eng Oil Press Sensor Low Error
Failure code [CA144] Coolant Temp Sens High Error
Failure code [CA145] Coolant Temp Sens Low Error
Failure code [CA153] Chg Air Temp Sensor High Error
Failure code [CA154] Chg Air Temp Sensor Low Error
Failure code [CA187] Sens Supply 2 Volt Low Error
Failure code [CA221] Ambient Press Sens High Error
Failure code [CA222] Ambient Press Sens Low Error
Failure code [CA227] Sens Supply 2 Volt High Error
Failure code [CA234] Eng Overspeed
Failure code [CA238] Ne Speed Sens Supply Volt Error
Failure code [CA263] Fuel Temp Sensor High Error
Failure code [CA265] Fuel Temp Sensor Low Error
Failure code [CA273] PCV2 Short Error
Failure code [CA274] PCV2 Open Error
Failure code [CA322] Inj #1 (L#1) Open/Short Error
Failure code [CA323] Inj #5 (L#5) Open/Short Error
Failure code [CA324] Inj #3 (L#3) Open/Short Error
Failure code [CA325] Inj #6 (L#6) Open/Short Error
Failure code [CA331] Inj #2 (L#2) Open/Short Error
Failure code [CA332] Inj #4 (L#4) Open/Short Error
Failure code [CA342] Calibration Code Incompatibility
Failure code [CA351] INJ. Drive Circuit Error
Failure code [CA352] Sens Supply 1 Volt Low Error
Failure code [CA386] Sens Supply 1 Volt High Error
Failure code [CA441] Battery Voltage Low Error
Failure code [CA442] Battery Voltage High Error
Failure code [CA449] Rail Press Very High Error
Failure code [CA451] Rail Press Sensor High Error
Failure code [CA452] Rail Press Sensor Low Error
Failure code [CA553] Rail Press High Error
Failure code [CA554] Rail Press Sensor In Range Error
Failure code [CA559] Rail Press Low Error
Failure code [CA689] Eng Ne Speed Sensor Error
Failure code [CA731] Eng Bkup Speed Sens Phase Error
Failure code [CA757] All Persistent Data Lost Error
Failure code [CA778] Eng Bkup Speed Sensor Error
Failure code [CA1228] EGR Valve Servo Error 1
Failure code [CA1625] EGR Valve Servo Error 2
Failure code [CA1633] CAN Communication Error (engine controller)
Failure code [CA2185] Throt Sens Sup Volt High Error
Failure code [CA2186] Throt Sens Sup Volt Low Error
Failure code [CA2249] Rail Press Very Low Error
Failure code [CA2271] EGR Valve Lift Position Sens High Error
Failure code [CA2272] EGR Valve Lift Position Sens Low Error
Failure code [CA2351] EGR Valve Sol Current High Error
Failure code [CA2352] EGR Valve Sol Current Low Error
Failure code [CA2555] Grid Heater Relay Open Error
Failure code [CA2556] Grid Heater Relay Short Error
Failure code [D162KY] Short circuit in horn relay
Failure code [D162KZ] Disconnection or short circuit in horn relay
Failure code [DA22KK] Solenoid power source too low
Failure code [DA25KP] Abnormality in pressure sensor power source
Failure code [DA2RMC] CAN communication error (work equipment and pump controller)52 topics
  • Failure code [DA2SKQ] Abnormality in model code input
  • Failure code [DAFRMC] CAN communication error (monitor controller)
  • Failure code [DDA6KA] Disconnection in engine stop switch
  • Failure code [DGH2KB] Short circuit in hydraulic oil temperature sensor
  • Failure code [DHPAMA] Abnormality in F pump pressure sensor
  • Failure code [DHPBMA] Abnormality in R pump pressure sensor
  • Failure code [DUB0KY] Short circuit in beacon solid state relay
  • Failure code [DUB0KZ] Disconnection or short circuit in beacon solid state relay
  • Failure code [DXA0KA] Disconnection in PC-EPC Solenoid
  • Failure code [DXA0KB] Short circuit in PC-EPC Solenoid
  • Failure code [DXA0KY] Short circuit in PC-EPC Solenoid
  • Failure code [DXE0KA] Disconnection in LS-EPC solenoid
  • Failure code [DXE0KB] Short circuit in LS-EPC solenoid
  • Failure code [DXE0KY] Short circuit in LS-EPC solenoid
  • Information in troubleshooting table
  • Engine does not start (Engine does not turn)
  • The engine stops while it is running
  • Automatic warming-up does not operate
  • Preheater does not operate
  • The whole work equipment stops suddenly
  • The red mark of emergency stop is indicated just after the engine is started
  • The machine monitor does not display any item
  • Some items are not displayed on the machine monitor
  • Contents of display by machine monitor are different from applicable machine
  • Fuel level monitor was lighted in red while engine running
  • Engine coolant temperature gauge does not indicate normally
  • The fuel level gauge does not display normally
  • The hydraulic oil temperature gauge does not display normally
  • The travel, work, and inspection modes do not change
  • The crusher clearance adjustment mode does not change
  • The crusher rotation direction does not change
  • Machine does not travel
  • Travel cannot be controlled by radio control
  • The feeder cannot be turned ON and OFF by radio control
  • One-touch start, stop switch cannot be operated by radio control
  • The monitor switches do not work
  • KOMTRAX system does not operate normally
  • System chart for hydraulic and mechanical systems
  • Information contained in troubleshooting table
  • The speed or power of the whole work equipment and travel is low
  • The engine speed lowers extremely or the engine stalls
  • The work equipment and travel systems do not work
  • Abnormal sound comes out from around the hydraulic pump
  • Fine control performance or response is low
  • The conveyor does not operate
  • The speed or power of the conveyor is low
  • The crusher does not operate
  • The speed or power of crusher is low
  • The feeder does not operate
  • The feeder does not feed smoothly (Vibration frequency is low)
  • The magnetic separator does not operate
  • The speed of magnetic separator belt is low
The muck discharge conveyor does not operate
The speed or power of the muck discharge conveyor is low
The primary conveyor does not move up and down
The muck discharge conveyor does not move up and down
The open and close hopper does not move up and down
The machine deviates during travel
The travel speed is low
The machine is not steered well or steering power is low
The travel motor does not work (only one side)1 topic
  • the machine does not travel
The crusher clearance cannot be adjusted
Method of using troubleshooting chart
Starting performance is poor
Engine does not start
Engine does not pick up smoothly
Engine stops during operations
Engine does not rotate smoothly
Engine lacks output (or lacks power)
Exhaust smoke is black (incomplete combustion)
Oil consumption is excessive (or exhaust smoke is blue)
Oil becomes contaminated quickly
Fuel consumption is excessive
Oil is in coolant (or coolant spurts back or coolant level goes down)
Oil pressure drops
Oil level rises (Entry of coolant or fuel)
Coolant temperature becomes too high (overheating)
Abnormal noise is made
Vibration is excessive
How to read this manual
Coating materials list
Special tool list
Sketches of special tools
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of engine front seal
Removal and installation of engine rear seal
Removal and installation of cylinder head assembly
Removal and installation of engine and hydraulic pump assembly
Removal and installation of radiator assembly
Removal and installation of hydraulic oil cooler assembly
Removal and installation of aftercooler assembly
Removal and installation of fuel tank assembly
Removal and installation of final drive assembly
Disassembly and assembly of final drive assembly
Disassembly and assembly of track roller assembly
Disassembly and assembly of idler assembly
Disassembly and assembly of recoil spring
Removal and installation of sprocket
Repair of guide plate with wear plates43 topics
  • Spreading and installation of track shoe assembly
  • Removal and installation of hydraulic tank assembly
  • Removal and installation of hydraulic pump assembly
  • Removal and installation of control valve assembly
  • Disassembly and assembly of control valve assembly
  • Removal and installation of crusher motor assembly
  • Removal and installation of crusher lock cylinder assembly
  • Disassembly and assembly of crusher lock cylinder assembly
  • Bleeding air from crusher lock cylinder
  • Removal and installation of primary belt conveyor motor
  • Removal and installation of feeder vibrator motor assembly
  • Removal and installation of muck discharge conveyor motor assembly
  • Removal and installation of magnetic separator motor assembly
  • Removal and installation of cheek plates
  • Removal and installation of fixed tooth
  • Removal and installation of swing tooth
  • Removal and installation of toggle plate
  • Removal and installation of fixing link
  • Removal and installation of swing jaw assembly
  • Removal and installation of crusher main bearing
  • Removal and installation of crusher motor and motor housing assembly
  • Removal and installation of crusher motor V-sheave
  • Removal and installation of V-sheave and balance weight
  • Removal and installation of potentiometer
  • Removal and installation of fixing link lifting spring assembly
  • Removal and installation of link pin dust cover
  • Removal and installation of crusher assembly
  • Removal and installation of primary belt conveyor assembly
  • Removal and installation of primary belt conveyor head pulley frame
  • Removal and installation of muck discharge conveyor assembly (if equipped)
  • Removal and installation of muck discharge conveyor head pulley (if equipped)
  • Removal and installation of muck discharge conveyor tail pulley (if equipped)
  • Removal and installation of magnetic separator assembly
  • Removal and installation of engine controller assembly
  • Removal and installation of work equipment and pump controller assembly
  • Hydraulic circuit diagram (1/2)
  • Hydraulic circuit diagram (2/2)
  • Electrical circuit diagram (1/4)
  • Electrical circuit diagram (2/4)
  • Electrical circuit diagram (3/4)
  • Electrical circuit diagram (4/4)
  • Connector arrangement diagram (1/2)
  • Connector arrangement diagram (2/2)

Inside this manual

Real pages from this service manual (1,068 pages). Open the sample pages (PDF, 875 KB)

Sample pages from the Komatsu BR580JG-1 Mobile Crusher Service Manual: Specifications, Troubleshooting, Diagram, Foldout diagram
  • Specifications, page 61: 01 Specification
  • Troubleshooting, page 429: Contents of troubleshooting table
  • Diagram, page 573: Failure code [7RJLKB] Short circuit in magnetic separator EPC valve
  • Foldout diagram, page 1,061: Electrical circuit diagram (1/4)

Other manuals for this machine

Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the BR580JG-1 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.

This manual: Service Manual SEN02602-06$109.51
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Details

This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 1,068 pages

Quantity one is the manual described above.

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