Komatsu BR380JG-1 Operator Panel Operation PDF

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EXPLANATION OF COMPONENTS OPERATION
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) Check before starting screen (4) Normal travel screen

(2) Maintenance warning screen (5) Normal inspection screen
(3) Normal operation screen
A Basic check items D Meter display portion

B Caution items E Monitor switch
C Emergency stop items
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CLASS REF ONLY PDF PAGE 1 of 64
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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) When in travel mode (c) When in inspection mode

(b) When in operation 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) When in operation mode (3) When in inspection mode

(2) When in travel 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 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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WHEN AN ABNORMALITY OCCURS DURING OPERATIONS
(1) When in operation mode (3) When in inspection mode

(2) When in travel 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

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(3) Maintenance time monitor

A(2) Engine oil level 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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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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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(4) Engine coolant temperature monitor

B(2) Fuel level monitor B(5) Hydraulic oil temperature monitor
B(3) Air cleaner clogging 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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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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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(4) Emergency stop monitor

C(2) Hydraulic oil temperature monitor C(5) Engine stop monitor
C(3) Engine oil pressure monitor
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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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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 When At low
normal abnormal temperature
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 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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METER DISPLAY PORTION
(A) Normal operation screen (C) Normal inspection screen

(B) Normal travel screen
(1) Engine pre-heating monitor (6) Fuel gauge

(2) Operating mode monitor (7) Hydraulic oil temperature gauge
(3) Travel mode monitor (8) Service meter
(4) Inspection mode monitor (9) Crusher actual clearance monitor
(5) Engine coolant temperature gauge (10) 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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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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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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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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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 Operation

0 - 55 mm
Crushing operations impossible
(0 - 2.167 in)
55 - 100 mm
Only concrete crushing operations possible
(2.167 - 3.940 in)
100 - 200 mm
Crushing operations possible
(3.940 - 7.880 in)
More than 200 mm
Crushing operation is impossible
(More than 7.880 in)
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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.
Magnetic Muck discharge

Conveyor Crusher Feeder separator conveyor
(if equipped) (if equipped)
White lamp White lamp White lamp
Stop Transparent Transparent
lights up lights up lights up
Normal rotation White lamp White lamp White lamp
Transparent Transparent
drive lights up lights up lights up
Reverse rotation White lamp
- - - -
drive lights up
Red lamp Red lamp Red lamp
Overload - -
flashed flashed flashed
Red lamp Red lamp Red lamp Red lamp
Abnormal load -
lights up lights up lights up lights up
Crusher abnormal Red lamp Red lamp
- - -
load flashed flashed
Green lamp
Reducing overload - - - -
flashed
Crusher operation
prohibited period Red lamp
- - - -
after adjusting flashed
clearance
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MONITOR SWITCH UNIT
(1) Return switch (9) Crusher manual reverse rotation switch

(2) UP and numeral input (+) switch (10) Crusher manual normal rotation switch
(3) DOWN and numeral input (-) switch (11) Conveyor manual normal rotation switch
(4) Input confirmation switch (12) Conveyor manual reverse rotation switch
(5) Liquid-crystal monitor adjustment switch (13) Buzzer cancel switch
(6) Maintenance screen selector switch (14) Crusher speed setting screen selector switch
(7) Crusher clearance increase switch (15) Feeder speed setting screen selector switch
(8) Crusher clearance decrease switch (16) 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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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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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 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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Maintenance display items are as follows:
Initial
Monitor
Maintenance items setting
No.
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
Replace corrosion resister
06 -
(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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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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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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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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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.
direction (A).
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 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.
direction (A).
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
3 - 34
SEN03153-00
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
BR580JG-1 1

SEN03153-00 30 Testing and adjusting
Special functions of machine monitor 1
[1]: Figure input switch 1 [ ]: Decimal point input switch

[2]: Figure input switch 2 [ ]: Return switch
[3]: Figure input switch 3 [E]: Upward move switch
[4]: Figure input switch 4 [R]: Downward move switch
[5]: Figure input switch 5 [ ]: Input confirmation switch
[6]: Figure input switch 6
2 BR580JG-1

30 Testing and adjusting SEN03153-00
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 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 Function of abnor- Electrical systems
21
3 Check before starting function mality record [02] 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 Function of default Language
25
8 Function of testing mode [06] Unit
9 Function of setting feeder speed Pump absorption torque
10 Function of setting crusher speed Adjustment of feeder speed
Adjustment of crusher speed
11 Function of setting crusher load and the other work equipments
Function of adjust- speed
26
ment [07]
Display's brightness and contrast adjusting func- Initialization of clearance poten-
12
tion 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
BR580JG-1 3

Operation of operator menu and display 3. Check before starting function

(outline) Check before starting screen is displayed for 2
seconds succeeding to display of KOMATSU
a This section introduces only the outline of the logo.
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.
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.
2. KOMATSU logo display screen

KOMATSU logo is displayed for 2 seconds as
a password is entered (as a password is speci-
fied) or the starting switch is turned ON.
4 BR580JG-1

5. Caution items display function 7. Function of working mode

Succeeding display of the check before start- If the working mode is selected with the mode
ing sc r een, an appl ic able cau tion mark selector switch of the main control box, the
appears pointing a check before starting item operator can check the operating condition of
on which a problem was found. 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.
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. 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 abnor-
mally high, the travel mode display screen
is selected forcibly.
BR580JG-1 5

9. Function of setting feeder speed 11. Function of setting crusher load

The operator can adjust the feeder speed with The operator can adjust the crusher load with
the feeder speed setting switch of the machine the crusher load setting switch of the machine
monitor. monitor.
A: Feeding speed is minimum A: Load is set to minimum.
B: Feeding speed is maximum B: Load is set to maximum.
10. Function of setting crusher speed 12. Display's brightness and contrast adjusting
The operator can adjust the crusher speed with function
t he cr us he r s pee d s et tin g s wi tc h o f t he The screen adjustment switches allow adjust-
machine monitor. ing the display brightness and contrast.
A: Speed is minimum
B: Speed is maximum
6 BR580JG-1

13. Check of maintenance information function 15. Caution generation display function
The maintenance switch allows checking If a caution is warned for a caution item, appli-
detailed information of the maintenance items cable symbol mark is displayed large for 2 sec-
(specified maintenance time and elapsed onds and then it remains on the screen in a
time). It also allows resetting after the mainte- smaller size until the trouble is eliminated.
nance.
a Setting and resetting of the maintenance
function as well as setting of the mainte-
nance time is done from the service menu.
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
14. Service meter display function order to alert the operator to take an appropri-
Display of the service meter alone becomes ate action.
available by operating the following switches a Operating any switch while an user code
after the starting switch is turned OFF. is on the screen, switch the failure code
q Switch operation: [ ] + [E] display screen (see Item 17).
(Simultaneous operation)
BR580JG-1 7

a User codes and actions requested to operator
User code Failure mode Action

Pump control malfunctions and have inspection carried out
E02 PC-EPC valve error
immediately.
Engine controller power source error
Engine controller drive system circuit
E10 Have inspection carried out immediately.
error
(engine stopped)
Engine controller system error Operate machine to a safe posture and have inspection car-
E11
(Output reduced to protect engine) ried out immediately.
Operate machine to a safe posture and have inspection car-
E14 Throttle system error
ried out immediately.
Engine sensor (coolant temperature, fuel
Operations are possible, but have inspection carried out
E15 temperature and oil pressure) system
immediately.
error
Network error
Operate machine to a safe posture and have inspection car-
E0E Pump controller solenoid power source
ried out immediately.
error
8 BR580JG-1

17. Failure code display function (3) Telephone number

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: ( )
E02
a The telephone mark and telephone num-

ber are displayed only when the telephone
number is registered to the machine moni-
B JZ 138 28
tor.
Registration, correction or deletion of a
a The screen display sequentially changes telephone number is done from the ser-
as shown below. vice menu.
a For detailed information of failure codes,
(1) Failure code see the “Failure code table”.
(2) Telephone symbol mark
BR580JG-1 9

Failure code table

User Failure Alarm Applicable History
Failure contents
code code buzzer equipment 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 BR580JG-1


Failure contents
— 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 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
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
BR580JG-1 11


Failure contents
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 system
E11 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 system
E02 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
12 BR580JG-1

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.
BR580JG-1 13

18. Function of monitoring emergency stop 19. Function for conveyor position display
1) Warning for turning emergency stop 1) Conveyor position display in operation
switch ON mode
When an emergency stop switch installed If the operation mode is selected with the
around the machine is depressed; mode selector switch of the main control
q The whole work equipment stops and box, the color of mode monitor (a)
the horn sounds. 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) 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 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.
14 BR580JG-1

Service menu operation and display 3) Displaying menu screen

The display is changed to the initial display of
Switching to service menu Service Menu program. Select an appropriate
a When using the service menu, switch the item from among the menu.
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.
No. Service menu

00 Return (Ends the service menu)
01 Monitoring
02 Abnormality record
03 Maintenance record
04 Maintenance mode change
2) Switch operation
Do the following switch operation. 05 Phone number entry
q Switch operation: 06 Default
[E] + [1] o [2] o [3] 07 Adjustment
(Enter the numbers while holding E down)
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.
BR580JG-1 15

20. Function of monitoring [01] q Select menu “99999” and press

The machine monitor monitors signals from the [ ] switch.
switch sensor actuators on various machine a When you have registered all the
parts. It allows displaying and checking the items that can be registered, the
monitored information through following opera- screen will be automatically switched
tions. to the monitoring information screen.
a Monitored information are transmitted
1) Menu selection via communication circuits. Thus the
Select “01 Monitoring” in the initial display number of selected items can impact
of Service Menu and depress [ ] switch. 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.
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: Selection
q [ ] switch: Registration
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.
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).
16 BR580JG-1

Monitoring items table

Unit (Initial setting ISO) Com-
Code
Monitoring item (Display on screen) ponent Remarks
No ISO meter inch charge
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
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. V V V MON
37200 Engine oil pressure sensor MPa kg/cm2 psi ENG
2
36400 Rail Pressure MPa kg/cm psi ENG
Indicated by absolute
37400 Ambient Pressure kPa kg/cm2 psi ENG value (Including
ambient pressure)
18500 Charge Temperature °C °C °F ENG
Indicated by absolute
36500 Boost Pressure kPa kg/cm2 psi ENG 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 MON
37201 Oil pressure sensor voltage V V V ENG
37401 Ambient Press Sens Volt V V V ENG
BR580JG-1 17


Code
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
Key Switch MON
Start MON
04500 Monitor input 1 Preheat ON•OFF MON
Light MON
Rad. Level MON
Air cleaner MON
04501 Monitor Input 2 Eng. Oil Level ON•OFF MON
Battery Charge MON
Conv. ON Sw. PUMP
Conv. OFF Sw. PUMP
Crusher ON Sw. PUMP
25000 Switch Input 0 ON•OFF
Crusher OFF Sw. PUMP
Feeder ON Sw. PUMP
Feeder OFF Sw. PUMP
R-Ctrl. Work Sw. PUMP
25001 Switch Input 1 R-Ctrl. Trv. Sw. ON•OFF PUMP
R-Ctrl. On Trv. PUMP
Mode Sel. Work PUMP
Mode Sel. Travel PUMP
25002 Switch Input 2 Crush. FWD/REV ON•OFF PUMP
Machine Select1 PUMP
Machine Select2 PUMP
Emergency Sw. PUMP
Engine Stop Sw. PUMP
1-touch start Sw PUMP
1-touch stop Sw. PUMP
Conv. Hi Sensor PUMP
Conv. Mi Sensor PUMP
MuckConv. Sen. PUMP
Overfeed Sensor PUMP
18 BR580JG-1


Code
Radio Sel. switch PUMP
TravelSpeed switch 1 PUMP
25005 Switch Input 5 TravelSpeed switch 2 ON•OFF PUMP
Clearance F-auto PUMP
Clearance Auto. PUMP
MuckConv.ON switch 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
Conveyor reverse solenoid PUMP
25500 Solenoid Valve Lock.Cyl. Unlock solenoid ON•OFF PUMP
Muck Conv. solenoid PUMP
Horn Relay PUMP
Becon Relay PUMP
Abno.Press Relay PUMP
25601 Relay Drive 0 ON•OFF
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 PUMP
20216 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
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.
BR580JG-1 19

21. Function of abnormality record [02] 3) Contents of display of electrical system

abnormality record information screen
The machine monitor records and classifies (1): Occurrence order of abnormalities
the past failure information as into the electri- fr o m l a t e s t o n e / To ta l n u m b e r o f
cal and mechanical failures. It allows display- records
ing and checking the information through the (2): Failure code (Equipment: 4 digits,
following operations. Phenomena: 2 digits)
1) Menu selection (3): Elapsed time on service meter from
Select “02 Abnormality Record” in the ini- the first occurrence
tial display of Service Menu and depress (4): Contents of trouble
[ ] switch. a See the operator menu “Failure
codes table”.
2) Sub menu selection

Select the sub menu from the abnormality 4) Contents of display of mechanical system
record menu screen and then press [ ] abnormality record information screen
switch. (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
20 BR580JG-1

5) Resetting electrical systems abnormality 2] From the reset screen, do the switch
record operation according to the screen
a Resetting abnormality record (dele- instructions.
tion) is possible only with the electri- a When a specific individual infor-
cal system. The abnormality record in mation alone is to be reset, be
the mechanical system cannot be sure to display the subject infor-
reset. mation on the screen using [E ]
a When resetting individual or all infor- switch or [R] switch.
mation in the abnormality record of a When resetting all information,
the electrical systems, implement the the information to be displayed
following procedure. on the screen can be any.
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.
BR580JG-1 21

22. Function of maintenance record [03] 23. Function of maintenance mode change [04]
The machine monitor records the maintenance Following procedure allows changing the cur-
information of the filters, oils, etc., which the rently set operating conditions of the mainte-
operator can display and check by the follow- nance display function.
ing operations. q Set function effective or ineffective
1) Menu selection q Change set replacement interval
Select “03 Maintenance Record” from the
initial display of Service Menu and then 1) Menu selection
depress [ ] switch. Select “04 Maintenance Mode Change”
from the Service Menu and then depress
[ ] switch.
2) Information to be displayed
q Oil and filter names
q Replacement time elapsed up to 2) Selection of item to be changed
present Select the item to be changed from the
q Time elapsed on service meter up to “Maintenance Mode Change” Selection
the last replacement Menu screen.
22 BR580JG-1

4) Description of individual setting items

Number Items of the maintenance mode change (1): Default value: The maintenance time
set in the monitor (recommended by
Return (End of change in the maintenance
00 the ma nufac turer an d c annot b e
mode)
changed).
01 Maintenance mode on/off (2): Set value: Denotes the maintenance
02 Engine oil change int. time that can be freely set. The main-
03 Engine oil filter change int. tenance mode operates based on this
time (the time can be increased or
04 Fuel main filter change int.
decreased in multiple of 50 hours by
05 Hyd oil filter change int. use of [E] and [R] switches).
06 Hyd tank breather change int. (3): Use (On): Maintenance display func-
07 Corrosion resistor change int. tion for this item is enabled.
(4): Not use (Off): Maintenance display
08 Damper case service int.
function for this item is disabled.
09 Final drive case oil change int. a The lower limit of this setting is 25
10 Feeder vibration oil change int. hours.
11 Crusher motor case oil change int.
12 Hydraulic oil change int.
13 Fuel pre-filter change int.
14 Initialize all items
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-related
items are turned effectual. (Irrespec-
tive of whether “On” or “Off” set for 5) Description of “Initialize all items”
individual items, this setting prevails) Select this menu and then press [ ]
q Not use (Off): The maintenance dis- switch to restore the default value for the
play function of all oils and filter- individually set information.
related items is disabled (prece-
dence is given to this setting over the
“On” or “Off” selected for an individual
items).
BR580JG-1 23

24. Function of phone number entry [05] 3) Entry and setting phone number
When the user code is displayed, following Following the method explained below,
procedure allows entering or correcting the entry a phone number in the “Phone Num-
phone numbers to be displayed alternately ber Entry” display. (Entry automatically
with the failure code. begins with a cursor at the left end)
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.
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 m ax . 1 2 di gi ts, bu t o mi t
unnecessary digits.
a When entered a wrong number,
2) Changing the display decimal point input switch
Select “Entry” next to change the display (Switch for setting crusher
to the “Phone Number Entry” display. speed) to return the cursor by
a Even if a Phone number is already one digit.
inputted, it is deleted if you switch the 2] Depress [ ] switch when all the num-
“Phone Number Entry” screen. bers 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 BR580JG-1

25. Function of default [06] 3) Language setting function

Following machine monitor- or machine- Service Menu allows switching the lan-
related settings are modifiable. Do necessary guage between Japanese and English.
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 initial screen and then press [ ]
switch.
a The default language of the machine

monitor 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
2) Selecting sub menu used in the monitoring function display of
Select the target sub menu of setting Service Menu.
change and then press [ ] switch. 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
BR580JG-1 25

26. Function of adjustment [07] q When the crusher maximum speed is

adjusted, adjust it by "06" (Hi idle
The operator can adjust various items related speed in working mode) (*1).
to the machine with the machine monitor.
1) Menu selection 3) Function for Pump Absorption Torque
Select “07 Adjustment” menu from the adjustment
Service Menu initial screen and then press The pump absorption torque can be
[ ] switch. adjusted within the range shown in the
table below.
2) Sub menu selection

Select the sub menu on which setting Adjust- Torque adjust- Adjust- Torque adjust-
change is to be done and then press [ ] ment ment value ment ment value
switch. value (kgm) 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) 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)
Number Adjustment of sub menu Max. speed 770 – 910
00 Return (Ends the adjustment) Min. speed 300 – 650
01 Pump absorption torque
02 Feeder speed adjustment
Crusher speed and other work equipments
03
(*1) adjustment
04 Clearance potentiometer initialization
05 Option register
06 Hi idle speed in working mode (*1)
q When the crusher minimum speed is

adjusted, adjust it by "03" (Crusher
speed and other work equipments
speed adjustment) (*1).
26 BR580JG-1

1] Move the cursor to the current to 1] Move the cursor to the current to
adjust with [ ] switch and [ ] switch adjust with [ ] switch and [ ] switch
and depress [ ] switch. and depress [ ] switch.
2] The adjusted current flashes and the 2] The adjusted current flashes and the
value input window is displayed. value input window is displayed.
3] Input a value with the numeral keys 3] Input a value with the numeral keys
and depress [ ] switch. and depress [ ] switch.
a If a value out of the proper range is a If a value out of the proper range is
input, the value before inputting is dis- input, the value before inputting is dis-
played again. 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) first, then
5) Crusher speed and other equipments adjust the other speeds.
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.
Input range
Item
(mA)
Other work equipments speed
10 – 1000
(LS-EPC solenoid current)
Min. speed Forward 250 – 600

(EPC current) Reverse 250 – 600
BR580JG-1 27

6) Function for clearance potentiometer ini- 7] Depress “1” (SET) on the clearance
tial adjustment potentiometer initialization screen.
When the tooth plate is replaced, initialize
the clearance potentiometer.
7) Function for option registration

1] Check that the display is in the ordi- Use/Disuse of the options of the machine
nary display mode. can be set.
2] Set mode selector switch (1) of the 1] On the option setting menu screen,
main control box in the testing mode move the cursor with the [E] switch
position. and [R] switch to an option to be
3] Set clearance adjustment selector adjusted and press the [ ] switch.
switch (2) of the main control box in Number Option registration menu
the manual mode position.
00 Return (Finish adjustment)
4] Rotate the crusher with crusher man-
ual forward switch (3) and reverse 01 Magnetic separator
switch (4) of the machine monitor to 02 Muck discharge conveyor
bring mark (B) of the flywheel to the 03 Overfeed sensor
center of adjustment range (A).
04 2nd conveyor
5] Depress crusher clearance closing
switch (5) of the machine monitor to 05 Travel lever
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.
28 BR580JG-1

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.
8) 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
BR580JG-1 29

27. Function of cylinder cut out operation [08]

The operator can perform the engine on cylin-
der 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) 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.
2) Selecting cylinder to be cut out

Press a switch corresponding to the cylin-
der 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 BR580JG-1

4) Engine speed holding function [Reference]: Using the holding function effectively
Pressing [E] switch while the engine The engine speed being displayed on the screen
operation on cylinder cut out screen is through the holding function remains on it until the
turned on holds the engine speed and its holding is cancelled. In other words, enabling or
speed is newly displayed in the lower disabling of the cylinder cut out mode does not
space. affect the display.
Pressing [ R] switch during holding can- Thus, when identifying a failed cylinder quicker, fol-
cels the holding function and deletes the lowing operation is effective.
display in the lower space.
a If the holding function is used, the (1) Run the engine from the normal operation
held speed is displayed in the lower mode (no cylinder cut out) and then hold the
space along with ( ) and the upper speed of that time.
space continuously displays the cur- (2) Specify the cylinder to be diagnosed as the cut
rent speed. out.
a The holding function is usable inde- (3) Run the engine under the same condition as
pendent of the currently set mode – that for (1). Then compare the engine speed at
the cylinder cut out or not. 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 com-
pare 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.
BR580JG-1 31

28. Function of no injection cranking [09] 3) As the checkup is over, following screen
No injection cranking of the engine is available appears.
from the machine monitor.
No injection cranking denotes stopping injec-
tion of fuel from the injector even if the engine
is run from the starting motor. This mode is
used, for instance, for measurement of com-
pressive pressure.
a This setting must be done after stopping
the engine.
1) Selecting menu
Select “09 No Injection Cranking” from the
Service Menu initial screen and press [ ]
switch.
4) Select “No Injection” and press [ ] switch.

“Under Preparation” will be displayed on
the screen.
a The letters “Under Preparation” are
displayed in red.
2) The initial screen for the no injection

cranking will appear.
a “Check Communication” will be dis-
played in red.
32 BR580JG-1

5) As the preparation for no injection crank- a If the no injection cranking function is

ing is completed, display of “Under Prepa- inadvertently selected while the
ration” is replaced with “After No engine is running, “Engine Running”
Injection”. will appear as No Injection in step 4)
a The letters “After No Injection” are is selected. This “Engine Running”
displayed in green. display remains on the screen even
6) From this state, crank the engine using after the engine is stopped. Restoring
the starting motor. the service menu screen alone
a Limit the cranking time to 20 seconds deletes the display.
to protect the starting motor.
7) 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.
8) Press “Return” when ending the no injec-
tion cranking.
BR580JG-1 33

29. Function for crusher clearance record [10] 30. Function for lock cylinder slip record [11]
The machine monitor records the information The machine monitor records the information
about the crusher clearance setting. about the past slip of the crusher lock cylinder
q The machine monitor records the informa- (service meter reading).
tion up to 10 times. After recording 10 q The machine monitor records the slips up
times, the machine monitor discards the to 10 times. After recording 10 times, the
data in order from the oldest one and machine monitor discards the data in
keeps the newest ones. order from the oldest one and keeps the
q When the mode selector switch is changed newest ones.
from the “testing mode” to “another mode”, q The total number of the recorded slips
if the crusher clearance saved previous above 10 is counted and recorded up to
time is different from the current crusher 999.
clearance, the machine monitor saves the
current crusher clearance.
1) Selection of menu
Select “10 Crusher Clearance Record” in
the initial display of Service Menu, and
depress [ ] switch.
1) Selection of menu
Select “11 Lock Cylinder Slip Record” in
the initial display of Service Menu, and
depress [ ] switch.
2) Information shown in display

1] Crusher clearance
2] Service meter reading at which
crusher clearance was saved
34 BR580JG-1

2) Deletion of data
[ ] + [1] o [2] o [3]
(While pressing [ ], input numbers]
BR580JG-1 35

SEN03153-00
BR580JG-1 Mobile crusher
Form No. SEN03153-00
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 06-07 (01)
36

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EXPLANATION OF COMPONENTS OPERATION

(1) Check before starting screen (4) Normal travel screen

A Basic check items D Meter display portion

EXPLANATION OF COMPONENTS OPERATION

MODE SELECTOR SWITCH

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

(a) When in travel mode (c) When in inspection mode

OPERATION EXPLANATION OF COMPONENTS

BASIC ACTUATION OF MACHINE MONITOR

WHEN THERE IS AN ABNORMALITY WHEN STARTING THE ENGINE

(1) When in operation mode (3) When in inspection mode

EXPLANATION OF COMPONENTS OPERATION

OPERATION EXPLANATION OF COMPONENTS

WHEN AN ABNORMALITY OCCURS DURING OPERATIONS

(1) When in operation mode (3) When in inspection mode

EXPLANATION OF COMPONENTS OPERATION

BASIC CHECK ITEMS

A(1) Radiator coolant level monitor A(3) Maintenance time monitor

RADIATOR COOLANT LEVEL MONITOR

OPERATION EXPLANATION OF COMPONENTS

ENGINE OIL LEVEL MONITOR

MAINTENANCE TIME MONITOR

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

EXPLANATION OF COMPONENTS OPERATION

B(1) Charge level monitor B(4) Engine coolant temperature monitor

CHARGE LEVEL MONITOR

OPERATION EXPLANATION OF COMPONENTS

FUEL LEVEL MONITOR

AIR CLEANER CLOGGING MONITOR

ENGINE COOLANT TEMPERATURE MONITOR

HYDRAULIC OIL TEMPERATURE MONITOR

EXPLANATION OF COMPONENTS OPERATION

EMERGENCY STOP ITEMS

C(1) Engine coolant temperature monitor C(4) Emergency stop monitor

OPERATION EXPLANATION OF COMPONENTS

ENGINE COOLANT TEMPERATURE MONITOR

HYDRAULIC OIL TEMPERATURE MONITOR

ENGINE OIL PRESSURE MONITOR

EXPLANATION OF COMPONENTS OPERATION

Color when monitor lights up

EMERGENCY STOP MONITOR

ENGINE STOP MONITOR

OPERATION EXPLANATION OF COMPONENTS

METER DISPLAY PORTION

(A) Normal operation screen (C) Normal inspection screen

(1) Engine pre-heating monitor (6) Fuel gauge

PILOT DISPLAY PORTION

ENGINE PRE-HEATING MONITOR

EXPLANATION OF COMPONENTS OPERATION

OPERATING MODE MONITOR

TRAVEL MODE MONITOR

INSPECTION MODE MONITOR

(a) A: Automatic mode

OPERATION EXPLANATION OF COMPONENTS

ENGINE COOLANT TEMPERATURE GAUGE

EXPLANATION OF COMPONENTS OPERATION

HYDRAULIC OIL TEMPERATURE GAUGE

OPERATION EXPLANATION OF COMPONENTS

CRUSHER ACTUAL CLEARANCE MONITOR

O.S.S. clearance Operation

EXPLANATION OF COMPONENTS OPERATION

OPERATING STATUS DISPLAY LAMP