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KOMATSU BR480RG-1 SERVICE REPAIR MANUAL (SN:1001 & UP) KOMATSU BR480RG 1 – PDF DOWNLOAD
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- KOMATSU BR480RG-1 SERVICE REPAIR MANUAL
- SERIAL NUMBER:1001 & UP
- PUBLICATION NUMBER:SEBM027901
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Description
KOMATSU BR480RG-1 SERVICE REPAIR MANUAL (SN:1001 & UP) KOMATSU BR480RG 1
KOMATSU BR480RG-1 SERVICE REPAIR MANUAL (SN:1001 & UP) KOMATSU BR480RG 1 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU BR480RG-1 SERVICE REPAIR MANUAL (SN:1001 & UP) KOMATSU BR480RG 1
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
- STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. - TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. - MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. - OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
KOMATSU BR480RG-1 SERVICE REPAIR MANUAL (SN:1001 & UP) KOMATSU BR480RG 1
MAIN MENU.................................................................................................................................... 0 COVER........................................................................................................................................ 1 CONTENTS..................................................................................................................................... 2 LIST OF REVISED PAGES........................................................................................................................ 3 SAFETY....................................................................................................................................... 6 FOREWARD..................................................................................................................................... 8 01 GENERAL................................................................................................................................... 26 SPECIFICATION DRAWING.................................................................................................................... 27 SPECIFICATIONS........................................................................................................................... 28 WEIGHT TABLE............................................................................................................................. 31 FUEL, COOLANT AND LUBRICANTS............................................................................................................. 32 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD.............................................................................................. 34 ENGINE MOUNT AND DAMPER.................................................................................................................. 35 RADIATOR, OIL, AND AFTERCOOLER........................................................................................................... 37 POWER TRAIN.............................................................................................................................. 38 DRIVE SYSTEM OF EACH DEVICE.............................................................................................................. 39 FINAL DRIVE.............................................................................................................................. 41 TRACK FRAME AND RECOIL SPRING............................................................................................................ 43 IDLER.................................................................................................................................... 45 CARRIER ROLLER........................................................................................................................... 47 TRACK ROLLER............................................................................................................................. 48 TRACK SHOE............................................................................................................................... 49 HYDRAULIC EQUIPMENT LAYOUT DRAWING....................................................................................................... 53 HYDRAULIC TANK AND FILTER................................................................................................................ 54 HYDRAULIC PUMP........................................................................................................................... 55 MAIN CONTROL VALVE....................................................................................................................... 75 SELF-REDUCING PRESSURE VALVE............................................................................................................. 81 CLSS..................................................................................................................................... 86 CRUSHER MOTOR............................................................................................................................102 GRIZZLY FEEDER MOTOR.....................................................................................................................103 TRAVEL MOTOR.............................................................................................................................105 TRAVEL PPC VALVE.........................................................................................................................114 TRAVEL JUNTION VALVE.....................................................................................................................118 SOLENOID VALVES..........................................................................................................................121 8-EPC VALVE..............................................................................................................................124 ENGINE CONTROL SYSTEM....................................................................................................................131 MONITOR SYSTEM...........................................................................................................................139 WORK EQUIPMENT MONITOR SYSTEM............................................................................................................151 DISPLAY ON SCREEN IN WORKING MODE........................................................................................................152 DISPLAY ON SCREEN WHEN MACHINE STOPS ABNORMALLY..........................................................................................153 PROXIMITY SWITCH.........................................................................................................................155 IMPACT CRUSHER...........................................................................................................................159 IMPACT PLATE ADJUSTMENT MACHINERY........................................................................................................160 20 TESTING AND ADJUSTING.....................................................................................................................162 STANDARD VALUE TABLE.....................................................................................................................163 STANDARD VALUE TABLE FOR ENGINE......................................................................................................163 STANDARD VALUE TABLE FOR CHASSIS.....................................................................................................164 TESTING AND ADJUSTING....................................................................................................................170 SERVICE TOOLS TABLE..................................................................................................................171 MEASURING ENGINE SPEED...............................................................................................................172 MEASURING EXHAUST COLOR..............................................................................................................173 ADJUSTING VALVE CLEARANCE............................................................................................................174 MEASURING COMPRESSION PRESSURE.......................................................................................................175 MEASURING BLOW-BY PRESSURE...........................................................................................................176 FUEL INJECTION TIMING................................................................................................................177 MEASURING ENGINE OIL PRESSURE........................................................................................................179 TESTING AND ADJUSTING FAN BELT TENSION...............................................................................................180 ADJUSTING ENGINE SPEED SENSOR........................................................................................................180 MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE).......................................................................................181 INSPECTING AND ADJUSTING LEVER STROKE OF GOVERNOR MOTOR..............................................................................182 DIODE INSPECTION PROCEDURE...........................................................................................................183 TESTING AND ADJUSTING WORK EQUIPMENT, TRAVEL CIRCUIT.................................................................................184 TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)........................................................186 TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PSITON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE............................188 INSPECTING SOLENOID VALVE OUTPUT PRESSURE............................................................................................192 TRAVEL DEVIATION.....................................................................................................................193 MEASURING OIL LEAKAGE................................................................................................................194 TESTING WEAR OF SPROCKET.............................................................................................................195 TESTING AND ADJUSTING TRACK SHOE TENSION.............................................................................................196 BLEEDING AIR.........................................................................................................................197 SPECIAL FUNCTION OF MULTI-MONITOR....................................................................................................200 INSPECTING INSIDE OF CRUSHER.........................................................................................................211 ADJUSTING CLEARANCE BETWEEN CRUSHER STRIKING BOARD AND COLLIDING BOARD...............................................................220 INSPECTING AND ADJUSTING CRUSHER DRIVE BELT TENSION..................................................................................225 PRIMARY BELT CONVEYOR................................................................................................................226 ADJUSTING PROXIMITY SWITCH...........................................................................................................227 ADJUSTING CRUSHER ROTATION SENSOR....................................................................................................228 ADJUSTING NUT RUNNER ROTATION SENSOR.................................................................................................228 REFERENCE (RADIO CONTROLLER SUPPORT POINT)...........................................................................................229 TROUBLESHOOTING..........................................................................................................................230 POINTS TO REMEMBER WHEN TROUBLESHOOTING..............................................................................................231 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................................232 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.....................................................................................233 CHECKS BEFORE TROUBLESHOOTING........................................................................................................241 CLASSIFICATION AND STEPS FOR TROUBLESHOOTING.........................................................................................244 PHENOMENA THAT LOOK LIKE FAILURES AND TROUBLESHOOTING NO.............................................................................245 EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM...............................................................................248 DISPLAY METHOD AND SPECIAL FUNCTION OF MONITORING PANEL..............................................................................253 CONTENTS OF TROUBLESHOOTING..........................................................................................................261 MONITOR PANEL USER CODES AND ERROR CODES LIST........................................................................................264 FAILURE HISTORY FUNCTION OF MULTI-MONITOR PANEL......................................................................................265 MULTI-MONITOR PANEL ERROR CODES AND FAILURE CODES LIST...............................................................................266 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...........................................................................................268 T-ADAPTER TABLE......................................................................................................................290 TYPES AND LOCATIONS OF CONNECTORS....................................................................................................294 CONNECTOR ARRANGEMENT DRAWING (1/11).................................................................................................301 CONNECTOR ARRANGEMENT DRAWING (2/11).............................................................................................303 CONNECTOR ARRANGEMENT DRAWING (3/11).............................................................................................305 CONNECTOR ARRANGEMENT DRAWING (4/11).............................................................................................307 CONNECTOR ARRANGEMENT DRAWING (5/11).............................................................................................309 CONNECTOR ARRANGEMENT DRAWING (6/11).............................................................................................311 CONNECTOR ARRANGEMENT DRAWING (7/11).............................................................................................313 CONNECTOR ARRANGEMENT DRAWING (8/11).............................................................................................315 CONNECTOR ARRANGEMENT DRAWING (9/11).............................................................................................317 CONNECTOR ARRANGEMENT DRAWING (10/11)............................................................................................319 CONNECTOR ARRANGEMENT DRAWING (11/11)............................................................................................321 TROUBLESHOOTING OF ENGINE THROTTLE (GOVERNOR) AND PUMP CONTROLLER SYSTEM (E MODE)....................................................324 ELECTRICAL CIRCUIT DIAGRAM FOR E MODE............................................................................................325 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...................................................................................329 ERROR CODE [E101] (ABNORMALITY IN ERROR HISTORY DATA) [E102] (ABNORMALITY IN CLOCK DATA).........................................331 ERROR CODE [E102] (ABNORMALITY IN CLOCK DATA)....................................................................................331 ERROR CODE [E103] (SHORT CIRCUIT IN BUZZER OUTPUT OR SHORT CIRCUIT WITH POWER SOURCE IN BUZZER DRIVE WIRING HARNESS).............332 ERROR CODE [E104] (CLOGGING OF AIR CLEANER IS DISPLAYED).........................................................................333 ERROR CODE [E106] (LOWERING OF HI ENGINE OIL PRESSURE IS DISPLAYED)..............................................................333 ERROR CODE [E108] (105 C OF ENGINE COOLANT TEMPERATURE IS DISPLAYED).............................................................333 ERROR CODE [E204] (SHORT CIRCUIT IN TRAVEL RIGHT REVERSE SOLENOID SYSTEM)........................................................335 ERROR CODE [E205] (SHORT CIRCUIT IN TRAVEL LEFT REVERSE SOLENOID SYSTEM).........................................................337 ERROR CODE [E206] (SHORT CIRCUIT IN TRAVEL RIGHT FORWARD SOLENOID SYSTEM)........................................................339 ERROR CODE [E208] (SHORT CIRCUIT IN INPUT CIRCUIT)...............................................................................341 ERROR CODE [E214] (DISCONNECTION IN TRAVEL RIGHT REVERSE SOLENOID SYSTEM)........................................................345 ERROR CODE [E215] (DISCONNECTION IN TRAVEL LEFT REVERSE SOLENOID SYSTEM).........................................................347 ERROR CODE [E216] (DISCONNECTION IN TRAVEL RIGHT FORWARD SOLENOID SYSTEM)........................................................349 ERROR CODE [E217] (ERROR IN MODEL SELECTION INPUT)...............................................................................351 ERROR CODE [E218] (NETWORK RESPONSE OVERTIME)....................................................................................353 ERROR CODE [E224] (ABNORMAILTY IN F PUMP PRESSURE SENSORS SYSTEM)................................................................356 ERROR CODE [E225] (ABNORMALITY IN R PUMP PRESSURE SENSOR SYSTEM).................................................................357 ERROR CODE [E226] (ABNORMALITY IN PRESSURE SENSOR POWER SUPPLY)..................................................................358 ERROR CODE [E227] (ABNORMALITY IN ENGINE SPEED SENSOR)...........................................................................359 ERROR CODE [E232] (SHORT CIRCUIT IN F PUMP TVC SOLENOID SYSTEM)..................................................................361 ERROR CODE [E233] (DISCONNECTION IN F PUMP TVC SOLENOID SYSTEM)..................................................................363 ERROR CODE [E236] (SHORT CIRCUIT IN R PUMP TVC SOLENOID SYSTEM)..................................................................365 ERROR CODE [E237] (DISCONNECTION IN R PUMP TVC SOLENOID SYSTEM)..................................................................367 ERROR CODE [E302] (SHORT CIRCUIT IN TRAVEL LEFT FORWARD SOLENOID SYSTEM).........................................................369 ERROR CODE [E303] (DISCONNECTION IN TRAVEL LEFT FORWARD SOLENOID SYSTEM).........................................................371 ERROR CODE [E306] (ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED)....................................................373 ERROR CODE [E308] (ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED)....................................................374 ERROR CODE [E315] (SHORT CIRCUIT IN BATTERY RELAY OUTPUT SYSTEM).................................................................375 ERROR CODE [E316] (STEP-OUT OF MOTOR IS DISPLAYED)...............................................................................377 ERROR CODE [E317] (DISCONNECTION IN GOVERNOR MOTOR DRIVE SYSTEM IS DISPLAYED)....................................................378 ERROR CODE [E318] (SHORT CIRCUIT IN GOVERNOR MOTOR DRIVE SYSTEM IS DISPLAYED)....................................................379 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)........................................................................................380 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...................................................................................381 E-1 ABNORMALITY IN ENGINE THROTTLE AND PUMP CONTROLLER POWER SUPPLY SYSTEM (CONTROLLER LED IS TURNED OFF)........................382 E-2 ENGINE DOES NOT START........................................................................................................383 E-3 IRREGULAR ENGINE SPEED.......................................................................................................385 E-4 ENGINE DOES NOT STOP.........................................................................................................389 E-5 WHEN STARTING SWITCH IS TURNED ON, ALL MONITOR PANEL SEGMENTS DO NO LIGHT UP FOR 3 SECONDS...................................391 E-6 WHEN 3-SECOND SELF-CHECK IS FINISHED AFTER STARTING SWITCH IS TURNED ON, ANY MONITOR PANEL SEGMENT DOES NOT GO OFF...........392 E-7 WHEN STARTING SWITCH IS TURNED ON, LIGHTING ITEMS OF MONITOR PANEL ARE DIFFERENT FROM MACHINE (MODEL)........................392 E-8 WHEN STARTING SWITCH IS TURNED ON (BEFORE ENGINE IS STARTED), BASIC CHECK ITEMS FLASH........................................393 E-9 ENGINE PRE-HEATING MONITOR LAMP LIGHTS UP WHILE ENGINE PRE-HEATER IS NOT TURNED ON...........................................396 E-10 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH............................................397 E-11 WHEN STARTING SWITCH IS TURNED ON (BEFORE ENGINE IS STARTED), CAUTION ITEMS/EMERGENCY STOP ITEMS FLASH (BATTERY AND ENGI....400 E-12 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS/EMERGENCY STOP ITEMS FLASH (PERFORM THIS TROUBLES....403 E-13 WHEN STARTING SWITCH IS TURNED ON (BEFORE ENGINE IS STARTED), BUZZER DOES NOT SOUND FOR 1 SECOND BUZZER DOES NOT SOUND W....407 E-14 BUZZER SOUNDS WHILE MONITOR IS NOT DISPLAYING ANY ABNORMALITY...............................................................408 E-15 NIGHT LIGHT OF MONITOR PANEL DOES NOT LIGHT UP (LCD IS NORMAL)..............................................................409 E-16 COOLANT TEMPERATURE GAUGE DOES NOT RISE.....................................................................................410 E-17 COOLANT TEMPERATURE GAUGE DOES NOT DISPLAY (IT DOES NOT DISPLAY ANY LEVEL DURING OPERATION).................................411 E-18 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL.......................................................................................412 E-19 FUEL LEVEL GAUGE DOES NOT DISPLAY...........................................................................................413 E-20 WHEN MODE SELECTOR SWITCH IS TURNED ON (WORK/INSPECTION), TRAVEL LOCK MONITOR DOES NOT LIGHT UP.............................414 E-21 FUEL LEVEL SENSOR IS DEFECTIVE..............................................................................................416 E-22 COOLANT TEMPERATURE SENSOR IS DEFECTIVE.....................................................................................416 E-23 ENGINE OIL LEVEL SENSOR IS DEFECTIVE........................................................................................416 E-24 COOLANT LEVEL SENSOR IS DEFECTIVE...........................................................................................417 E-25 HYDRAULIC OIL LEVEL SENSOR IS DEFECTIVE.....................................................................................417 TROUBLESHOOTING OF WORK EQUIPMENT CONTROLLER SYSTEM (W MODE).........................................................................418 PRECAUTIONS FOR TROUBLESHOOTING WORK EQUIPMENT CONTROLLER SYSTEM.................................................................420 ELECTRICAL DIAGRAM FOR W MODE....................................................................................................421 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...................................................................................425 FAILURE CODE [7RF1KA] OR ERROR CODE [E201] (DISCONNECTION IN PRIMARY CONVEYOR FORWARD OPERATION EPC SOLENOID VALVE)..............427 FAILURE CODE [7RF1KB] OR ERROR CODE [E202] (SHORT CIRCUIT IN PRIMARY CONVEYOR NORMAL ROTATION EPC SOLENOID VALVE)................428 FAILURE CODE [7RF2KA] OR ERROR CODE [E203] (DISCONNECTION IN CRUSHER NORMAL ROTATION EPC SOLENOID VALVE) ........................429 FAILURE CODE [7RF2KB] OR ERROR CODE [E204] (SHORT CIRCUIT IN CRUSHER NORMAL ROTATION EPC SOLENOID VALVE) ........................430 FAILURE CODE [7RF3KA] OR ERROR CODE [E205] (DISCONNECTION IN CRUSHER REVERSE ROTATION EPC SOLENOID VALVE)........................431 FAILURE CODE [7RF3KB] OR ERROR CODE [E206] (SHORT CIRCUIT IN CRUSHER REVERSE ROTATION EPC SOLENOID VALVE)........................432 FAILURE CODE [7RF4KA] OR ERROR CODE [E207] (DISCONNECTION IN FEEDER NORMAL ROTATION EPC SOLENOID VALVE)..........................433 FAILURE CODE [7RF4KB] OR ERROR CODE [E208] (SHORT CIRCUIT IN FEEDER NORMAL ROTATION EPC SOLENOID VALVE)..........................434 FAILURE CODE [7RF5KA] OR ERROR CODE [E209] (DISCONNECTION IN F-LS CONTROL EPC SOLENOID VALVE)....................................435 FAILURE CODE [7RF5KB] OR ERROR CODE [E210] (SHORT CIRCUIT IN F-LS CONTROL EPC SOLENOID VALVE)....................................436 FAILURE CODE [7RF6KA] OR ERROR CODE [E211] (DISCONNECTION IN R-LS CONTROL EPC SOLENOID VALVE)....................................437 FAILURE CODE [7RF6KB] OR ERROR CODE [E212] (SHORT CIRCUIT IN R-LS CONTROL EPC SOLENOID VALVE)....................................438 FAILURE CODE [7RF7KA] OR ERROR CODE [E213] (DISCONNECTION IN ACCESSORY 1 DRIVE EPC SOLENOID VALVE)...............................439 FAILURE CODE [7RF7KB] OR ERROR CODE [E214] (SHORT CIRCUIT IN ACCESSORY 1 DRIVE EPC SOLENOID VALVE)...............................440 FAILURE CODE [7RF8KA] OR ERROR CODE [E215] (DISCONNECTION IN ACCESSORY 2 DRIVE EPC SOLENOID VALVE)...............................441 FAILURE CODE [7RF8KB] OR ERROR CODE [E216] (SHORT CIRCUIT IN ACCESSORY 2 DRIVE EPC SOLENOID VALVE)...............................442 FAILURE CODE [7RF9KA] OR ERROR CODE [E217] (DISCONNECTION IN CRUSHER SPEED SELECTION (HI/LO) ON/OFF SOLENOID VALVE)..............443 FAILURE CODE [7RF9KB] OR ERROR CODE [E218] (SHORT CIRCUIT IN CRUSHER SPEED SELECTION (HI/LO) ON/OFF SOLENOID VALVE)..............445 FAILURE CODE [7RFAKB] OR ERROR CODE [E220] (SHORT CIRCUIT IN ENGINE STOP RELAY (ACC CUT RELAY)...................................447 FAILURE CODE [7RFBKA] OR ERROR CODE [E221] (DISCONNECTION IN SIDE CONVEYOR OPERATION ON/OFF SOLENOID VALVE)......................449 FAILURE CODE [7RFBKB] OR ERROR CODE [E222] (SHORT CIRCUIT IN SIDE CONVEYOR OPERATION ON/OFF SOLENOID VALVE)......................451 FAILURE CODE [7RFCKA] OR ERROR CODE [E223] (DISCONNECTION IN MAGNETIC SEPARATOR OPERATION ON/OFF SOLENOID VALVE).................453 FAILURE CODE [7RFCKB] OR ERROR CODE [E224] (SHORT CIRCUIT IN MAGNETIC SEPARATOR OPERATION ON/OFF SOLENOID VALVE).................455 FAILURE CODE [7RFDKA] OR ERROR CODE [E225] (DISCONNECTION IN NO.1 IMPACT PLATE LIFTING ON/OFF SOLENOID VALVE)....................457 FAILURE CODE [7RFDKB] OR ERROR CODE [E226] (SHORT CIRCUIT IN NO.1 IMPACT PLATE LIFTING ON/OFF SOLENOID VALVE)....................459 FAILURE CODE [7RFEKA] OR ERROR CODE [E227] (DISCONNECTION IN NO.1 IMPACT PLATE LOWERING ON/OFF SOLENOID VALVE)...................461 FAILURE CODE [7RFEKB] OR ERROR CODE [E228] (SHORT CIRCUIT IN NO.1 IMPACT PLATE LOWERING ON/OFF SOLENOID VALVE)...................463 FAILURE CODE [7RFFKA] OR ERROR CODE [E229] (DISCONNECTION IN NO.2 IMPACT PLATE LIFTING ON/OFF SOLENOID VALVE)....................465 FAILURE CODE [7RFFKB] OR ERROR CODE [E230] (SHORT CIRCUIT IN NO.2 IMPACT PLATE LIFTING ON/OFF SOLENOID VALVE)....................467 FAILURE CODE [7RFGKA] OR ERROR CODE [E231] (DISCONNECTION IN NO.2 IMPACT PLATE LOWERING ON/OFF SOLENOID VALVE)...................469 FAILURE CODE [7RFGKB] OR ERROR CODE [E232] (SHORT CIRCUIT IN NO.2 IMPACT PLATE LOWERING ON/OFF SOLENOID VALVE)...................471 FAILURE CODE [D162KB] OR ERROR CODE [E233] (SHORT CIRCUIT IN HORN RELAY).........................................................473 FAILURE CODE [DUB0KB] OR ERROR CODE [E234] (SHORT CIRCUIT IN REVOLVING WARNING LAMP SSR).........................................477 FAILURE CODE [7R96KA] OR ERROR CODE [E300] (DISCONNECTION IN EMERGENCY STOP SWITCH)..............................................478 FAILURE CODE [DDA6KA] OR ERROR CODE [E301] (DISCONNECTION IN ENGINE STOP SWITCH).................................................481 FAILURE CODE [7RC1KB] OR ERROR CODE [E302] (SHORT CIRCUIT IN PRIMARY CONVEYOR ON SWITCH) ........................................483 FAILURE CODE [7RC1KA] OR ERROR CODE [E303] (DISCONNECTION IN PRIMARY CONVEYOR OFF SWITCH)........................................484 FAILURE CODE [7RE1KB] OR ERROR CODE [E304] (SHORT CIRCUIT IN CRUSHER ON SWITCH)..................................................485 FAILURE CODE [7RE1KA] OR ERROR CODE [E305] (DISCONNECTION IN CRUSHER OFF SWITCH).................................................487 FAILURE CODE [7RE3KB] OR ERROR CODE [E306] (SHORT CIRCUIT IN CRUSHER MANUAL NORMAL ROTATION SWITCH)..............................489 FAILURE CODE [7RE4KB] OR ERROR CODE [E307] (SHORT CIRCUIT IN CRUSHER MANUAL REVERSE ROTATION SWITCH).............................490 FAILURE CODE [7RE5KB] OR ERROR CODE [E308] (SHORT CIRCUIT IN FEEDER MANUAL OPERATION SWITCH).....................................491 FAILURE CODE [7RE6KB] OR ERROR CODE [E309] (SHORT CIRCUIT IN SIDE CONVEYOR ON SWITCH)............................................492 FAILURE CODE [7RE7KA] OR ERROR CODE [E310] (DISCONNECTION IN SIDE CONVEYOR OFF SWITCH)...........................................493 FAILURE CODE [7RE8KB] OR ERROR CODE [E311] (SHORT CIRCUIT IN MAGNETIC SEPARATOR ON SWITCH).......................................494 FAILURE CODE [7RE9KA] OR ERROR CODE [E312] (DISCONNECTION IN MAGNETIC SEPARATOR OFF SWITCH)......................................495 FAILURE CODE [7REAKB] OR ERROR CODE [E313] (SHORT CIRCUIT IN ACCESSORY INPUT CIRCUIT 1)..........................................496 FAILURE CODE [7REBKX] OR ERROR CODE [E314] (ABNORMALITY IN CRUSHER SPEED CONTROL DIAL)...........................................499 FAILURE CODE [7RECKX] OR ERROR CODE [E315] (ABNORMALITY IN FEEDER SPEED CONTROL DIAL)............................................501 FAILURE CODE [7REDKX] OR ERROR CODE [E316] (ABNORMALITY IN PRIMARY CONVEYOR PRESSURE SENSOR).....................................503 FAILURE CODE [7REEKX] OR ERROR CODE [E317] (ABNORMALITY IN SIDE CONVEYOR PRESSURE SENSOR)........................................505 FAILURE CODE [7REFKX] OR ERROR CODE [E318] (ABNORMALITY IN CRUSHER PRESSURE SENSOR)..............................................507 FAILURE CODE [DB6SKR] OR ERROR CODE [E319] (DISCONNECTION IN S-NET SIGNAL LINE)..................................................509 FAILURE CODE [7REGKA] OR ERROR CODE [E320] (DISCONNECTION IN CRUSHER SPEED SENSOR)...............................................512 FAILURE CODE [DB79KZ] OR ERROR CODE [E321] (DISCONNECTION/SHORT CIRCUIT/ABNORMAL INPUT IN MODEL SELECTION SIGNAL)................513 FAILURE CODE [7REHKA] OR ERROR CODE [E322] (SHORT CIRCUIT IN ACCESSORY INPUT CIRCUIT 2)..........................................514 TROUBLESHOOTING FOR WORK EQUIPMENT ELECTRICAL SYSTEM (W MODE)........................................................................516 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...................................................................................517 W-1 ANY WORK EQUIPMENT DOES NOT OPERATE SINCE JUST AFTER ENGINE IS STARTED ABNORMALITY IN WORK EQUIPMENT CONTROLLER POWER SUP....518 W-2 CASING COVER OPENING WARNING IS DISPLAYED ABNORMALLY.........................................................................519 W-3 MAINTENANCE DOOR OPENING WARNING IS DISPLAYED ABNORMALLY.....................................................................521 W-4 DETECTION OF OVERLOAD ON NO. 1 IMPACT PLATE IS DISPLAYED ABNORMALLY..........................................................523 W-5 DETECTION OF OVERLOAD ON NO. 2 IMPACT PLATE IS DISPLAYED ABNORMALLY..........................................................525 W-6 OVERLOAD OR ABNORMAL LOAD ON MAGNETIC SEPARATOR IS DISPLAYED ABNORMALLY......................................................527 W-7 WHEN FEEDER TEMPORARY STOP/RESTART SWITCH IS PRESSED, FEEDER DOES NOT STOP...................................................529 W-8 WHEN FEEDER TEMPORARY STOP/RESTART SWITCH IS PRESSED, FEEDER IS NOT RESET....................................................533 W-9 CRUSHER CASING CANNOT BE OPENED AND CLOSED...................................................................................535 W-10 LEFT-HAND HOPPER CANNOT BE MOVED UP AND DOWN................................................................................538 W-11 RIGHT-HAND HOPPER CANNOT BE MOVED UP AND DOWN...............................................................................541 W-12 SIDE CONVEYOR CANNOT BE MOVED UP AND DOWN...................................................................................544 W-13 MAGNETIC SEPARATOR CANNOT BE ROTATED IN REVERSE.............................................................................547 W-14 CONVEYOR CANNOT BE ROTATED IN REVERSE.......................................................................................550 W-15 MACHINE CANNOT TRAVEL.......................................................................................................553 W-16 WHEN CRUSHER SPEED SELECTION SWITCH IS CHANGED, SPEED DOES NOT CHANGE.......................................................556 W-17 GAP SETTING MACHINERY STOPS ABNORMALLY AND GAP CANNOT BE SET................................................................558 W-18 GAP CANNOT BE SET...........................................................................................................561 W-19 IMPACT PLATE ADJUSTMENT MODE CANNOT BE CHANGED..............................................................................563 W-20 HORN DOES NOT SOUND.........................................................................................................565 W-21 MULTI-MONITOR PANEL DOES NOT LIGHT UP AT ALL................................................................................570 W-22 MULTI-MONITOR PANEL DOES NOT LIGHT UP PARTLY................................................................................572 W-23 WHEN SWITCH OF MULTI-MONITOR PANEL IS OPERATED, ANY ITEM IS NOT DISPLAYED...................................................572 W-24 WATER SPRINKLER DOES NOT OPERATE (IF EQUIPPED)..............................................................................573 W-25 LARGE-CAPACITY WATER SPRINKLER DOES NOT OPERATE (IF EQUIPPED)...............................................................576 W-26 CRANE CANNOT BE TURNED ON (IF EQUIPPED).....................................................................................579 W-27 SIDE CONVEYOR DOES NOT OPERATE (IF EQUIPPED)................................................................................581 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)..........................................................................584 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...................................................................................585 H-1 SPEED OR POWER OF ALL WORK EQUIPMENT AND TRAVEL IS LOW.......................................................................586 H-2 ENGINE SPEED LOWERS LARGELY OR ENGINE STALLS.................................................................................587 H-3 WORK EQUIPMENT AND TRAVEL MOTORS DO NOT OPERATE AT ALL.......................................................................588 H-4 ABNORMAL SOUND COMES OUT FROM AROUND HYDRAULIC PUMP..........................................................................588 H-5 FINE CONTROLLABILITY OR RESPONSE IS LOW......................................................................................589 H-6 CONVEYOR DOES NOT OPERATE....................................................................................................589 H-7 SPEED OR POWER OF CONVEYOR IS LOW............................................................................................590 H-8 CRUSHER DOES NOT OPERATE.....................................................................................................590 H-9 SPEED OR POWER OF CRUSHER IS LOW.............................................................................................591 H-10 FEEDER SPEED IS LOW.........................................................................................................591 H-11 SPEED OR POWER OF SIDE CONVEYOR IS LOW......................................................................................592 H-12 SPEED OF MAGNETIC SEPARATOR BELT IS LOW.....................................................................................592 H-13 WHEN RADIO-CONTROL TRAVEL SWITCH IS PRESSED, MACHINE DOES NOT TRAVEL (RIGHT FORWARD/REVERSE, LEFT FORWARD/REVERSE)..........593 H-14 TRAVEL SPEED IS LOW.........................................................................................................594 H-15 MACHINE DEVIATES DURING TRAVEL..............................................................................................595 H-16 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW........................................................................596 H-17 MACHINE DOES NOT TRAVEL (ONLY ONE SIDE).....................................................................................596 90 OTHERS....................................................................................................................................598 HYDRAULIC CIRCUIT DIAGRAM................................................................................................................599 ELECTRICAL CIRCUIT DIAGRAM (1/3).........................................................................................................601 ELECTRICAL CIRCUIT DIAGRAM (2/3).........................................................................................................603 ELECTRICAL CIRCUIT DIAGRAM (3/3).........................................................................................................605
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