Manual Komatsu Cod Errores

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OPERATION

EXPLANATION OF COMPONENTS

EXPLANATION OF COMPONENTS The 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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OPERATION


MODE SELECTOR SWITCH

CAUTION Stop 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


BASIC ACTUATION OF MACHINE MONITOR WHEN THERE IS AN ABNORMALITY WHEN STARTING THE ENGINE

(1) (2)

When in operation mode When in travel mode

(3)


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OPERATION


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 the normal operation screen (C). (The screen corresponding to the position of the mode selector switch is displayed.) After displaying the check before starting screen (A) for 2 seconds, the screen changes to the warning screen (D) or error screen (E).


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OPERATION


WHEN AN ABNORMALITY OCCURS DURING OPERATIONS

(1) (2)

When in operation mode When in travel mode

(3)


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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OPERATION


BASIC CHECK ITEMS

CAUTION These monitors are not provided for the purpose of guaranteeing the conditions of the machine. Do not solely rely on the monitors 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) Radiator coolant level monitor A(2) Engine oil level monitor

A(3) Maintenance time monitor

RADIATOR COOLANT LEVEL MONITOR Monitor (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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OPERATION


ENGINE OIL LEVEL MONITOR Monitor (2) warns the operator that the oil level in 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 MONITOR This 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 out after 30 seconds and switches to the normal 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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OPERATION


CAUTION ITEMS

CAUTION When 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) Charge level monitor B(2) Fuel level monitor B(3) Air cleaner clogging monitor

B(4) Engine coolant temperature monitor B(5) Hydraulic oil temperature monitor

CHARGE LEVEL MONITOR Monitor (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 work equipment 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)".

REMARK When 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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OPERATION


FUEL LEVEL MONITOR Monitor (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 as possible.

AIR CLEANER CLOGGING MONITOR Monitor (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 MONITOR If 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 MONITOR If 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. REMARK This monitor is displayed only in the travel mode. In the working mode, it is not displayed.


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OPERATION


EMERGENCY STOP ITEMS

CAUTION When 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) Engine coolant temperature monitor C(2) Hydraulic oil temperature monitor C(3) Engine oil pressure monitor

C(4) Emergency stop monitor C(5) Engine stop monitor


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OPERATION


ENGINE COOLANT TEMPERATURE MONITOR Monitor (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 automatically actuated, and the engine speed goes down. Stop operations and run engine at low idle until monitor (1) changes to green.

HYDRAULIC OIL TEMPERATURE MONITOR Monitor (2) warns operator that the hydraulic oil temperature has risen. If monitor lights up red during operations, run engine at low idle or stop the engine and wait until the oil temperature goes down and monitor (2) changes to green.

ENGINE OIL PRESSURE MONITOR This monitor (3) lights up red when the engine lubricating oil pressure goes below the correct value. At the same time, all the work equipment stops and the horn sounds. If the monitor lights up red, stop the engine, and check the lubricating system and oil level in the oil pan. REMARK When 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 idling position. The horn will stop.


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OPERATION


REMARK Color when the monitor lights up for basic check items, caution items, and emergency stop items are as follows. Color when monitor lights up Type of monitor

When normal

When At low abnormal temperature

Radiator coolant level monitor

OFF

Red

-

Engine oil level monitor

OFF

Red

-

Maintenance interval monitor

OFF

Red

-

Charge monitor

OFF

Red

-

Green

Red

-

OFF

Red

-

Engine coolant temperature monitor

Green

Red

White

Hydraulic oil temperature monitor

Green

Red

White

OFF

Red

-

Fuel level monitor Air cleaner clogging monitor

Engine oil pressure monitor

EMERGENCY STOP MONITOR This monitor (4) shows that the emergency stop switch located around the machine has been pressed and the work equipment has all stopped. Check that there is no abnormality on the machine and that the surrounding area is safe, then cancel the switch.

ENGINE STOP MONITOR This 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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OPERATION


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 PORTION When the starting switch is ON, the pilot display lights up when the display items are functioning.

ENGINE PRE-HEATING MONITOR This 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 30 seconds to show that the pre-heating is completed. (The monitor lamp will go off after about 10 seconds)


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OPERATION


OPERATING MODE MONITOR This 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 suffered excessive load or abnormal load.

TRAVEL MODE MONITOR This 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 the height 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 MONITOR This 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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OPERATION


METER PORTION ENGINE COOLANT TEMPERATURE GAUGE This 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, and all work equipment stops. 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 GAUGE This 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. REMARK When 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 engine stalling. 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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OPERATION


HYDRAULIC OIL TEMPERATURE GAUGE This 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 temperature goes down. REMARK The 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 monitor lights 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 METER This 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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OPERATION


CRUSHER ACTUAL CLEARANCE MONITOR This monitor (9) displays the clearance at the discharge port when the crusher jaw and fixed teeth are fully opened (O.S.S. clearance). REMARK On 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 0 - 55 mm (0 - 2.167 in) 55 - 100 mm (2.167 - 3.940 in) 100 - 200 mm (3.940 - 7.880 in) More than 200 mm (More than 7.880 in)

Operation Crushing operations impossible Only concrete crushing operations possible Crushing operations possible Crushing operation is impossible


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OPERATION


OPERATING STATUS DISPLAY LAMP This lamp (10) display is as shown in the diagram on the right when 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 that has 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.

Stop Normal rotation drive Reverse rotation drive Overload Abnormal load

Magnetic separator (if equipped)

Muck discharge conveyor (if equipped)

Transparent

Transparent

Transparent

Transparent

-

-

-

-

-

-

Red lamp lights up

Red lamp flashed Red lamp lights up

-

-

-

-

-

-

Conveyor

Crusher

Feeder

White lamp lights up White lamp lights up

White lamp lights up White lamp lights up White lamp lights up Red lamp flashed Red lamp lights up Red lamp flashed

White lamp lights up White lamp lights up

Red lamp flashed Red lamp lights up

Crusher abnormal load

-

Reducing overload

-

-

Crusher operation prohibited period after adjusting clearance

-

Red lamp flashed

Red lamp flashed Green lamp flashed

-


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OPERATION


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 SWITCH This 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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OPERATION


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) DOWN Each 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 SWITCH This 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 modes and the selected contents are determined.

LIQUID-CRYSTAL MONITOR ADJUSTMENT SWITCH This 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 as shown at right.


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OPERATION


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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OPERATION


MAINTENANCE SCREEN SELECTOR SWITCH Switch (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 Yellow display: 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 red on the maintenance screen, carry out maintenance for that item also.


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OPERATION


Maintenance display items are as follows: Monitor No.

Maintenance items

Initial setting screen(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 and press 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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OPERATION


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, press return 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 confirmation switch (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 SWITCH If this switch (7) is kept pressed, the discharge port clearance of the jaw crusher becomes larger.

CRUSHER CLEARANCE INCREASE SWITCH NOTICE Operate this switch only after confirming that no debris or earth remains inside the crusher chamber. If this switch (8) is kept pressed, the discharge port clearance of 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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OPERATION


CRUSHER MANUAL REVERSE ROTATION SWITCH This 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 (normal rotation) (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 SWITCH This 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.

REMARK While 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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OPERATION


CONVEYOR MANUAL NORMAL ROTATION SWITCH

CAUTION Use 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 area around the conveyor is safe.

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

CONVEYOR MANUAL REVERSE ROTATION SWITCH While this switch (12) is kept pressed, the conveyor rotates in the reverse direction.

REMARK Switches (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 abnormality has occurred in a warning item during operation of the engine.


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OPERATION


CRUSHER SPEED SETTING SCREEN SELECTOR SWITCH This 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 in direction (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 SWITCH This switch (15) is used to change the vibration speed of the grizzly feeder and to adjust the feed speed for rubble and rock. 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 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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OPERATION


CRUSHER LOAD SETTING SCREEN SELECTOR SWITCH This switch (16) is designed to maintain the charge ratio inside the crusher chamber to 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 the grizzly feeder to 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 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)SOFT<------------------------------------------------------>HARD(B) Concrete rubble

Andesite

Granite

Limestone

Sandstone

Basalt Greywacke


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MOBILE CRUSHER 1SHOP MANUAL

BR580JG-1

Machine model

Serial number

BR580JG-1

1001 and up

30 Testing and adjusting

1

Testing and adjusting, Part 2 Special functions of machine monitor ............................................................................................................. 2

1

BR580JG-1 CLASS REF ONLY PDF PAGE 29 of 64

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Special functions of machine monitor

[1]: Figure input switch 1 [2]: Figure input switch 2 [3]: Figure input switch 3 [4]: Figure input switch 4 [5]: Figure input switch 5 [6]: Figure input switch 6 [7]: Figure input switch 7 [8]: Figure input switch 8 [9]: Figure input switch 9 [0]: Figure input switch 0

1

[ ]: Decimal point input switch [ ]: Return switch [E]: Upward move switch [R]: Downward move switch [ ]: Input confirmation switch

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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. q 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. q Special functions: Service menu The functions in this mode are not ordinarily displayed. Display and setting of these functions are available 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 2 KOMATSU logo display screen

20 Function of monitoring [01] 21

3 Check before starting function

Function of abnormality record [02]

Electrical systems 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 mode

25

8 Function of testing mode

Function of default [06]

Language Unit

9 Function of setting feeder speed

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

26 12

Display's brightness and contrast adjusting function

Function of adjustment [07]

Initialization of clearance potentiometer

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

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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 maintenance 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.

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.

KOMATSU logo display screen KOMATSU logo is displayed for 2 seconds as a password is entered (as a password is specified) or the starting switch is turned ON.

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5.

Caution items display function Succeeding display of the check before starting sc r een, an appl ic able cau tion 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 abnormally. q If the hydraulic oil temperature is abnormally 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 mode selector switch of the main control box, then the operator can adjust the crusher clearance in each mode. q If the hydraulic oil temperature is abnormally high, the travel mode display screen is selected forcibly.

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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

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.

10. Function of setting crusher speed The operator can adjust the crusher speed with t he cr us he r s pee d s et tin g s wi tc h o f t he machine monitor. A: Speed is minimum B: Speed is maximum

12. Display's brightness and contrast adjusting function The screen adjustment switches allow adjusting the display brightness and contrast.

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SEN03153-00

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 maintenance. a Setting and resetting of the maintenance function as well as setting of the maintenance 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, applicable symbol mark is displayed large for 2 seconds 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 applicable user code is automatically displayed depending on the seriousness of the trouble in order to alert the operator to take an appropriate action. a Operating any switch while an user code is on the screen, switch the failure code display screen (see Item 17).

7


SEN03153-00 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.

E11

Engine controller system error (Output reduced to protect engine)

Operate machine to a safe posture and have inspection carried out immediately.

E14

Throttle system error


E15

Engine sensor (coolant temperature, fuel Operations are possible, but have inspection carried out temperature and oil pressure) system immediately. error

E0E

Network error Pump controller solenoid power source error


8



SEN03153-00

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: ( )

(3) Telephone number

E02

a

B JZ 138 28

a

The screen display sequentially changes as shown below. (1) Failure code

a

The telephone mark and telephone number are displayed only when the telephone number is registered to the machine monitor. Registration, correction or deletion of a telephone number is done from the service menu. For detailed information of failure codes, see the “Failure code table”.

(2) Telephone symbol mark

9


SEN03153-00


Failure code table User code

Failure code

Failure 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

10



User code

SEN03153-00

Failure code

Failure contents

Alarm buzzer



—

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

—

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

MON

Mechanical system

ENG

Mechanical system

— —

7RJMMW Lock cylinder slipping

AB00KE Charge voltage too low B@BAZG Engine oil pressure too low

e

—

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 system

E15

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

E11

CA323


q

ENG

Electrical system

E11

CA324


q

ENG

Electrical system

E11

CA325


q

ENG

Electrical system

E11

CA331


q

ENG

Electrical system

E11

CA332


q

ENG

Electrical system Electrical system

E10

CA342

Calibration Code Incompatibility

ENG

E10

CA351

INJ. Drive Circuit Error

ENG

Electrical system

E15

CA352

Sens Supply 1 Volt Low Error

ENG

Electrical system

q

11


SEN03153-00

User code

Failure code

E15

CA386


Alarm buzzer



Sens Supply 1 Volt High Error

q

ENG

Electrical system

Failure contents

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 system

E11

CA451

Rail Press Sensor High Error

q

ENG


E11

CA452

Rail Press Sensor Low Error

q

ENG

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 — E0E — E0E —

DA22KK Solenoid power source too low

q

DA25KP Abnormality in pressure sensor power source DA2RMC CAN communication error (work equipment and pump controller)

q

DA2SKQ Abnormality in model code input DAFRMC CAN communication error (monitor controller)

q

DDA6KA Disconnection in engine stop switch

PUMP

Electrical system

PUMP

Electrical system

PUMP

Electrical system

PUMP

Electrical system

MON

Electrical system

W/E


—

DGH2KB Short circuit in hydraulic oil temperature sensor

MON

—

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

W/E

Electrical system

E02

—

DXA0KA Disconnection in PC-EPC Solenoid

DUB0KZ Disconnection or short circuit in beacon solid state relay 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

12


30 Testing and adjusting a a

a

a

a

SEN03153-00

Entry order of items in table The items are entered in the order of their failure codes (incremental order). User code Attached : If the failure code is detected, the user code, failure code, and telephone No. (if registered) 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. 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. 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. 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.

13


SEN03153-00


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)

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 monitor (a) changes according to the conveyor position. 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.

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.

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 monitor (b) changes according to the conveyor position. 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.

14



SEN03153-00

Service menu operation and display

3)

Switching to service menu a When using the service menu, switch the screen through the following special operation. 1)

Displaying menu screen The display is changed to the initial display of Service Menu program. Select an appropriate item from among the menu.

Confirmation of display Make sure that the conventional display is turned on. a Changing to Service Menu is usually available only from this conventional display.

No.

Service menu

00 Return (Ends the service menu) 01 Monitoring 02 Abnormality record 03 Maintenance record

2)

04 Maintenance mode change

Switch operation Do the following switch operation. q Switch operation: [E] + [1] o [2] o [3] (Enter the numbers while holding E down)

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

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.

15


SEN03153-00


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 operations. 1)

a

a

Menu selection Select “01 Monitoring” in the initial display of Service Menu and depress [ ] switch. a

2)

Select menu “99999” and press [ ] switch. When you have registered all the items that can be registered, the screen will be automatically switched to the monitoring information screen. 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. For details on the monitoring items, display unit, etc., refer to the “Monitoring Items table”.

q

3)

Operation for monitoring As the monitoring information screen is displayed, confirm the monitored information operating the machine.

4)

Monitored information holding function You can hold every monitored information by pressing [E] while monitoring is continued. If you press [R] switch again in this condition, the currently held information will be released.

Setting a monitoring item Select and register an item to be monitored through the following switch operation. q [E] switch: Selection q [R] switch: Selection q [ ] switch: Registration

a

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) In case of monitoring 1 to 3 items, move to the monitoring information screen through any of the following switch operations after the registration work has been completed. q [Hold down [ ] switch (for about 3 seconds).

16



SEN03153-00

Monitoring items table Unit (Initial setting ISO)

Code No

Monitoring item (Display on screen)

ISO

meter

inch

Component charge

—

—

—

PUMP

00200

Controller Model Select

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

2

24102

Crusher reverse pressure

MPa

kg/cm

psi

PUMP

24300

Conv. Pressure

MPa

kg/cm2

psi

PUMP

2

24400

Muck Conv. Pressure

MPa

kg/cm

psi

PUMP

24401

Mag. Pressure

MPa

kg/cm2

psi

PUMP

2

24402

2nd Conv. Pressure

MPa

kg/cm

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

PUMP

25708

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.

37200

Engine oil pressure sensor

V

V

V

MON

MPa

kg/cm2

psi

ENG

2

36400

Rail Pressure

MPa

kg/cm

psi

ENG

37400

Ambient Pressure

kPa

kg/cm2

psi

ENG

18500

Charge Temperature

°C

°C

°F

ENG

36500

Boost Pressure

kPa

kg/cm2

psi

ENG

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

MON

37201

Oil pressure sensor voltage

V

V

V

ENG

37401

Ambient Press Sens Volt

V

V

V

ENG

Remarks

Indicated by absolute value (Including ambient pressure) Indicated by absolute value (Including ambient pressure)

17


SEN03153-00

Code No


Unit (Initial setting ISO) Monitoring item (Display on screen)

ISO

meter

inch

Component charge

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

MON

Start

MON

Preheat

ON•OFF

Light

04501

Monitor Input 2

Switch Input 0

Rad. Level

MON

Air cleaner

MON

Eng. Oil Level

ON•OFF

Switch Input 1

Conv. ON Sw.

PUMP

Conv. OFF Sw.

PUMP

Crusher ON Sw. Crusher OFF Sw.

ON•OFF

25003

Switch Input 2

Switch Input 3

Feeder ON Sw.

PUMP PUMP

R-Ctrl. Trv. Sw.

PUMP ON•OFF

Switch Input 4

PUMP

R-Ctrl. On Trv.

PUMP

Mode Sel. Work

PUMP

Crush. FWD/REV

PUMP ON•OFF

PUMP

Machine Select1

PUMP

Machine Select2

PUMP

Emergency Sw.

PUMP

Engine Stop Sw.

PUMP

1-touch start Sw

ON•OFF

1-touch stop Sw.

25004

PUMP PUMP

Feeder OFF Sw.

Mode Sel. Travel 25002

MON MON

R-Ctrl. Work Sw. 25001

MON MON

Battery Charge

25000

Remarks

PUMP PUMP

Conv. Hi Sensor

PUMP

Conv. Mi Sensor

PUMP

MuckConv. Sen.

ON•OFF

Overfeed Sensor

18

PUMP PUMP



Unit (Initial setting ISO)

Code No

25005

25006

SEN03153-00

Monitoring item (Display on screen)

Switch Input 5

ISO

meter

inch

Radio Sel. switch

PUMP

TravelSpeed switch 1

PUMP

TravelSpeed switch 2

ON•OFF

PUMP

Clearance Auto.

PUMP

MuckConv.ON switch

PUMP

MuckConv.OFF switch

PUMP

Mag. ON switch

PUMP

ON•OFF

Mag. OFF switch

PUMP

Acc. 1 input

PUMP

Acc. 2 input Switch Input 7

25500

Solenoid Valve

PUMP

Key Switch (ACC)

ON•OFF

PUMP

ON•OFF

PUMP

Conveyor reverse solenoid

25601

PUMP

Lock.Cyl. Unlock solenoid

Relay Drive 0

Muck Conv. solenoid

PUMP

Horn Relay

PUMP

Becon Relay

PUMP

Abno.Press Relay

PUMP

ON•OFF

LockCyl.Push Re.

PUMP

LockCyl.Pull Re.

PUMP

Eng. Stop Relay

PUMP

26100

Clearance Potentio Vol.

26200

Clearance Angle

rad

°

°

PUMP

26300

Last 0 Clearance Vol.

V

V

V

PUMP

20216

ECM Build Version

—

—

—

ENG

20217

ECM CAL Data Ver

—

—

—

ENG

V

V

V

PUMP

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

a a

a

Remarks

PUMP

Clearance F-auto

Switch Input 6

02202

Component charge

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

19


SEN03153-00


21. Function of abnormality record [02]

3)

Contents of display of electrical system abnormality record information screen (1): Occurrence order of abnormalities fr o m l a t e s t o n e / To ta l n u m b e r o f 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 occurrence a See the operator menu “Failure codes table”.

The machine monitor records and classifies the past failure information as into the electrical and mechanical failures. It allows displaying and checking the information through the following operations. 1) Menu selection Select “02 Abnormality Record” in the initial display of Service Menu and depress [ ] switch.

2)

Number

Sub menu selection Select the sub menu from the abnormality record menu screen and then press [ ] switch.

Sub menu of abnormality record

00

Return (End of abnormality record)

01

Electrical systems

02

Mechanical systems

20



5)

SEN03153-00

Resetting electrical systems abnormality record a Resetting abnormality record (deletion) is possible only with the electrical system. The abnormality record in the mechanical system cannot be reset. a When resetting individual or all information in the abnormality record of the electrical systems, implement the following procedure.

1]

a

2]

From the reset screen, do the switch operation according to the screen instructions. a When a specific individual information alone is to be reset, be sure to display the subject information 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.

Following switch operation from the electrical system abnormality record screen opens the reset screen. q Switch operation: [E] + [1] o [2] o [3] Above is the same as that done when switching to the service menu.

21


SEN03153-00


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 following 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 currently set operating conditions of the maintenance 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.

22



Number

SEN03153-00

Description of individual setting items (1): Default value: The maintenance time set in the monitor (recommended by the ma nufac turer an d c annot b e changed). (2): Set value: Denotes the maintenance time that can be freely set. The maintenance 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 function 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 this menu and then press [ ] switch to restore the default value for the individually set information.

Items of the maintenance mode change

00

Return (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

a

3)

4)

01 and 14 menus are provided for setting the whole maintenance mode, while those from 02 through 13 are for setting individual items.

Contents of Maintenance Mode On/Off q Use (On): The maintenance display function of all oil and filter-related items are turned effectual. (Irrespective of whether “On” or “Off” set for individual items, this setting prevails) q Not use (Off): The maintenance display function of all oils and filterrelated items is disabled (precedence is given to this setting over the “On” or “Off” selected for an individual items).

23


SEN03153-00


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)

3)

Entry and setting phone number Following the method explained below, entry a phone number in the “Phone Number Entry” display. (Entry automatically begins with a cursor at the left end)

Menu selection Select “05 Phone Number Entry” menu from the Service Menu initial screen and then depress [ ] switch.

1]

2)

Changing the display Select “Entry” next to change the display to the “Phone Number Entry” display. a Even if a Phone number is already inputted, it is deleted if you switch the “Phone Number Entry” screen.

2]

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 m ax . 1 2 di gi ts, bu t o mi t unnecessary digits. a When entered a wrong number, decimal point input switch (Switch for setting crusher speed) to return the cursor by one digit. Depress [ ] switch when all the numbers have been entered. a As the input is finished, the screen changes to entry screen shown above. If the entered phone number is shown on this display, the input is normal.

24



SEN03153-00

25. Function of default [06] Following machine monitor- or machinerelated settings are modifiable. Do necessary modifications as needed. q Language used in the service menu q Unit to be displayed in relation to the monitoring function 1)

3)

Language setting function Service Menu allows switching the language between Japanese and English.

Menu selection Select “06 Default” menu from the Service Menu initial screen and then press [ ] switch.

a a

4) 2)

Selecting sub menu Select the target sub menu of setting change and then press [ ] switch.

Number

The default language of the machine monitor is English. When using the machine monitor, which is a spare part, in the Japanese-speaking sphere, switch this function from English to Japanese.

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.

Sub menu of default value

00

Return (End of default)

01

Language

02

Unit

25


SEN03153-00


26. Function of adjustment [07]

q

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.

3)

Adjustment of sub menu

00

Return (Ends the adjustment)

01

Pump absorption torque

02

Feeder speed adjustment

03

Crusher speed and other work equipments (*1) adjustment

04

Clearance potentiometer initialization

05

Option register

06

Hi idle speed in working mode (*1) q

Function for Pump Absorption Torque adjustment The pump absorption torque can be adjusted within the range shown in the table below.

Adjustment value

Torque adjustment value (kgm)

Adjustment value

Torque adjustment value (kgm)

220

+8.0

225

–2.0

221

+6.0

226

–4.0

222

+4.0

227

–6.0

223

+2.0

228

–8.0

224

0.0

4)

Number

When the crusher maximum speed is adjusted, adjust it by "06" (Hi idle speed in working mode) (*1).

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. Item

Input range (mA)

Max. speed

770 – 910

Min. speed

300 – 650

When the crusher minimum speed is adjusted, adjust it by "03" (Crusher speed and other work equipments speed adjustment) (*1).

26



1]

2] 3] a

SEN03153-00

Move the cursor to the current to adjust with [ ] switch and [ ] switch and depress [ ] switch. The adjusted current flashes and the value input window is displayed. Input a value with the numeral keys and depress [ ] switch. If a value out of the proper range is input, the value before inputting is displayed again.

1]

2] 3] a a

a

5)

Crusher speed and other equipments speed adjustment q Other work equipments speed adjustment Adjust the LS-EPC current. q Minimum speed adjustment Adjust the crusher forward/reverse EPC current. Item

Input range (mA)

Other work equipments speed (LS-EPC solenoid current)

10 – 1000

Forward

250 – 600

Reverse

250 – 600

Min. speed (EPC current)

Move the cursor to the current to adjust with [ ] switch and [ ] switch and depress [ ] switch. The adjusted current flashes and the value input window is displayed. Input a value with the numeral keys and depress [ ] switch. If a value out of the proper range is input, the value before inputting is displayed again. 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 equipments. Accordingly, first adjust the Hi idle speed in working mode, then adjust the other speeds. 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 (LSEPC solenoid current) first, then adjust the other speeds.

27


SEN03153-00

6)


Function for clearance potentiometer initial adjustment When the tooth plate is replaced, initialize the clearance potentiometer.

7]

7) 1] 2]

3]

4]

5]

6]

Check that the display is in the ordinary display mode. Set mode selector switch (1) of the main control box in the testing mode position. Set clearance adjustment selector switch (2) of the main control box in the manual mode position. Rotate the crusher with crusher manual 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). 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).

Depress “1” (SET) on the clearance potentiometer initialization screen.

Function for option registration Use/Disuse of the options of the machine can 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

Select the service menu to display the clearance potentiometer initialization screen.

28



8)

SEN03153-00

2]

The screen changes to the use (on)/ disuse (off) setting screen for the selected option. Move the cursor with the [E] switch and [R] switch to “Use”/“Disuse” and press the [ ] switch.

3]

When the option is set normally, the monitor buzzer sounds for 3 seconds and then the screen returns to the previous screen.

Function for adjustment of Hi idle speed in working mode Hi idle speeds in working mode can be adjusted within the range of the table below. a When adjusting the crusher maximum speed, adjust it by "Hi idle speed in working mode". That brings speed changes of the all work equipments. Accordingly, first adjust the "Hi idle speed in working mode", then adjust the other speeds.

Adjustment Hi idle speed Adjustment Hi idle speed value (rpm) value (rpm) 67F

1900

677

1740

67E

1880

676

1720

67D

1860

675

1700

67C

1840

674

1680

67B

1820

673

1660

67A

1800

672

1640

679

1780

671

1620

678

1760

670

1600

29


SEN03153-00


27. Function of cylinder cut out operation [08] The operator can perform the engine on cylinder cut out operation with the machine monitor. “Cylinder cut out” operation means to run the engine with 1 or more fuel injectors disabled electrically to reduce the number of effective cylinders. This operation is used to find out a cylinder which does not output power normally (combustion in it is abnormal). 1)

Selecting menu Select “08 Cylinder cut out” menu from the Service Menu initial screen and press [ ] switch. 3)

2)

Resetting cut out cylinder Press the switch corresponding to the cut out cylinder number from switches [1] to [6] of the machine monitor to be reset. a If pressing the switch changes the cylinder number on the screen to a black letter enclosed in the black frame, the cylinder is reset.

Selecting cylinder to be cut out Press a switch corresponding to the cylinder No. to be cut out from switches [1] to [6] of the machine monitor. a If pressing the switch changes the cylinder number on the screen to a white letter enclosed in the white frame, the cylinder is cut out (when a wrong number is selected, press the correct switch again). a Number of cylinders to be reduced is any.

30



4)

SEN03153-00

Engine speed holding function Pressing [E] switch while the engine operation on cylinder cut out screen is turned on holds the engine speed and its speed is newly displayed in the lower space. Pressing [ R] switch during holding cancels the holding function and deletes the display in the lower space. a If the holding function is used, the held speed is displayed in the lower space along with ( ) and the upper space continuously displays the current speed. a The holding function is usable independent of the currently set mode – the cylinder cut out or not.

[Reference]: Using the holding function effectively The engine speed being displayed on the screen through the holding function remains on it until the holding is cancelled. In other words, enabling or disabling of the cylinder cut out mode does not affect the display. Thus, when identifying a failed cylinder quicker, following operation is effective. (1) Run the engine from the normal operation mode (no cylinder cut out) and then hold the speed of that time. (2) Specify the cylinder to be diagnosed as the cut out. (3) Run the engine under the same condition as that for (1). Then compare the engine speed at that time and the held speed being displayed to diagnose the cylinder. (4) Reset a cut out cylinder independent of the fluctuations in the engine speed. (5) Repeat above steps (2) to (4) and then compare the results against that obtained from other cylinders. a If the diagnosis identified a cylinder on which there was no decrease in the engine speed or the decrease was small, it can be safely judged that there must be some abnormalities in its combustion.

31


SEN03153-00


28. Function of no injection cranking [09] No injection cranking of the engine is available from the machine monitor. No injection cranking denotes stopping injection of fuel from the injector even if the engine is run from the starting motor. This mode is used, for instance, for measurement of compressive pressure. a This setting must be done after stopping the engine. 1)

2)

3)

As the checkup is over, following screen appears.

4)

Select “No Injection” and press [ ] switch. “Under Preparation” will be displayed on the screen. a The letters “Under Preparation” are displayed in red.

Selecting menu Select “09 No Injection Cranking” from the Service Menu initial screen and press [ ] switch.

The initial screen for the no injection cranking will appear. a “Check Communication” will be displayed in red.

32



5)

6)

7)

8)

SEN03153-00

As the preparation for no injection cranking is completed, display of “Under Preparation” is replaced with “After No Injection”. a The letters “After No Injection” are displayed in green. From this state, crank the engine using the starting motor. a Limit the cranking time to 20 seconds to protect the starting motor.

a

If the no injection cranking function is inadvertently selected while the engine is running, “Engine Running” will appear as No Injection in step 4) is selected. This “Engine Running” display remains on the screen even after the engine is stopped. Restoring the service menu screen alone deletes the display.

After the no injection cranking is over, press [ ] switch from the previous screen and the letters “End” will be displayed for 3 seconds. a The letters “End” are displayed in green. Press “Return” when ending the no injection cranking.

33


SEN03153-00


29. Function for crusher clearance record [10] The machine monitor records the information about the crusher clearance setting. q The machine monitor records the information up to 10 times. After recording 10 times, the machine monitor discards the data in order from the oldest one and keeps the newest ones. q When the mode selector switch is changed from the “testing mode” to “another mode”, if the crusher clearance saved previous time is different from the current crusher clearance, the machine monitor saves the current crusher clearance. 1)

30. Function for lock cylinder slip record [11] The machine monitor records the information about the past slip of the crusher lock cylinder (service meter reading). q The machine monitor records the slips up to 10 times. After recording 10 times, the machine monitor discards the data in order from the oldest one and keeps the newest ones. q The total number of the recorded slips above 10 is counted and recorded up to 999.

Selection of menu Select “10 Crusher Clearance Record” in the initial display of Service Menu, and depress [ ] switch.

1)

2)

Information shown in display 1] Crusher clearance 2] Service meter reading at crusher clearance was saved

Selection of menu Select “11 Lock Cylinder Slip Record” in the initial display of Service Menu, and depress [ ] switch.

which

34



2)

SEN03153-00

Deletion of data [ ] + [1] o [2] o [3] (While pressing [ ], input numbers]

35


SEN03153-00

BR580JG-1 Mobile crusher Form No. SEN03153-00

© 2007 KOMATSU All Rights Reserved Printed in Japan 06-07 (01)

36 CLASS REF ONLY PDF PAGE 64 of 64

Manual Komatsu Cod Errores

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