Manual Komatsu Cod Errores

8/17/2019 Manual Komatsu Cod Errores

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OPERATIONEXPLANATION OF COMPONENTS

EXPLANATION OF COMPONENTSThe following is an explanation of devices needed for operating the machine.

To perform suitable operations correctly and safely, it is important to completely understand methods of operating

the equipment, and the meanings of the displays.

MACHINE MONITOR

(1)

(2)

(3)

Check before starting screen

Maintenance warning screen

Normal operation screen

(4)

(5)

Normal travel screen

Normal inspection screen

A

B

C

Basic check items

Caution items

Emergency stop items

D

E

Meter display portion

Monitor switch

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CLASS REF ONLY PDF PAGE 1 of 64


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MODE SELECTOR SWITCH

CAUTIONStop all the working equipment before operating the mode selector switch. If the mode selector switch is operated while the work

equipment is moving, the work equipment makes an emergency stop.

This switch (5) is used to switch between travel, work, and

inspection.

(a) Travel: Select this when traveling.

(b) Operation: Select this when carrying out crushing operations.

(c) Inspection: Select this when carrying out inspection operations.

When this switch (5) is operated, the machine monitor display changes as shown below.

(a)

(b)

When in travel mode

When in operation mode

(c) When in inspection mode

REMARK

If the radio control selector switch (if equipped) has been set to "Radio Control" and it has been made possible to

operate the travel with the radio control transmitter (if equipped), even if operation mode (b) is selected with the

mode selector switch, the machine monitor display will show travel mode (a).

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OPERATION EXPLANATION OF COMPONENTS

BASIC ACTUATION OF MACHINE MONITOR

WHEN THERE IS AN ABNORMALITY WHEN STARTING THE ENGINE

(1)

(2)


When in travel mode

(3) When in inspection mode

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If there is any abnormality when starting the engine, the check before starting screen (A) changes to the

maintenance interval warning screen (B), warning screen (D), or error screen (E).

After displaying the check before starting screen (A) for 2 seconds, the screen changes to the maintenance

interval warning screen (B).

After the maintenance time warning screen (B) has been displayed for 30 seconds, the screen will switch to thenormaloperationscreen(C). (The screencorrespondingto theposition of themode selector switch is displayed.)

After displaying the check before starting screen (A) for 2 seconds, the screen changesto the warning screen (D)

or error screen (E).

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WHEN AN ABNORMALITY OCCURS DURING OPERATIONS

(1)

(2)


When in travel mode

(3) When in inspection mode

If any abnormality occurs during operation, the normal operation screen (A) changes to warning screen (B) or the

error screen (D).

After displaying warning screen (B) for 2 seconds, the screen automatically changes to warning screen (C).

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BASIC CHECK ITEMS

CAUTIONThese monitors arenot provided for thepurpose of guaranteeing theconditions of themachine.Do notsolely rely on themonitors

for the daily inspection, but conduct each specified item of the daily inspection without fail.

This displays the basic items that should be checked before starting the engine.

If there is any problem, the appropriate monitor lamp will flash.

A(1)

A(2)

Radiator coolant level monitor

Engine oil level monitor

A(3) Maintenance time monitor

RADIATOR COOLANT LEVEL MONITORMonitor (1) warns the operator that there has been a drop in the

radiator coolant level.

If the radiator coolant is low, the lamp lights up red, so check

coolant level in the radiator and subtank, and add coolant.

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ENGINE OIL LEVEL MONITORMonitor (2) warns the operator that the oil levelin the engine oil pan

has dropped.

If oil level in the engine oil pan is low, the lamp lights up red, so

check the oil level, and add oil.

MAINTENANCE TIME MONITORThis monitor (3) lights up red to warn the operator when the set

time has passed from the time of the previous maintenance.

This monitor screen goes outafter 30 secondsandswitches to thenormal screen.

For details of the method of checking the maintenance time,see

"MAINTENANCE SCREEN SELECTOR SWITCH (PAGE

3-28)".

If it is desired to change settings for the maintenance interval, have

your Komatsu distributor change the settings.

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CAUTION ITEMS

CAUTIONWhen the warning monitor lamp begins to flash or the revolving warning lamp lights up, check and identify the cause in no time.

If left unattended for some time, it will lead to a failure.

These are items which need to be observed while the engine is running. If any problem occurs, items which need

to be repaired as soon as possible are displayed.

If there is any problem, the appropriate monitor lamp will flash to indicate the location of the problem.

B(1)

B(2)

B(3)

Charge level monitor

Fuel level monitor

Air cleaner clogging monitor

B(4)

B(5)

Engine coolant temperature monitor

Hydraulic oil temperature monitor

CHARGE LEVEL MONITORMonitor (1) warns the operator of an abnormality in the charging

system while the engine is running.

If charging is not being carried out correctly when the engine is

running, the red lamp lights up, and at the same time, all workequipment stops and the horn sounds.

If the red lamp lights up, check for looseness of the V-belt, and if

there is any abnormality, see "OTHER TROUBLE (PAGE 3-178)".

REMARKWhen the starting switch is at the ON position, the lamp is always lighted up, and after the engine started, it goes

out.

When the starting switch is at the ON position, the lamp may light up and the buzzer and horn may sound for a

moment when the engine is started or stopped, but this is not an abnormality.

If the horn sounds, set the fuel control dial to low idling. The horn will stop.

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FUEL LEVEL MONITORMonitor (2) lights up to warn the operator the fuel level in the tank

is low.

If the remaining amount of fuel goes down to 80 liters (21.14 US

gal), the light changes from green to red, so add fuel as soon aspossible.

AIR CLEANER CLOGGING MONITORMonitor (3) warns the operator of a clogged air cleaner.

If the monitor lights up red, stop the engine, inspect and clean the

air cleaner.

ENGINE COOLANT TEMPERATURE MONITORIf this monitor (4) lights up white in low temperatures, carry out the

warming-up operation. For details, see "ENGINE WARM UP

(PAGE 3-86)".

Continue the warming-up operation until monitor (4) changes to

green.

HYDRAULIC OIL TEMPERATURE MONITORIf this monitor (5) lights up white in low temperatures, carry out the

warming-up operation. For details, see "WORK EQUIPMENT

WARM UP (PAGE 3-89)".

Continue the warming-up operation until monitor (5) changes to

green.

REMARKThis monitor is displayed only in the travel mode. In the working

mode, it is not displayed.

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EMERGENCY STOP ITEMS

CAUTIONWhen this monitor begins to flash or the revolving warning lamp lights up, either stop the engine or reduce the engine speed to

low idling immediately, and then check for the trouble spot and take appropriate actions, if necessary.

These items must be observed when the engine is running. If there is any abnormality, the monitor for the problem

location lights up and the buzzer and horn sound.

C(1)

C(2)

C(3)

Engine coolant temperature monitor

Hydraulic oil temperature monitor

Engine oil pressure monitor

C(4)

C(5)

Emergency stop monitor

Engine stop monitor

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ENGINE COOLANT TEMPERATURE MONITORMonitor (1) warns operator that the engine coolant temperature

has risen.

If engine coolant temperature becomes abnormally high, monitor

lights up red, overheat prevention system is automaticallyactuated, and the engine speed goes down.

Stop operations and run engine at low idle until monitor (1)

changes to green.

HYDRAULIC OIL TEMPERATURE MONITORMonitor (2) warns operator that the hydraulic oil temperature has

risen.

If monitor lights up red during operations, run engine at low idle orstop the engine and wait until the oil temperature goes down and

monitor (2) changes to green.

ENGINE OIL PRESSURE MONITORThis monitor (3) lights up red when the engine lubricating oil

pressure goes below the correct value. At the same time, all the

work equipmentstops and thehornsounds. If themonitor lightsup

red, stop the engine, andcheck the lubricating system and oil level

in the oil pan.

REMARKWhen the starting switch is at the ON position, the lamp is

always lighted up, and after the engine started, it goes

out.When the engine is started, the buzzer may sound for a

moment, but this is not an abnormality.

When the horn sounds, turn the fuel control dial to the low idlingposition. The horn will stop.

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REMARKColor when the monitor lights up for basic check items, caution items, and emergency stop items are as follows.

Type of monitor

Color when monitor lights up

Whennormal

Whenabnormal

At lowtemperature

Radiator coolant level monitor OFF Red -

Engine oil level monitor OFF Red -

Maintenance interval monitor OFF Red -

Charge monitor OFF Red -

Fuel level monitor Green Red -

Air cleaner clogging monitor OFF Red -

Engine coolant temperature monitor Green Red White

Hydraulic oil temperature monitor Green Red White

Engine oil pressure monitor OFF Red -

EMERGENCY STOP MONITORThis monitor (4) shows that the emergency stop switch located

around the machine has been pressed and the work equipment

hasallstopped. Check thatthere is no abnormalityon themachine

and that the surrounding area is safe, then cancel the switch.

ENGINE STOP MONITORThis monitor (5) shows that the engine stop switch located on the

control box has been pressed and the engine has been stopped.

Turn the starting switch to the OFF position, check that there is no

abnormality on the machine and that the surrounding area is safe,

then start the machine again.

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METER DISPLAY PORTION

(A)

(B)

Normal operation screen

Normal travel screen

(C) Normal inspection screen

(1)

(2)

(3)

(4)

(5)

Engine pre-heating monitor

Operating mode monitor

Travel mode monitor

Inspection mode monitor

Engine coolant temperature gauge

(6)

(7)

(8)

(9)

(10)

Fuel gauge

Hydraulic oil temperature gauge

Service meter

Crusher actual clearance monitor

Operating status display lamp

PILOT DISPLAY PORTIONWhen the starting switch is ON, the pilot display lights up when the display items are functioning.

ENGINE PRE-HEATING MONITORThis monitor (1) indicates the pre-heating time required when

starting the engine at an ambient temperature below 0°C (32°F).

The monitor lamp lights up when the engine starting switch is

turned to the HEAT position and begins to flash after about 30seconds to show that the pre-heating is completed. (The monitor

lamp will go off after about 10 seconds)

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OPERATING MODE MONITORThis monitor (2) shows that the mode selector switch is at working

mode.

It is possible to check the operating condition of each piece of work

equipment and to identify the work equipment that has sufferedexcessive load or abnormal load.

TRAVEL MODE MONITORThis monitor (3) shows the setting for the travel speed.

The monitor display is as follows according to the operation of the

travel speed selector switch.Lo: Low-speed travel

Mi: Mid-range speed travel

Hi: High-speed travel

This monitor (3) lights up yellow when it is possible to travel. When

theheight of the conveyor makes it impossible to accept any travel

command, it lights up red.

For details, see "TRAVEL PREPARATIONS FOR PRIMARY

CONVEYOR (PAGE 3-94)".

INSPECTION MODE MONITORThis monitor (4) shows that the mode selector switch is at

inspection mode.

The monitor display changes as follows according to the operation

of the crusher selector switch on the control panel.

(a) A: Automatic mode

(b) S: Semi-automatic mode

(c) M: Manual mode

For details of the method of adjusting the clearance for each mode,

see "CHECK AND ADJUSTMENT OF OUTLET CLEARANCE(PAGE 4-39)".

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METER PORTION

ENGINE COOLANT TEMPERATURE GAUGEThis meter (5) shows the engine coolant temperature.

During operation, the indicator should be in black range (A) to (C).If the indicator enters red range (A) to (B) during operation, the

overheat prevention system is actuated.

The overheat prevention system acts as follows.

Red range (A) position: Engine coolant temperature monitor (1)

lights up red.

Red range (B) position: Engine speed is set to low idling, engine

coolant monitor lamp(C) lights up red, and

at the same time, the alarm buzzer and

horn sound,andallwork equipmentstops.

To stop the horn, turn the fuel control dial

to the low idling position.The overheat prevention system works until the temperature enters the black range (A) to (C).

When the engine is started, if the indicator is at position (C), engine water temperature monitor (1) lights up white.

In this case, carry out the warming-up operation. For details, see "ENGINE WARM UP (PAGE 3-86)".

FUEL GAUGEThis meter (6) displays the level of the fuel in the fuel tank. During

operations, the indicator should be in the black range.

If the indicator enters red range(A) during operations, there is less

than 110 liters (29.06 US gal) of fuel remaining in the tank, so

check and add fuel.

REMARKWhen the indicator reaches red range (B), there is less than 80

liters (21.14 US gal) of fuel remaining.

When the indicator is in the red range (B), fuel level monitor (D)

lights up red.

If the indicator enters the red range (A) to (B), do not carry out

operations on steep slopes. There is danger of the enginestalling.

The correct fuel level may not be displayed for a short time when

the starting switch is turned ON, but this is not an abnormality.

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HYDRAULIC OIL TEMPERATURE GAUGEThis meter (7) shows the hydraulic oil temperature.

During operation, the indicator should be in black range (A) to (C).

If the indicator enters red range (A) during operation, the hydraulic

oil temperature is more than 102 °C (215.6

°F). Run the engine at

low idling or stop it and wait until the hydraulic oil temperaturegoes

down.

REMARKThe hydraulic oil temperature when the indicator enters red range

(A) is as follows.

Red range (A) position: More than 102 °C (215.6 °F)

The hydraulic oil temperature monitor

lights up red.

Red range (B) position: More than 105 °C (221.0 °F)

The hydraulic oil temperature monitorlights up red and the alarm buzzer sounds

at the same time.

If the indicator is at position (C) when the engine is started, the

hydraulic oil temperature is less than 25 °C (77.0 °F) and hydraulic

oil temperature minitor (1) lights up white. When this happens, see

"WORK EQUIPMENT WARM UP (PAGE 3-89)" and carry out the

warming-up operation.

SERVICE METERThis monitor (8) shows the total hours of operation of the machine.

Use the time display to set the periodic maintenance intervals.

When the starting switch is at the ON position, the service meter

advances even if the machine is not moving. The reading of the

meter advances by 1 for every hour of operation, regardless of the

engine speed.

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CRUSHER ACTUAL CLEARANCE MONITORThis monitor (9) displays the clearanceat the discharge port when

the crusher jaw and fixed teeth are fully opened (O.S.S.

clearance).

REMARKOn this display, value (A) and the color of backlighting (B)

change according to the O.S.S. clearance value.

The O.S.S. clearance display value may not be exactly the

same as the actual measured value.

O.S.S. clearance Operation

0 - 55 mm

(0 - 2.167 in) Crushing operations impossible

55 - 100 mm(2.167 - 3.940 in)

Only concrete crushing operations possible

100 - 200 mm

(3.940 - 7.880 in) Crushing operations possible

More than 200 mm

(More than 7.880 in) Crushing operation is impossible

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OPERATING STATUS DISPLAY LAMPThis lamp (10)display is as shown in the diagram on the rightwhen

the working mode is selected with the mode selector switch on the

control panel. It is possible to confirm the operating status of each

piece of work equipment and to identify the work equipment thathas suffered excessive load or abnormal load.

(a) Crusher status confirmation lamp

(b) Grizzly feeder status lamp

(c) Conveyor status lamp

(d) Magnetic separator status lamp (if equipped)

(e) Muck discharge conveyor status lamp (if equipped)

The status display by the lamps is as shown in the table below.

Conveyor Crusher FeederMagneticseparator

(if equipped)

Muck dischargeconveyor

(if equipped)

Stop White lamp

lights up

White lamp

lights up

White lamp

lights up Transparent Transparent

Normal rotation

drive

White lamp

lights up

White lamp

lights up

White lamp

lights up Transparent Transparent

Reverse rotation

drive -

White lamp

lights up - - -

Overload Red lamp

flashed

Red lamp

flashed - -

Red lamp

flashed

Abnormal load Red lamp

lights up

Red lamp

lights up -

Red lamp

lights up

Red lamp

lights up

Crusher abnormal

load -

Red lamp

flashed

Red lamp

flashed - -

Reducing overload - - Green lamp

flashed - -

Crusher operation

prohibited period

after adjusting

clearance

- Red lamp

flashed - - -

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MONITOR SWITCH UNIT

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

Return switch

UP and numeral input (+) switch

DOWN and numeral input (-) switch

Input confirmation switch

Liquid-crystal monitor adjustment switch

Maintenance screen selector switch

Crusher clearance increase switch

Crusher clearance decrease switch

(9)

(10)

(11)

(12)

(13)

(14)

(15)

(16)

Crusher manual reverse rotation switch

Crusher manual normal rotation switch

Conveyor manual normal rotation switch

Conveyor manual reverse rotation switch

Buzzer cancel switch

Crusher speed setting screen selector switch

Feeder speed setting screen selector switch

Crusher load setting screen selector switch

RETURN SWITCHThis switch (1) has a function to return the current display to the

immediately foregoing one. It works in displays of the maintenance

mode as well as brightness and contrast adjusting mode. Every

time the switch is pressed in those modes, a display in the screen

continuously returns to the immediately foregoing one.

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UP/DOWN SWITCH AND NUMERAL INPUT (+/-) SWITCH 1. These switches (2) and (3) function to move the cursor on the

screen display up and down.

(2) UP

(3) DOWNEach time this switch is pressed, the cursor moves. The

screen display is highlighted to match this.

2. This switch is used to input the values when adjusting the

crusher clearance (all automatic/automatic).

(2) Increase input

(3) Decrease input

INPUT CONFIRMING SWITCHThis switch (4)has a function to determine selected contents in the

display. It works in the maintenance mode as well as in the

brightness and contrast mode. Press the switch in those modesand the selected contents are determined.

LIQUID-CRYSTAL MONITOR ADJUSTMENT SWITCHThis switch (5) is used when adjusting brightness and contrast of

the display in the screen.

When this switch is pressed, the display in the screen changes to

the selective display for brightness and contrast adjustment asshown at right.

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BRIGHTNESS ADJUSTMENT

1. Press either UP switch (2) or DOWN switch (3) to call the

brightness adjusting monitor.

2. When the display in the screen is changed to brightness

adjusting monitor, press either UP switch (2) or DOWN switch

(3) for desired brightness.

3. When selecting the desired brightness is finished, press input

confirmation switch (4).

CONTRAST ADJUSTMENT

1. Press either UP switch (2) or DOWN switch (3) to call the

contrast monitor.

2. When the display is changed to the contrast monitor, press

either UP switch (2) or DOWN switch (3) for desired contrast.

3. When selecting the desired contrast is finished, press input

confirmation switch (4).

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MAINTENANCE SCREEN SELECTOR SWITCHSwitch (6) is used to check the time remaining until

maintenance.

When switch (6) is pressed, screen on the monitor display

changes to the maintenance screen, as shown in diagram on

the right.

The time remaining until maintenance is indicated by the color of

each monitor display. After confirming the maintenance time,perform the maintenance.

White display: More than 30 hours remaining until maintenance

Yellowdisplay: Less than 30 hours remaining until maintenance

Red display : Maintenance time has already passed

NOTICE

1. If the monitor display changes to the maintenance warning screen when

the engine is started or when the machine is being operated, stop

operations immediately. When this happens, the monitor

corresponding to the maintenance warning screen will light up red.2. Press switch (6) to display the maintenance screen and check that there

is no abnormality in any other monitor.

3. If another monitor is lighted up redon the maintenance screen, carry out

maintenance for that item also.

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Maintenance display items are as follows:

MonitorNo.

Maintenance itemsInitial

settingscreen(H)

01 Change engine oil 500

02 Replace engine oil filter 500

03 Replace fuel main filter 1000

04 Replace hydraulic oil filter 1000

05 Replace hydraulic tank breather 500

06 Replace corrosion resister

(if equipped) -

07 Check damper case oil, add oil 1000

08 Change final draive case oil 2000

10 Change hydraulic oil 5000

27 Change feeder excitation machine oil 1000

28 Change crusher motor case oil 1000

41 Replace fuel pre-filter 500

If it is desired to change settings for the maintenance interval, have your Komatsu distributor change the settings.

The method of checking time remaining until maintenance is as follows:

1. Look at the maintenance screen andpress the UP switch (2) or

DOWN switch (3) on the monitor switches to select the item.

(The selector monitor is highlighted in black.)

2. After selecting the monitor item, press input confirmation

switch (4). The display changes to the time remaining to

maintenance.

(If return switch (1) is pressed, the screen returns to the

previous screen.)

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OPERATIONEXPLANATION OF COMPONENTS OPERATIONEXPLANATION OF COMPONENTS

3. Confirm the time remaining to maintenance.

(a): Time remaining to maintenance

(b): Initial set time for maintenance

When checking only the time remaining to maintenance,pressreturn switch (1) twice.

The screen returns to the monitor screen for normal

operations.

To cancel the time remaining to maintenance and return to the

initial set time, press input confirmationswitch (4). The screen

switches to the initial set screen.

4. After checking the time on the initial set time screen, press

input confirmation switch (4).

The screen returns to the maintenance screen.

(If return switch (1) is pressed, the screen returns to the

previous screen.)

CRUSHER CLEARANCE DECREASE SWITCHIf thisswitch (7) is kept pressed, the discharge port clearanceof the

jaw crusher becomes larger.

CRUSHER CLEARANCE INCREASE SWITCH

NOTICE

Operate this switch only after confirming that no debris or earth remainsinside the crusher chamber.

If thisswitch (8) is kept pressed, the discharge port clearanceof the

jaw crusher becomes smaller.

REMARK

Switches (7) and(8)are effective only when the mode selector switch on the control panel is at inspection mode and

the crusher clearance adjustment mode is at manual mode.

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CRUSHER MANUAL REVERSE ROTATION SWITCHThis switch (9) is used during maintenance and inspection of the

jaw crusher or to escape from the bridging or blocking condition.

It is used when adjusting the discharge port clearance of the jaw

crusher, or when carrying out operations to position the flywheel(inching operation).

It can also be used to together with the starting switch for manual

operation of the jaw crusher (normalrotation) (10) to make it easier

to remove foreign material from the discharge port of the jaw

crusher.

When using this switch, set the engine speed at low idling.

CRUSHER MANUAL NORMAL ROTATION SWITCHThis switch (10) is used during maintenance and inspection of the

jaw crusher or to escape from the bridging or blocking condition.The function is the same as the manual reverse rotation switch (9),

but when the discharge port of the jaw crusher is clogged with

foreign material, this switch can be pressed after stopping the jaw

crusher to make it easier to remove the foreign material.

REMARKWhile these switches are kept pressed, the jaw crusher rotates in the normal direction or reverse direction.

Switches (9) and (10) are effective only when the mode selector switch on the control panel is at working mode

or inspection mode.

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CONVEYOR MANUAL NORMAL ROTATION SWITCH

CAUTIONUse the conveyor manual switch for operations only when an abnormality has occurred in the conveyor or when carrying out

inspection, maintenance, or repair, and use it only for inching operations. When carrying out this operation, check that the areaaround the conveyor is safe.

While this switch (11) is kept pressed, the conveyor rotates in the

normal direction.

CONVEYOR MANUAL REVERSE ROTATION SWITCHWhile this switch (12) is kept pressed, the conveyor rotates in the

reverse direction.

REMARKSwitches (11) and (12) are effective only when the mode selector switch on the control panel is at inspection mode.

BUZZER CANCEL SWITCH

NOTICE

If the engine starting switch is turned OFF because some abnormality has

been noticed in the machine, and turned ON again, the buzzer sounds,unless that abnormality has not been removed.

This switch (13) is used to stop the alarm buzzer when an

abnormalityhas occurred in a warning item during operation of the

engine.

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CRUSHER SPEED SETTING SCREEN SELECTOR SWITCHThis switch (14) is used to adjust the rotating speed of the crusher.

When numeral input switch (3) is pressed, the scale goes down in

direction (A).

When numeral input switch (2) is pressed, the scale goes up indirection (B).

(A) Rotating speed at minimum (MIN): Whole scale is reduced in

direction (A)

(B) Rotating speed at maximum (MAX): Whole scale is increased

in direction (B)

FEEDER SPEED SETTING SCREEN SELECTOR SWITCHThis switch (15) is used to change the vibrationspeedof the grizzly

feeder and to adjust the feed speed for rubble and rock.


direction (A).

When numeral input switch (2) is pressed, the scale goes up in

direction (B).

(A) Feed speed at minimum (MIN): Whole scale is reduced in

direction (A)

(B) Feed speed at maximum (MAX): Whole scale is increased in

direction (B)

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CRUSHER LOAD SETTING SCREEN SELECTOR SWITCHThis switch (16) is designed to maintain the charge ratio inside the

crusher chamberto around 60% under any working conditions and

to enable the crusher to display the maximum operating capacity.

With the scale, it is possible to adjust the feed speed from thegrizzly feeder to the crusher.


direction (A).

When numeral input switch (2) is pressed, the scale goes up in

direction (B).

After starting operations, check the charge ratio of the crusher for

around one hour and adjust the crusher load setting to the optimum

position.

Guideline for adjusting scale

(A)SOFTHARD(B)

Concrete rubble Andesite Granite

Limestone Sandstone Basalt

Greywacke

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BR580JG-1 1

SEN03153-00

MOBILE CRUSHER1SHOP MANUAL

BR580JG-1

Machine model Serial number

BR580JG-1 1001 and up

30 Testing and adjusting 1Testing and adjusting, Part 2

Special functions of machine monitor ............................................................................................................. 2



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SEN03153-00 30 Testing and adjusting

2 BR580JG-1

Special functions of machine monitor 1

[1]: Figure input switch 1










[ ]: Decimal point input switch

[ ]: Return switch

[E]: Upward move switch

[R]: Downward move switch

[ ]: Input confirmation switch



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30 Testing and adjusting SEN03153-00

BR580JG-1 3

Ordinary functions and special functions of machine monitor

The machine monitor has the ordinary function and special functions and displays information of various

types on the multi-display.

Some items are displayed automatically and others are displayed through the switch operations according to

the internal setting of the machine monitor. Ordinary functions: Operator menu

The functions in this mode are displayed ordinarily. Display and setting of these functions are available

from the operator's switch operations.

Special functions: Service menu

The functions in this mode are not ordinarily displayed. Display and setting of these functions are avail-

able from the serviceman's operations of the special switches.

This mode is used for special setting, testing, adjusting or troubleshooting.

Operator menu Service menu

1 Password input and setting function 20 Function of monitoring [01]

2 KOMATSU logo display screen

21

Function of abnor-

mality record [02]

Electrical systems

3 Check before starting function Mechanical systems

4 Maintenance display function 22 Function of maintenance record [03]

5 Caution items display function 23 Function of maintenance mode change [04]

6 Function of travel mode 24 Function of phone number entry [05]

7 Function of working mode25

Function of default

[06]

Language

8 Function of testing mode Unit

9 Function of setting feeder speed

26Function of adjust-

ment [07]

Pump absorption torque

10 Function of setting crusher speed Adjustment of feeder speed

11 Function of setting crusher load

Adjustment of crusher speed

and the other work equipments

speed

12Display's brightness and contrast adjusting func-

tion

Initialization of clearance poten-

tiometer

13 Check of maintenance information function Option registration

14 Service meter display function Hi idle speed in working mode

15 Caution generation display function 27 Function of cylinder cut-out operation [08]

16 User code display function 28 Function of no injection cranking [09]

17 Failure code display function 29 Function of crusher clearance record [10]

18 Function of monitoring emergency stop 30 Function of lock cylinder slip record [11]

19 Function for conveyor position display



32/64


4 BR580JG-1

Operation of operator menu and display

(outline)

a This section introduces only the outline of the

operator menu. For details on the contents and

operation steps of each menu, refer to the“Operation and maintenance manual” or the

chapter of “Structure, function and mainte-

nance standard” in this shop manual.

1. Password input and setting function

Password input screen is displayed as the

starting switch is turned ON.

a Above display is available only when the

password function is selected.

2. KOMATSU logo display screenKOMATSU logo is displayed for 2 seconds as

a password is entered (as a password is speci-

fied) or the starting switch is turned ON.

3. Check before starting function

Check before starting screen is displayed for 2

seconds succeeding to display of KOMATSU

logo.

4. Maintenance display function

Succeeding to display of the check before

starting screen, a maintenance mark appears

for 30 seconds pointing the oil or filter whose

specified maintenance time has already

expired or going to expire soon.

a Above display is available only when the

maintenance function is selected.



33/64


BR580JG-1 5

5. Caution items display function

Succeeding display of the check before start-

ing screen, an appl icable caution mark

appears pointing a check before starting item

on which a problem was found.

6. Function of travel mode

If the travel mode is selected with the mode

selector switch of the main control box, the Hi,

Mi or Lo speed is displayed according to the

setting of the travel speed selector switch of the

upper control box.

7. Function of working mode

If the working mode is selected with the mode

selector switch of the main control box, the

operator can check the operating condition of

each work equipment unit and specify the work

equipment that is overloaded or loaded abnor-

mally.

q If the hydraulic oil temperature is abnor-

mally high, the travel mode display screen

is selected forcibly.

8. Function of testing mode

If the testing mode is selected with the mode

selector switch of the main control box, the

screen changes according to the position of

Manual (M), Semiauto (S), or Auto (A) selected

with the crusher clearance adjustment modeselector switch of the main control box, then

the operator can adjust the crusher clearance

in each mode.

q If the hydraulic oil temperature is abnor-

mally high, the travel mode display screen

is selected forcibly.



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6 BR580JG-1

9. Function of setting feeder speed

The operator can adjust the feeder speed with

the feeder speed setting switch of the machine

monitor.

A: Feeding speed is minimum

B: Feeding speed is maximum

10. Function of setting crusher speed

The operator can adjust the crusher speed with

the crusher speed sett ing switch of the

machine monitor.

A: Speed is minimum

B: Speed is maximum

11. Function of setting crusher load

The operator can adjust the crusher load with

the crusher load setting switch of the machine

monitor.

A: Load is set to minimum.

B: Load is set to maximum.

12. Display's brightness and contrast adjusting

function

The screen adjustment switches allow adjust-

ing the display brightness and contrast.



35/64


BR580JG-1 7

13. Check of maintenance information function

The maintenance switch allows checking

detailed information of the maintenance items

(specified maintenance time and elapsed

time). It also allows resetting after the mainte-

nance.

a Setting and resetting of the maintenance

function as well as setting of the mainte-

nance time is done from the service menu.

14. Service meter display function

Display of the service meter alone becomes

available by operating the following switches

after the starting switch is turned OFF.

q Switch operation: [ ] + [E]

(Simultaneous operation)

15. Caution generation display function

If a caution is warned for a caution item, appli-

cable symbol mark is displayed large for 2 sec-

onds and then it remains on the screen in a

smaller size until the trouble is eliminated.

16. User code display function

If a trouble occurs on the machine, an applica-

ble user code is automatically displayed

depending on the seriousness of the trouble in

order to alert the operator to take an appropri-

ate action.

a Operating any switch while an user code

is on the screen, switch the failure code

display screen (see Item 17).



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8 BR580JG-1

a User codes and actions requested to operator

User code Failure mode Action

E02 PC-EPC valve error Pump control malfunctions and have inspection carried out

immediately.

E10

Engine controller power source error Engine controller drive system circuit

error

(engine stopped)

Have inspection carried out immediately.

E11Engine controller system error

(Output reduced to protect engine)

Operate machine to a safe posture and have inspection car-

ried out immediately.

E14 Throttle system error Operate machine to a safe posture and have inspection car-

ried out immediately.

E15

Engine sensor (coolant temperature, fuel

temperature and oil pressure) system

error

Operations are possible, but have inspection carried out

immediately.

E0E

Network error

Pump controller solenoid power sourceerror

Operate machine to a safe posture and have inspection car-ried out immediately.



37/64


BR580JG-1 9

17. Failure code display function

Operating the following switch while an user

code is on the screen, sequentially displays

the failure code, the phone mark (if registered)

and phone number (if registered).

q Switching operation: ( )

a The screen display sequentially changes

as shown below.

(1) Failure code

(2) Telephone symbol mark

(3) Telephone number

a The telephone mark and telephone num-

ber are displayed only when the telephone

number is registered to the machine moni-

tor.Registration, correction or deletion of a

telephone number is done from the ser-

vice menu.

a For detailed information of failure codes,

see the “Failure code table”.

E 0 2

B J Z 1 3 8 2 8



38/64


10 BR580JG-1

Failure code table

User

code

Failure

codeFailure contents

Alarm

buzzer

Applicable

equipment

History

classification

— 7RC1KB Short circuit conveyor ON switch W/E Electrical system

— 7RC2KA Disconnection in conveyor OFF switch W/E Electrical system

— 7RC5KB Short circuit in feeder ON switch W/E Electrical system

— 7RD2KB Short circuit in discharge conveyor reverse solenoid W/E Electrical system

— 7RD2KZ Disconnection or short circuit in discharge conveyor reverse solenoid W/E Electrical system

— 7RE1KB Short circuit in crusher ON switch W/E Electrical system

— 7RE2KA Disconnection in crusher OFF switch W/E Electrical system

— 7RE6KB Short circuit in muck discharge conveyor ON switch W/E Electrical system

— 7RE7KA Disconnection in muck discharge conveyor OFF switch W/E Electrical system

— 7RE8KB Short circuit in magnetic separator ON switch W/E Electrical system

— 7RE9KA Disconnection in magnetic separator OFF switch W/E Electrical system

— 7REAKB Short circuit in accessory input 1 circuit W/E Electrical system

— 7REDMA Abnormality in conveyor pressure sensor W/E Electrical system

— 7REEMA Abnormality in muck conveyor pressure sensor W/E Electrical system— 7REHKB Short circuit in accessory input circuit 2 W/E Electrical system

— 7RENKZ Abnormality in clearance potentiometer W/E Electrical system

— 7REPKA Disconnection in feeder OFF switch W/E Electrical system

— 7RESKB Short circuit in one-touch start switch W/E Electrical system

— 7RETKA Disconnection in one-touch stop switch W/E Electrical system

— 7RF2KA Disconnection in crusher forward EPC valve W/E Electrical system

— 7RF2KB Short circuit in crusher forward EPC valve W/E Electrical system

— 7RF2KY Short circuit in crusher forward EPC valve W/E Electrical system

— 7RF3KA Disconnection in crusher reverse EPC valve W/E Electrical system

— 7RF3KB Short circuit in crusher reverse EPC valve W/E Electrical system

— 7RF3KY Short circuit in crusher reverse EPC valve W/E Electrical system

— 7RF4KA Disconnection in feeder forward EPC valve W/E Electrical system

— 7RF4KB Short circuit in feeder forward EPC valve W/E Electrical system

— 7RF4KY Short circuit in feeder forward EPC valve W/E Electrical system

— 7RF8KA Disconnection in accessory 2 EPC valve W/E Electrical system

— 7RF8KB Short circuit in accessory 2 EPC valve W/E Electrical system

— 7RF8KY Short circuit in accessory 2 EPC valve W/E Electrical system

— 7RFAKY Short circuit in engine stop relay W/E Electrical system

— 7RFAKZ Disconnection or short circuit in engine stop relay W/E Electrical system

— 7RFBKB Short circuit in muck conveyor solenoid W/E Electrical system

— 7RFBKZ Disconnection or short circuit in muck conveyor solenoid W/E Electrical system

— 7RFHKA Disconnection in conveyor forward EPC valve W/E Electrical system

— 7RFHKB Short circuit in conveyor forward EPC valve W/E Electrical system— 7RFHKY Short circuit in conveyor forward EPC valve W/E Electrical system

— 7RFKKB Short circuit in lock cylinder pull relay W/E Electrical system

— 7RFKKY Short circuit in lock cylinder pull relay W/E Electrical system

— 7RFLKA Disconnection in accessory 1 EPC solenoid W/E Electrical system

— 7RFLKB Short circuit in accessory 1 EPC solenoid W/E Electrical system

— 7RFLKY Short circuit in accessory 1 EPC solenoid W/E Electrical system

— 7RFMKY Short circuit in abnormal pressure relay W/E Electrical system

— 7RFMKZ Disconnection or short circuit in abnormal pressure relay W/E Electrical system

— 7RFNKA Disconnection in lock cylinder unlock solenoid valve W/E Electrical system

— 7RFNKB Short circuit in lock cylinder unlock solenoid valve W/E Electrical system

— 7RFNKY Short circuit in lock cylinder unlock solenoid valve W/E Electrical system

— 7RFPKB Short circuit in lock cylinder push relay W/E Electrical system

— 7RFPKY Short circuit in lock cylinder push relay W/E Electrical system



39/64


BR580JG-1 11

— 7RGAMA Abnormality in 2nd conveyor pressure sensor W/E Electrical system

— 7RJAKA Disconnection in travel lock EPC solenoid valve W/E Electrical system

— 7RJAKB Short circuit in travel lock EPC solenoid valve W/E Electrical system

— 7RJAKY Short circuit in travel lock EPC solenoid valve W/E Electrical system— 7RJDMA Abnormality in crusher forward pressure sensor W/E Electrical system

— 7RJEMA Abnormality in crusher reverse pressure sensor W/E Electrical system

— 7RJLKA Disconnection in magnetic separator EPC valve W/E Electrical system

— 7RJLKB Short circuit in magnetic separator EPC valve W/E Electrical system

— 7RJLKY Short circuit in magnetic separator EPC valve W/E Electrical system

— 7RJMMW Lock cylinder slipping W/E Mechanical system

— 7RJPKB Short circuit in radio control work-mode switch W/E Electrical system

— 7RJQKB Short circuit in radio control travel-mode switch W/E Electrical system

— 7RJRKB Short circuit on travel signal W/E Electrical system

— 7RJSMA Abnormality in magnetic separator pressure sensor W/E Electrical system

— AA10NX Air cleaner Clogging MON Mechanical system

— AB00KE Charge voltage too low MON Mechanical system

— B@BAZG Engine oil pressure too low e ENG Mechanical system

— B@BAZK Engine oil level reduction MON Mechanical system

— B@BCNS Engine coolant overheat e ENG Mechanical system

— B@BCZK Radiator coolant level reduction e MON Mechanical system

— B@HANS Hydraulic Oil Overheat e MON Mechanical system

E11 CA111 ECM Critical Internal Failure q ENG Electrical system

E10 CA115 Eng Ne and Bkup Speed Sens Error q ENG Electrical system

E11 CA122 Chg Air Press Sensor High Error q ENG Electrical system

E11 CA123 Chg Air Press Sensor Low Error q ENG Electrical system

E14 CA131 Throttle Sensor High Error q ENG Electrical system

E14 CA132 Throttle Sensor Low Error q ENG Electrical system

E15 CA135 Eng Oil Press Sensor High Error q ENG Electrical system

E15 CA141 Eng Oil Press Sensor Low Error q ENG Electrical system

E15 CA144 Coolant Temp Sens High Error q ENG Electrical system

E15 CA145 Coolant Temp Sens Low Error q ENG Electrical system

E15 CA153 Chg Air Temp Sensor High Error q ENG Electrical system

E15 CA154 Chg Air Temp Sensor Low Error q ENG Electrical system

E15 CA187 Sens Supply 2 Volt Low Error q ENG Electrical system

E11 CA221 Ambient Press Sens High Error q ENG Electrical system

E11 CA222 Ambient Press Sens Low Error q ENG Electrical system

E15 CA227 Sens Supply 2 Volt High Error q ENG Electrical system

— CA234 Eng Overspeed q

ENG Mechanical systemE15 CA238 Ne Speed Sens Supply Volt Error q ENG Electrical system

E15 CA263 Fuel Temp Sensor High Error q ENG Electrical system

E15 CA265 Fuel Temp Sensor Low Error q ENG Electrical system

E11 CA273 PCV2 Short Error q ENG Electrical system

E11 CA274 PCV2 Open Error q ENG Electrical system

E11 CA322 Inj #1 (L#1) Open/Short Error q ENG Electrical system






E10 CA342 Calibration Code Incompatibility ENG Electrical system

E10 CA351 INJ. Drive Circuit Error ENG Electrical system

E15 CA352 Sens Supply 1 Volt Low Error q ENG Electrical system

User

code

Failure


Alarm

buzzer

Applicable

equipment

History

classification



40/64


12 BR580JG-1

E15 CA386 Sens Supply 1 Volt High Error q ENG Electrical system

E10 CA441 Battery Voltage Low Error q ENG Electrical system

E10 CA442 Battery Voltage High Error q ENG Electrical system

E11 CA449 Rail Press Very High Error q ENG Electrical systemE11 CA451 Rail Press Sensor High Error q ENG Electrical system

E11 CA452 Rail Press Sensor Low Error q ENG Electrical system

E15 CA553 Rail Press High Error q ENG Electrical system

— CA554 Rail Press Sensor In Range Error ENG Electrical system

E15 CA559 Rail Press Low Error q ENG Electrical system

E15 CA689 Eng Ne Speed Sensor Error q ENG Electrical system

E15 CA731 Eng Bkup Speed Sens Phase Error q ENG Electrical system

E10 CA757 All Persistent Data Lost Error q ENG Electrical system

E15 CA778 Eng Bkup Speed Sensor Error q ENG Electrical system

E15 CA1228 EGR Valve Servo Error 1 q ENG Electrical system

E11 CA1625 EGR Valve Servo Error 2 q ENG Electrical system

E0E CA1633 CAN Communication Error (engine controller) q ENG Electrical system

E14 CA2185 Throt Sens Sup Volt High Error q ENG Electrical system

E14 CA2186 Throt Sens Sup Volt Low Error q ENG Electrical system

E11 CA2249 Rail Press Very Low Error q ENG Electrical system

E11 CA2271 EGR Valve Lift Position Sens High Error q ENG Electrical system

E11 CA2272 EGR Valve Lift Position Sens Low Error q ENG Electrical system

E11 CA2351 EGR Valve Sol Current High Error q ENG Electrical system

E11 CA2352 EGR Valve Sol Current Low Error q ENG Electrical system

E15 CA2555 Grid Heater Relay Open Error q ENG Electrical system

E15 CA2556 Grid Heater Relay Short Error q ENG Electrical system

— D162KY Short circuit in horn relay W/E Electrical system

— D162KZ Disconnection or short circuit in horn relay W/E Electrical system

E0E DA22KK Solenoid power source too low q PUMP Electrical system

— DA25KP Abnormality in pressure sensor power source PUMP Electrical system

E0E DA2RMC CAN communication error (work equipment and pump controller) q PUMP Electrical system

— DA2SKQ Abnormality in model code input PUMP Electrical system

E0E DAFRMC CAN communication error (monitor controller) q MON Electrical system

— DDA6KA Disconnection in engine stop switch W/E Electrical system

— DGH2KB Short circuit in hydraulic oil temperature sensor MON Electrical system

— DHPAMA Abnormality in F pump pressure sensor PUMP Electrical system

— DHPBMA Abnormality in R pump pressure sensor PUMP Electrical system

— DUB0KY Short circuit in beacon solid state relay W/E Electrical system

— DUB0KZ Disconnection or short circuit in beacon solid state relay W/E Electrical systemE02 DXA0KA Disconnection in PC-EPC Solenoid q PUMP Electrical system

E02 DXA0KB Short circuit in PC-EPC Solenoid q PUMP Electrical system

E02 DXA0KY Short circuit in PC-EPC Solenoid q PUMP Electrical system

— DXE0KA Disconnection in LS-EPC solenoid PUMP Electrical system

— DXE0KB Short circuit in LS-EPC solenoid PUMP Electrical system

— DXE0KY Short circuit in LS-EPC solenoid PUMP Electrical system

User

code

Failure


Alarm

buzzer

Applicable

equipment

History

classification



41/64


BR580JG-1 13

a Entry order of items in table

The items are entered in the order of their failure codes (incremental order).

a User code

Attached : If the failure code is detected, the user code, failure code, and telephone No. (if regis-

tered) are displayed on the ordinary screen to notify the operator of the abnormality.

Not attached: Even if the failure code is detected, the machine monitor does not notify the operator of

the abnormality.

a Alarm buzzer

q : When occurrence of an error is notified to the operator, the buzzer sounds (The operator can stop

the buzzer with the alarm buzzer cancel switch).

e: Since the caution monitor is also turned ON, its function sounds the buzzer.

a Component in charge

MON: The machine monitor is in charge of detection of abnormality.

W/E: The work equipment and pump controller is in charge of detection of abnormality.

PUMP: The pump controller is in charge of detection of abnormality.

ENG: The engine controller is in charge of detection of abnormality.

a Category of record

Mechanical system: Abnormality information is recorded in the mechanical system abnormality record.

Electrical system: Abnormality information is recorded in the electrical system abnormality record.



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14 BR580JG-1

18. Function of monitoring emergency stop

1) Warning for turning emergency stop

switch ON

When an emergency stop switch installed

around the machine is depressed;

q The whole work equipment stops and

the horn sounds.

2) Warning for turning engine stop switch ON

When the engine stop switch installed to

the upper operation box is depressed;

q The whole work equipment and

engine stop and the horn sounds.

19. Function for conveyor position display

1) Conveyor position display in operation

mode

If the operation mode is selected with the

mode selector switch of the main control

box, the color of mode moni tor (a)

changes according to the conveyor posi-

tion.

q When conveyor position is “Upper”

Mode monitor (a) becomes red. At

this time, the whole work equipment

stops.

q When conveyor position is “Middle” or

“Lower”

Mode monitor (a) becomes yellow. At

this time, the work equipment can

operate.

2) Conveyor position display in travel mode

If the travel mode is selected with the

mode selector switch of the main control

box, the color of mode moni tor (b)

changes according to the conveyor posi-

tion.

q When conveyor position is “Lower”

Mode monitor (b) becomes red. At

this time, the machine cannot travel.

q When conveyor position is “Middle” or

“Upper”

Mode monitor (b) becomes yellow. At

this time, the machine can travel.



43/64


BR580JG-1 15

Service menu operation and display

Switching to service menu

a When using the service menu, switch the

screen through the following special operation.

1) Confirmation of display

Make sure that the conventional display is

turned on.

a Changing to Service Menu is usually avail-

able only from this conventional display.

2) Switch operation

Do the following switch operation.

q Switch operation:

[E] + [1] o [2] o [3]

(Enter the numbers while holding E down)

3) Displaying menu screen

The display is changed to the initial display of

Service Menu program. Select an appropriate

item from among the menu.

4) Ending the menu and function

When ending the operation from the service

menu screen or respective menu screens,

select either of the following operations.

q Press [ ] switch (enables every screen).

q

When “RETURN” switch is displayed,press the applicable switch.

q When “Return” menu is displayed, select

the menu and press [ ] switch.

No. Service menu

00 Return (Ends the service menu)

01 Monitoring

02 Abnormality record

03 Maintenance record

04 Maintenance mode change

05 Phone number entry

06 Default

07 Adjustment

08 Cylinder cut out

09 No injection cranking

10 Crusher clearance record

11 Lock cylinder slip record



44/64


16 BR580JG-1

20. Function of monitoring [01]

The machine monitor monitors signals from the

switch sensor actuators on various machine

parts. It allows displaying and checking the

monitored information through following opera-

tions.

1) Menu selection

Select “01 Monitoring” in the initial display

of Service Menu and depress [ ] switch.

2) Setting a monitoring item

Select and register an item to be moni-

tored through the following switch opera-

tion.

q [E] switch: Selection

q [R] switch: Selectionq [ ] switch: Registration

a A monitoring item can be set from 1 to

4 at maximum (Depending upon the

selected item, the max. number can

be less than four)

a In case of monitoring 1 to 3 items,

move to the monitoring information

screen through any of the following

switch operations after the registra-

tion work has been completed.q [Hold down [ ] switch (for about

3 seconds).

q Select menu “99999” and press

[ ] switch.

a When you have registered all the

items that can be registered, the

screen will be automatically switched

to the monitoring information screen.

a Monitored information are transmitted

via communication circuits. Thus the

number of selected items can impact

the communication speed. If truly real

time monitoring is required, reduce

the selected items to the minimum.

a For details on the monitoring items,

display unit, etc., refer to the “Monitor-

ing Items table”.

3) Operation for monitoring

As the monitoring information screen is

displayed, confirm the monitored informa-tion operating the machine.

4) Monitored information holding function

You can hold every monitored information

by pressing [E] while monitoring is contin-

ued.

If you press [R] switch again in this condi-

tion, the currently held information will be

released.



45/64


BR580JG-1 17

Monitoring items table

Code

NoMonitoring item (Display on screen)

Unit (Initial setting ISO) Com-

ponent

charge

RemarksISO meter inch

00200 Controller Model Select — — — PUMP

00201 Machine ID — — — ENG

01002 Engine speed r/min rpm rpm ENG

01601 2nd Eng. Speed Command r/min rpm rpm PUMP

01100 F Pump Pressure MPa kg/cm2 psi PUMP

01101 R Pump Pressure MPa kg/cm2 psi PUMP

24101 Crusher forward pressure MPa kg/cm2 psi PUMP

24102 Crusher reverse pressure MPa kg/cm2 psi PUMP

24300 Conv. Pressure MPa kg/cm2 psi PUMP

24400 Muck Conv. Pressure MPa kg/cm2 psi PUMP

24401 Mag. Pressure MPa kg/cm2 psi PUMP

24402 2nd Conv. Pressure MPa kg/cm2 psi PUMP

04107 Coolant Temperature °C °C °F ENG

14200 Fuel temperature °C °C °F ENG

04401 Hydr. Oil Temperature °C °C °F MON

01300 PC-EPC Sol. Curr.(F) mA mA mA PUMP

01500 LS-EPC Sol. Curr. mA mA mA PUMP

24700 Feeder FWD EPC Curr. mA mA mA PUMP

25900 Crusher FWD EPC Curr. mA mA mA PUMP

26000 Crusher REV EPC Curr. mA mA mA PUMP

25705 Accessory 1 EPC mA mA mA PUMP

25706 Accessory 2 EPC mA mA mA PUMP

25707 Conveyor forward EPC mA mA mA PUMP25708 Magnetic separator mA mA mA PUMP

28801 Travel Lock EPC Curr. mA mA mA PUMP

03200 Battery Voltage V V V PUMP

03203 Battery Power Supply V V V ENG

04300 Battery Charge Vol. V V V MON

37200 Engine oil pressure sensor MPa kg/cm2 psi ENG

36400 Rail Pressure MPa kg/cm2 psi ENG

37400 Ambient Pressure kPa kg/cm2 psi ENG

Indicated by absolute

value (Including

ambient pressure)

18500 Charge Temperature °C °C °F ENG

36500 Boost Pressure kPa kg/cm2 psi ENG

Indicated by absolute

value (Including

ambient pressure)

18100 EGR valve position mm mm in ENG

36700 Engine Torque Ratio % % % ENG

18700 Engine Output Torque Nm Nm kgfm ENG

03000 Fuel Dial Pos Sens Volt V V V ENG

04200 Fuel Level Sensor Vol. V V V MON

04105 Eng. Water Temp. Vol. Lo V V V ENG

14201 Fuel temperature sensor voltage V V V ENG

04402 Hydr. Temp. Sensor Vol. V V V MON37201 Oil pressure sensor voltage V V V ENG

37401 Ambient Press Sens Volt V V V ENG



46/64


18 BR580JG-1

18501 Charge Temp Sens Volt V V V ENG

36501 Charge Press Sens Volt V V V ENG

36401 Rail Pressure Sens Volt V V V ENG

18101 EGR valve position sensor voltage V V V ENG

17201 PCV close valve timing (TDC standard) CA CA CA ENG

17500 Engine Power Mode — — — ENG

31701 Throttle Position % % % ENG

31706 Final Throttle Position % % % ENG

18600 Inject Fueling Command mg/st mg/st mg/st ENG

36200 Rail Press Command MPa kg/cm2 psi ENG

36300 Injection Timing Command CA CA CA ENG

37300 Fuel Rate l/h l/h l/h ENG

01602 2nd Eng. Speed Command % % % PUMP

13113 Main Pump Absorb Torque Nm kgm lbft PUMP

04500 Monitor input 1

Key Switch

ON•OFF

MON

Start MON

Preheat MON

Light MON

Rad. Level MON

04501 Monitor Input 2

Air cleaner

ON•OFF

MON

Eng. Oil Level MON

Battery Charge MON

25000 Switch Input 0

Conv. ON Sw.

ON•OFF

PUMP

Conv. OFF Sw. PUMPCrusher ON Sw. PUMP

Crusher OFF Sw. PUMP

Feeder ON Sw. PUMP

Feeder OFF Sw. PUMP


R-Ctrl. Work Sw.

ON•OFF

PUMP

R-Ctrl. Trv. Sw. PUMP

R-Ctrl. On Trv. PUMP


Mode Sel. Work

ON•OFF

PUMP

Mode Sel. Travel PUMP

Crush. FWD/REV PUMP

Machine Select1 PUMP

Machine Select2 PUMP


Emergency Sw.

ON•OFF

PUMP

Engine Stop Sw. PUMP

1-touch start Sw PUMP

1-touch stop Sw. PUMP


Conv. Hi Sensor

ON•OFF

PUMP

Conv. Mi Sensor PUMP

MuckConv. Sen. PUMP

Overfeed Sensor PUMP

Code



ponent

charge




47/64


BR580JG-1 19

a Entry order of items in table

The items are entered in the order of display on the monitoring selection menu screen.

a Unit

The display unit can be set to ISO, meter, or inch freely (Set it with “Unit selecting” in “Initialization” of

the service menu).

“CA” in the display unit is an abbreviation for crankshaft angle.

“mg/st” in the display unit is an abbreviation for milligram/stroke.

a Component in charge

MON: The machine monitor is in charge of detection of monitoring information.

ENG: The engine controller is in charge of detection of monitoring information.

PUMP: The pump controller is in charge of detection of monitoring information.


Radio Sel. switch

ON•OFF

PUMP

TravelSpeed switch 1 PUMP

TravelSpeed switch 2 PUMP

Clearance F-auto PUMP

Clearance Auto. PUMP


MuckConv.ON switch

ON•OFF

PUMP

MuckConv.OFF switch PUMP

Mag. ON switch PUMP

Mag. OFF switch PUMP

Acc. 1 input PUMP

Acc. 2 input PUMP

02202 Switch Input 7 Key Switch (ACC) ON•OFF PUMP

25500 Solenoid Valve

Conveyor reverse solenoid

ON•OFF

PUMP

Lock.Cyl. Unlock solenoid PUMP

Muck Conv. solenoid PUMP

25601 Relay Drive 0

Horn Relay

ON•OFF

PUMP

Becon Relay PUMP

Abno.Press Relay PUMP

LockCyl.Push Re. PUMP

LockCyl.Pull Re. PUMP

Eng. Stop Relay PUMP

26100 Clearance Potentio Vol. V V V PUMP

26200 Clearance Angle rad ° ° PUMP

26300 Last 0 Clearance Vol. V V V PUMP20216 ECM Build Version — — — ENG

20217 ECM CAL Data Ver — — — ENG

18900 ECM Internal Temp °C °C °F ENG

20400 ECM Serial No. — — — ENG

20200 Monitor Prog. Version — — — MON

20227 Monitor Ass'y P/N — — — MON

20402 Monitor Serial No — — — MON

20212 Pump Con. Prog. Version — — — PUMP

20230 Pump Con. Prog. P/N — — — PUMP

20229 Pump Con. Ass'y P/N — — — PUMP

20403 Pump Con. Serial No — — — PUMP

Code



ponent

charge




48/64


20 BR580JG-1

21. Function of abnormality record [02]

The machine monitor records and classifies

the past failure information as into the electri-

cal and mechanical failures. It allows display-

ing and checking the information through the

following operations.

1) Menu selection

Select “02 Abnormality Record” in the ini-

tial display of Service Menu and depress

[ ] switch.

2) Sub menu selection

Select the sub menu from the abnormality

record menu screen and then press [ ]

switch.

3) Contents of display of electrical system

abnormality record information screen

(1): Occurrence order of abnormalities

f rom latest one/Tota l number of

records

(2): Failure code (Equipment: 4 digits,

Phenomena: 2 digits)

(3): Elapsed time on service meter from

the first occurrence

(4): Contents of trouble

a See the operator menu “Failure

codes table”.

4) Contents of display of mechanical system

abnormality record information screen

(1): Record number

(2): Contents of trouble(3): Failure code (Equipment: 4 digits,

Pheomena: 2 digits)

(4): Total number of occurrences

(5): Service meter reading at first occur-

rence

a See the operator menu “Failure

codes table”.

Number Sub menu of abnormality record

00 Return (End of abnormality record)

01 Electrical systems

02 Mechanical systems



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BR580JG-1 21

5) Resetting electrical systems abnormality

record

a Resetting abnormality record (dele-

tion) is possible only with the electri-

cal system. The abnormality record in

the mechanical system cannot be

reset.

a When resetting individual or all infor-

mation in the abnormality record of

the electrical systems, implement the

following procedure.

1] Following switch operation from the

electrical system abnormality record

screen opens the reset screen.

q Switch operation:

[E] + [1] o [2] o [3]a Above is the same as that done when

switching to the service menu.

2] From the reset screen, do the switch

operation according to the screen

instructions.

a When a specific individual infor-

mation alone is to be reset, be

sure to display the subject infor-

mation on the screen using [E]

switch or [R] switch.

a When resetting all information,

the information to be displayed

on the screen can be any.



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22 BR580JG-1

22. Function of maintenance record [03]

The machine monitor records the maintenance

information of the filters, oils, etc., which the

operator can display and check by the follow-

ing operations.

1) Menu selection

Select “03 Maintenance Record” from the

initial display of Service Menu and then

depress [ ] switch.

2) Information to be displayed

q Oil and filter names

q Replacement time elapsed up to

present

q Time elapsed on service meter up to

the last replacement

23. Function of maintenance mode change [04]

Following procedure allows changing the cur-

rently set operating conditions of the mainte-

nance display function.

q Set function effective or ineffective

q Change set replacement interval

1) Menu selection

Select “04 Maintenance Mode Change”

from the Service Menu and then depress

[ ] switch.

2) Selection of item to be changed

Select the item to be changed from the

“Maintenance Mode Change” Selection

Menu screen.



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BR580JG-1 23

a 01 and 14 menus are provided for

setting the whole maintenance mode,

while those from 02 through 13 are

for setting individual items.

3) Contents of Maintenance Mode On/Off

q Use (On): The maintenance display

function of all oil and filter-relateditems are turned effectual. (Irrespec-

tive of whether “On” or “Off” set for

individual items, this setting prevails)

q Not use (Off): The maintenance dis-

play function of all oils and filter-

related items is disabled (prece-

dence is given to this setting over the

“On” or “Off” selected for an individual

items).

4) Description of individual setting items

(1): Default value: The maintenance time

set in the monitor (recommended by

the manufacturer and cannot be

changed).

(2): Set value: Denotes the maintenance

time that can be freely set. The main-

tenance mode operates based on this

time (the time can be increased or

decreased in multiple of 50 hours by

use of [E] and [R] switches).

(3): Use (On): Maintenance display func-

tion for this item is enabled.

(4): Not use (Off): Maintenance display

function for this item is disabled.

a The lower limit of this setting is 25

hours.

5) Description of “Initialize all items”

Select th is menu and then press [ ]

switch to restore the default value for the

individually set information.

Number Items of the maintenance mode change

00Return (End of change in the maintenance

mode)

01 Maintenance mode on/off

02 Engine oil change int.

03 Engine oil filter change int.

04 Fuel main filter change int.

05 Hyd oil filter change int.

06 Hyd tank breather change int.

07 Corrosion resistor change int.

08 Damper case service int.

09 Final drive case oil change int.

10 Feeder vibration oil change int.

11 Crusher motor case oil change int.

12 Hydraulic oil change int.

13 Fuel pre-filter change int.

14 Initialize all items



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24 BR580JG-1

24. Function of phone number entry [05]

When the user code is displayed, following

procedure allows entering or correcting the

phone numbers to be displayed alternately

with the failure code.

a If a telephone number is not input, the

phone number screen is not displayed.

1) Menu selection

Select “05 Phone Number Entry” menu

from the Service Menu initial screen and

then depress [ ] switch.

2) Changing the display

Select “Entry” next to change the display

to the “Phone Number Entry” display.

a Even if a Phone number is alreadyinputted, it is deleted if you switch the

“Phone Number Entry” screen.

3) Entry and setting phone number

Following the method explained below,

entry a phone number in the “Phone Num-

ber Entry” display. (Entry automatically

begins with a cursor at the left end)

1] Using the numerical keypad, enter

the number starting with the cursor

position situated at the left end.

a Numbers can be entered up to

the max. 12 digi ts, but omit

unnecessary digits.

a When entered a wrong number,

dec ima l po in t i npu t sw i t ch

(Swi tch fo r se t t ing c rusher

speed) to return the cursor by

one digit.2] Depress [ ] switch when all the num-

bers have been entered.

a As the input is finished, the

screen changes to entry screen

shown above. I f the entered

phone number is shown on this

display, the input is normal.



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BR580JG-1 25

25. Function of default [06]

Following machine monitor- or machine-

related settings are modifiable. Do necessary

modifications as needed.

q Language used in the service menu

q Unit to be displayed in relation to the mon-

itoring function

1) Menu selection

Select “06 Default” menu from the Service

Menu init ial screen and then press [ ]

switch.

2) Selecting sub menu

Select the target sub menu of setting

change and then press [ ] switch.

3) Language setting function

Service Menu allows switching the lan-

guage between Japanese and English.

a The default language of the machinemonitor is English.

a When using the machine monitor,

which is a spare part, in the Japa-

nese-speaking sphere, switch this

function from English to Japanese.

4) Unit selection function

You can select 1 from the 3 units to be

used in the monitoring function display of

Service Menu.

a SI unit system is the default setting of

the machine monitor.

Number Sub menu of default value

00 Return (End of default)

01 Language

02 Unit



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26 BR580JG-1

26. Function of adjustment [07]

The operator can adjust various items related

to the machine with the machine monitor.

1) Menu selection

Select “07 Adjustment” menu from the

Service Menu initial screen and then press

[ ] switch.

2) Sub menu selection

Select the sub menu on which setting

change is to be done and then press [ ]

switch.

q When the crusher minimum speed is

adjusted, adjust it by "03" (Crusher speed and other work equipments

speed adjustment) (*1).

q When the crusher maximum speed is

adjusted, adjust it by "06" (Hi idle

speed in working mode) (*1).

3) Function for Pump Absorption Torque

adjustment

The pump absorpt ion torque can be

adjusted within the range shown in the

table below.

4) Function for feeder speed adjustment

The maximum and minimum feeder speed

can be adjusted within the range shown in

the table below by adjusting the feeder

EPC current.

Number Adjustment of sub menu00 Return (Ends the adjustment)

01 Pump absorption torque

02 Feeder speed adjustment

03Crusher speed and other work equipments

(*1) adjustment

04 Clearance potentiometer initialization

05 Option register

06 Hi idle speed in working mode (*1)

Adjust-

ment

value

Torque adjust-

ment value

(kgm)

Adjust-

ment

value

Torque adjust-

ment value

(kgm)

220 +8.0 225 –2.0

221 +6.0 226 –4.0

222 +4.0 227 –6.0223 +2.0 228 –8.0

224 0.0

Item Input range (mA)

Max. speed 770 – 910

Min. speed 300 – 650



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BR580JG-1 27

1] Move the cursor to the current to

adjust with [ ] switch and [ ] switch

and depress [ ] switch.

2] The adjusted current flashes and the

value input window is displayed.3] Input a value with the numeral keys


a If a value out of the proper range is

input, the value before inputting is dis-

played again.

5) Crusher speed and other equipments

speed adjustment

q Other work equipments speed adjust-

ment

Adjust the LS-EPC current.

q Minimum speed adjustment

Adjust the crusher forward/reverse

EPC current.

1] Move the cursor to the current to

adjust with [ ] switch and [ ] switch


2] The adjusted current flashes and the

value input window is displayed.3] Input a value with the numeral keys


a If a value out of the proper range is

input, the value before inputting is dis-

played again.

a When adjusting the crusher maximum

speed, adjust it by "Hi idle speed in

working mode" (Page 29). That brings

speed changes of the all work equip-

ments. Accordingly, first adjust the Hi

idle speed in working mode, then

adjust the other speeds.a If the LS-EPC solenoid current is

adjusted, the minimum crusher speed

and maximum and minimum feeder

speeds change. When adjusting the

crusher and feeder speeds, adjust the

Hi idle speed in working mode and

other work equipments speed (LS-

EPC solenoid current) f irst, then

adjust the other speeds.

ItemInput range

(mA)

Other work equipments speed

(LS-EPC solenoid current)10 – 1000

Min. speed

(EPC current)

Forward 250 – 600

Reverse 250 – 600



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28 BR580JG-1

6) Function for clearance potentiometer ini-

tial adjustment

When the tooth plate is replaced, initialize

the clearance potentiometer.

1] Check that the display is in the ordi-

nary display mode.

2] Set mode selector switch (1) of the

main control box in the testing mode

position.

3] Set clearance adjustment selector

switch (2) of the main control box in

the manual mode position.

4] Rotate the crusher with crusher man-

ual forward switch (3) and reverse

switch (4) of the machine monitor to

bring mark (B) of the flywheel to the

center of adjustment range (A).5] Depress crusher clearance closing

switch (5) of the machine monitor to

press the swing jaw of the crusher

against the fixed jaw (and the monitor

buzzer sounds).

6] Select the service menu to display the

clearance potentiometer initialization

screen.

7] Depress “1” (SET) on the clearance

potentiometer initialization screen.

7) Function for option registration

Use/Disuse of the options of the machinecan be set.

1] On the option setting menu screen,

move the cursor with the [E] switch

and [R] switch to an option to be

adjusted and press the [ ] switch.

Number Option registration menu

00 Return (Finish adjustment)

01 Magnetic separator

02 Muck discharge conveyor

03 Overfeed sensor

04 2nd conveyor

05 Travel lever



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BR580JG-1 29

2] The screen changes to the use (on)/

disuse (off) setting screen for the

selected

Documents

Manual Komatsu Cod Errores