BR500JG-1A BR500JG-1A MOBILE CRUSHER BR500JG-1A WITH VIBRATORY GRIZZLY FEEDER
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1 BR500JG-1A WITH VIBRATORY GRIZZLY FEEDER FLYWHEEL HORSEPOWER 228 kw rpm OPERATING WEIGHT kg 126,000 lb BR500JG-1A BR500JG-1A MOBILE CRUSHER
2 BR500JG-1A Mobile Crusher WALK-AROUND With unsurpassed crushing power and a processing capacity of 85 to 460 U.S. ton/h, the BR500JG-1A is the optimum choice for your work site. Vibratory Grizzly Feeder. By vibrating the materials at an accelerated speed, the material is separated and fed evenly into the jaw. Komatsu s SA6D125E-2 engine provides 228 kw rpm for maximum crushing power while keeping emissions, noise, and vibration to a minimum. HydrauMind hydraulics and all-hydraulic drive. Fully hydraulic drive system gets you working right away. HydrauMind system provides the optimal amount of oil through load-sensing and pressure-compensated valves. Optional equipment can be connected through hydraulic outlets in the chassis. 2 Outstanding mobility. Hydraulic steering and high travel speed make the crusher easy to relocate. The BR500JG-1A uses the same track undercarriage as the PC400 Hydraulic Excavator.
3 BR500JG-1A MOBILE CRUSHER Fixed hopper for easy loading and transport. The overall height of the hopper (which can be loaded from three sides) is just 3790 mm 12'5". FLYWHEEL HORSEPOWER 228 kw rpm OPERATING WEIGHT kg 126,000 lb PROCESSING CAPACITY U.S. ton/h Rotating lamp flashes to indicate travel mode, shutdown, and high pressure malfunction. High-speed large-capacity conveyor belt. A 900 mm 2'11" wide, 12 mm 0.5" thick belt moves at 95 m 312' per minute. Discharge height is 2800 mm 9'2". The K-Series Jaw offers high performance with a simple design that facilitates maintenance. Designed by Komatsu, an adjustment of the jaw discharge setting requires less time than the competition. Hydraulic conveyor lifter at the high position ensures adequate ground clearance when driving. The lower position allows for more rebar space. Sprinkler nozzle and a connector are standard for a sprinkler pump. Emergency shut-off buttons are provided on the left and right sides of the chassis, the control panel, and radio remote control. 3
4 PRODUCTIVITY FEATURES Increased Productivity Vibratory Grizzly Feeder By vibrating the materials to be crushed on a two-stage grizzly bar, the Vibratory Grizzly Feeder removes muck before it can enter the crusher. This improves crushing efficiency and extends the service life of the crusher jaw plates. Feeder operating speed is controlled by a flow control valve so the volume going into the crusher can be regulated according to the type, size, and hardness of the material. The Grizzly Bar is a removable cassette-type, so replacement and build-up welding can be accomplished quickly. Superb Maneuverability Superior performance, in the form of 25 degree climbing power and a maximum traveling speed of 3 km/h 1.9 mph, is achieved through the powerful 228 kw 310 HP Komatsu SA6D125E-2 engine. The primary belt conveyor, which is raised/lowered by hydraulic cylinder, allows for a ground clearance of 370 mm 1'3" during traveling. Superior operating power is maintained on uneven ground. A Crusher with Superior Starting Torque The BR500JG-1A is equipped with a hydraulic drive system that stands up to rain, dust, and vibration, providing reliability, durability, and easy maintenance. Two powerful hydraulic motors mounted on the left and right sides of the crusher frame (an industry first) provide balance for high-efficiency crushing and exceptional durability. In the event of an emergency, the powerful drive torque allows for easy restart with rock still inside the crusher. A manual reverse button is also provided in the event that it should be necessary to eliminate bridging or remove foreign objects. Easy Operation Anyone can easily start and stop the crusher, reverse its direction, turn the grizzly feeder on and off, turn the belt conveyor on and off, and in an emergency, stop all functions with the push of a button. Dial operation allows the feed speed of the grizzly feeder to be changed to realize the optimal speed for the material being fed in. Malfunction Warning System (Caution Light) The caution light goes on in the following cases to warn of a malfunction: Overheating Belt conveyor malfunction the crusher and feeder stop at the same time The belt conveyor is not lifted when the machine starts to move 4
5 EASY MAINTENANCE Operation Emergency stop units are provided in a total of four places: on the left and right sides of the machine, on the control panel, and on the radio control panel, offering quick and easy access. A rotating lamp flashes when there is a malfunction on the monitor display (for example, when overheating occurs) and the operator is also alerted by a buzzer in the event of an abnormal shutdown of the conveyor belt or optional equipment. Handrails and guards are provided for all sections. A Crusher with Superior Ease of Maintenance Jaw discharge setting can be adjusted easily even by one person using Komatsu s proprietary easyadjust mechanism. Adjustment time has been significantly reduced. Since settings can be modified easily, depending upon site conditions or the intended use of the crushed material, operation Designed by Komatsu, the K-Series Jaw is portable efficiency is greatly enhanced. and practical. An adjustment of the jaw discharge setting requires less time than the competition. Two hydraulic motors are mounted on the main body of the crusher, allowing V-belt tension to be adjusted easily (the need for belt tension adjustment during disassembly and transport is avoided). The cheek plate is divided in two to facilitate replacement and to lower costs. BR500JG-1A MOBILE CRUSHER Easy Maintenance Each part is lubricated by a central lubrication system. A double air element and a precleaner are standard equipment. Employment of a flat floor allows engine room inspection and grizzly bar cleaning to be easily accomplished. The grizzly bar is a cassettetype, and can be easily removed, which makes its replacement and weld padding easy. A toolbox provided with a grease gun is standard equipment. Low Noise, Low Vibration, and Safe Design Employment of a low-noise engine, sound suppression materials, and a low-speed high-torque hydraulic motor provides low-noise and vibration levels of less than 65 db (VL). A sprinkler is also provided to protect against dust. Ground vibration Noise [at 7 m 22'11"] [7 m 22'11" in both directions] (Average energy value (Average energy value Operating conditions from 4 directions) from 2 directions) Crusher off (Ground vibration occurs during traveling) *Depends on the hardness of materials 76.5 db(a) less than 65.0 db(vl) Crusher on No load 77.5 db(a) less than 65.0 db(vl) Loaded 82.5~88.0 db(a)* less than 65.0 db(vl) 5
6 SPECIFICATIONS ENGINE Model Komatsu SA6D125E-2 Type cycle, water-cooled, direct injection Aspiration Turbocharged Number of cylinders Bore mm 4.92" Stroke mm 5.91" Piston displacement ltr 674 in 3 Flywheel horsepower kw rpm (SAE J1349) Governor All-speed, mechanical OPERATING WEIGHT (APPROXIMATE) Operating weight, including 500 mm shoes kg 126,000 lb CRUSHER Jaw K Series, hydraulic drive Inlet size mm x 762 mm 42" x 30" Outlet size (open side) mm to 198 mm 2.7" to 7.8" Crushing capacity U.S. ton/h Rotating speed (variable) rpm HYDRAULIC SYSTEM Type Variable capacity with pistons (inclined plate type) Main pump: Type Variable-capacity pistons Pumps for Travel, crusher, feeder, conveyor, and options Maximum flow x 321 ltr/min 2 x 85 U.S. gpm Maximum pressure kg/cm 2 Maximum travel speed km/h 1.9 mph Hydraulic system (travel, crusher, feeder, conveyor, and option): Travel ltr/min 82 U.S. gpm Crusher ltr/min 82 U.S. gpm Feeder ltr/min 31 U.S. gpm Main conveyor ltr/min 24 U.S. gpm Muck conveyor ltr/min 8 U.S. gpm Magnetic separator ltr/min 6 U.S. gpm Option (adjustable) ltr/min 13 U.S. gpm TRANSPORTATION The crusher can be disassembled in half a day, and then completely reassembled in half a day after it has been transported to the job site. For transportation For hopper, crusher, handrail, steps transportation Main body unit (self-propelled) GRIZZLY FEEDER Frequency Maximum 1100 rpm Size mm x 4200 mm 43" x 13'9" Amplitude (not loaded, all amplitude) mm 0.4" Drive type Hydraulic gear motor UNDERCARRIAGE Seal of track Sealed track Track adjuster Hydraulic Number of shoes each side Number of carrier rollers sets/one side Number of track rollers sets/one side COOLANT AND LUBRICANT CAPACITY Fuel tank ltr 160 U.S. gal Radiator ltr 11.6 U.S. gal Engine ltr 10 U.S. gal Final drive, each side ltr 3.2 U.S. gal Hydraulic system ltr 98 U.S. gal The main body unit can be transported on a 30-ton trailer mm 11'7" 6
7 BR500JG-1A MOBILE CRUSHER DIMENSIONS O Q K P B C D F G E G.L. L M N I A J H A Overall length mm 50'6" B Overall height 4875 mm 16'0" C Feed height side 3790 mm 12'5" D Feed height rear 3510 mm 11'6" E Minimum ground clearance 370 mm 1'3" F Discharge height 2800 mm 9'2" G Height to top of platform 3660 mm 12'0" H Track thickness (pad) 37 mm 1" I Length of track on ground 4350 mm 14'3" J Discharge from idler center 7316 mm 24'0" K Overall width 4030 mm 13'3" L Track gauge 2600 mm 8'6" M Track width 3200 mm 10'6" N Shoe width 600 mm 2'0" O Hopper width 2925 mm 9'7" P Hopper length 4870 mm 16'0" Q Discharge conveyor belt width 900 mm 2'11" MATERIAL FLOW Vibratory grizzly feeder Materials Magnetic Separator (option) Feed-in hopper Discharge belt conveyor Stationary jaw Swing jaw 7
8 ENGINE: STANDARD EQUIPMENT Engine, Komatsu SA6D125E-2 4-cycle, water-cooled, direct fuel injection, aspiration turbocharged Gross horsepower 228 kw rpm Fuel system: Fuel, light oil, ASTM specification Governor, centrifugal method, all-speed method Cooling fan, suction type Air cleaner, centrifugal method with paper filter ELECTRICAL SYSTEM: Starting motor, 11 kw 24 V Alternator, 33 ampere 24 V Battery, 150 Ah 2 x 12 V UNDERCARRIAGE: Number of rollers: Upper carrier, two sets/one side Lower track, six sets/one side SHOES: Assembled triple-grouser type, 600 mm 24" Tension adjustment, grease cylinder method (cushion springs attached) CRUSHER: Type, FS4230SA single toggle crusher Size, 1050 mm x 750 mm 42" x 30" Rotation, 250 rpm Drive method, hydraulic motor with V-belt FEEDER: Type, step deck speed controlled grizzly feeder Dimension (W x L), 1100 mm x 4200 mm 43" x 13'9" Grizzly bar opening, 45 mm 70 mm 1.77" 2.76" Drive method, hydraulic gear motor BELT CONVEYOR: Width x length, 900 mm x mm 35" x 35'5" Speed, 108 m/min 384 ft/min Drive method, hydraulic trochoid pump OPTIONAL EQUIPMENT MAGNETIC SEPARATOR: Magnetic separator for primary conveyor, 900 mm 35" wide MUCK CONVEYOR: Muck conveyor assembly, fixed type, 4500 mm x 600 mm 14'9" x 24" AESS Komatsu Printed in USA SN5(10M)C DataKom 5/00 (EV-3) Komatsu America International Company 440 N. Fairway Dr., Vernon Hills, IL Materials and specifications are subject to change without notice is a trademark of Komatsu Ltd. Japan
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