KOMATSU 730E TROLLEY DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30474, A30512 – A30517, & A30546 – A30549)
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KOMATSU 730E TROLLEY DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30474, A30512 – A30517, & A30546 – A30549)
- This manual is written for use by the operator and/or the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel must read and understand the materials in this manual before operating the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings, and cautions must be understood and followed when operating or repairing the truck.
- A product identification plate is located on the frame in front of the right side front wheel and designates the truck model number, product identification number (vehicle serial number), and maximum GVW (Gross Vehicle Weight) rating.
- The Komatsu truck model designation consists of three numbers and one letter (i.e. 930E).
The three numbers represent the basic truck model.
The letter E, when present, designates an electrical wheel motor drive system. - The product identification number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.
- The GVW is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight (GVW). GVW is total weight: the empty vehicle weight + the fuel and lubricants + the payload.
TABLE OF CONTENTS:
KOMATSU 730E TROLLEY DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30474, A30512 – A30517, & A30546 – A30549)
COVER ................................................................................................................................................................................................................................................................... 1 INTRODUCTION ............................................................................................................................................................................................................................................................ 5 FORWARD ............................................................................................................................................................................................................................................................. 5 TRUCK MODEL ILLUSTRATION ............................................................................................................................................................................................................................................ 6 ABOUT THIS MANUAL ................................................................................................................................................................................................................................................... 7 ALERTS PAGE ......................................................................................................................................................................................................................................................... 8 TABLE OF CONTENTS ....................................................................................................................................................................................................................................................... 9 TORQUE TABLES AND CONVERSION CHARTS...................................................................................................................................................................................................................................... 19 EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values................................................................................................................................................................................................. 20 STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts................................................................................................................................................................................................ 20 STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws................................................................................................................................................................................................... 21 STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws............................................................................................................................................................................................................... 22 GENERAL SAFETY........................................................................................................................................................................................................................................................... 29 PERSONAL SAFETY...................................................................................................................................................................................................................................................... 29 Safety Rules..................................................................................................................................................................................................................................................... 29 Truck Safety Features............................................................................................................................................................................................................................................ 29 Clothing And Personal Items...................................................................................................................................................................................................................................... 29 Unauthorized Modification........................................................................................................................................................................................................................................ 29 Leaving The Operator’s Seat...................................................................................................................................................................................................................................... 29 Mounting And Dismounting......................................................................................................................................................................................................................................... 29 Fire Extinguishers And First Aid Kits............................................................................................................................................................................................................................ 30 Precautions For High Temperature Fluids.......................................................................................................................................................................................................................... 30 Asbestos Dust Hazard Prevention.................................................................................................................................................................................................................................. 30 Fire Prevention For Fuel And Oil................................................................................................................................................................................................................................. 30 ROPS Precautions................................................................................................................................................................................................................................................. 31 Preventing Injury From Work Equipment............................................................................................................................................................................................................................ 31 Precautions For Optional Attachments............................................................................................................................................................................................................................. 31 Precautions When Starting The Machine............................................................................................................................................................................................................................ 31 PRECAUTIONS FOR TRUCK OPERATION...................................................................................................................................................................................................................................... 32 Safety Is Thinking Ahead......................................................................................................................................................................................................................................... 32 Safety At The Work Site.......................................................................................................................................................................................................................................... 32 Fire Prevention.................................................................................................................................................................................................................................................. 32 Preparing For Operation.......................................................................................................................................................................................................................................... 32 Ventilation For Enclosed Areas................................................................................................................................................................................................................................... 32 Mirrors, Windows, And Lights..................................................................................................................................................................................................................................... 32 In The Operator’s Cab - Before Starting The Engine............................................................................................................................................................................................................... 33 Seat Belts....................................................................................................................................................................................................................................................... 33 OPERATING THE MACHINE................................................................................................................................................................................................................................................ 33 Starting The Engine.............................................................................................................................................................................................................................................. 33 Truck Operation - General........................................................................................................................................................................................................................................ 33 Traveling In The Truck........................................................................................................................................................................................................................................... 34 Precautions When Traveling In Reverse............................................................................................................................................................................................................................ 34 Traveling On Slopes.............................................................................................................................................................................................................................................. 34 Ensuring Good Visibility......................................................................................................................................................................................................................................... 35 Operating On Snow................................................................................................................................................................................................................................................ 35 Avoid Damage To The Dump Body.................................................................................................................................................................................................................................... 35 Driving Near High-Voltage Cables................................................................................................................................................................................................................................. 35 When Loading The Truck........................................................................................................................................................................................................................................... 35 When Dumping..................................................................................................................................................................................................................................................... 35 Working On Loose Ground.......................................................................................................................................................................................................................................... 35 Parking The Machine.............................................................................................................................................................................................................................................. 36 TOWING............................................................................................................................................................................................................................................................... 36 WORKING NEAR BATTERIES............................................................................................................................................................................................................................................... 36 Battery Hazard Prevention........................................................................................................................................................................................................................................ 36 Jump-Starting With Booster Cables................................................................................................................................................................................................................................ 37 Jump Starting With Receptacles................................................................................................................................................................................................................................... 37 PRECAUTIONS FOR MAINTENANCE.......................................................................................................................................................................................................................................... 38 BEFORE PERFORMING MAINTENANCE.................................................................................................................................................................................................................................... 38 Stopping The Engine Before Service........................................................................................................................................................................................................................... 38 Warning Tag.................................................................................................................................................................................................................................................. 38 Proper Tools................................................................................................................................................................................................................................................. 38 Securing The Dump Body....................................................................................................................................................................................................................................... 38 DURING MAINTENANCE............................................................................................................................................................................................................................................... 39 Personnel.................................................................................................................................................................................................................................................... 39 Attachments.................................................................................................................................................................................................................................................. 39 Working Under The Machine.................................................................................................................................................................................................................................... 39 Keeping The Machine Clean.................................................................................................................................................................................................................................... 39 Rules To Follow When Adding Fuel Or Oil...................................................................................................................................................................................................................... 39 Radiator Coolant Level....................................................................................................................................................................................................................................... 39 Use Of Lighting.............................................................................................................................................................................................................................................. 39 Precautions With The Battery................................................................................................................................................................................................................................. 40 Handling High-Pressure Hoses................................................................................................................................................................................................................................. 40 Precautions With High-Pressure Oil........................................................................................................................................................................................................................... 40 Maintenance Near High Temperatures And High Pressures........................................................................................................................................................................................................ 40 Rotating Fan And Belts....................................................................................................................................................................................................................................... 40 Waste Materials.............................................................................................................................................................................................................................................. 40 Use of Tie-Off Anchor During Maintenance and Repair.......................................................................................................................................................................................................... 40 TIRES............................................................................................................................................................................................................................................................ 41 Handling Tires............................................................................................................................................................................................................................................... 41 Tire Maintenance............................................................................................................................................................................................................................................. 42 Storing Tires After Removal.................................................................................................................................................................................................................................. 42 ADDITIONAL JOB SITE RULES............................................................................................................................................................................................................................................ 43 WHEN REPAIRS ARE NECESSARY........................................................................................................................................................................................................................................... 44 WARNINGS AND CAUTIONS.................................................................................................................................................................................................................................................... 47 OPERATING INSTRUCTIONS................................................................................................................................................................................................................................................... 55 PREPARING FOR OPERATION.............................................................................................................................................................................................................................................. 55 SAFETY IS THINKING talkAHEAD......................................................................................................................................................................................................................................... 55 WALK AROUND INSPECTION............................................................................................................................................................................................................................................... 55 ENGINE START-UP...................................................................................................................................................................................................................................................... 59 AFTER ENGINE HAS STARTED............................................................................................................................................................................................................................................. 60 EMERGENCY STEERING SYSTEM............................................................................................................................................................................................................................................ 61 Operation........................................................................................................................................................................................................................................................ 61 Pre-Operation Testing............................................................................................................................................................................................................................................ 61 Additional Guidelines............................................................................................................................................................................................................................................ 62 MACHINE OPERATION SAFETY PRECAUTIONS................................................................................................................................................................................................................................. 62 LOADING.............................................................................................................................................................................................................................................................. 63 HAULING.............................................................................................................................................................................................................................................................. 63 PASSING.............................................................................................................................................................................................................................................................. 64 DUMPING.............................................................................................................................................................................................................................................................. 64 To Raise The Dump Body:.......................................................................................................................................................................................................................................... 64 To Lower The Dump Body: (When dumping over a berm or into a crusher):............................................................................................................................................................................................ 65 To Lower The Dump Body (When dumping on flat ground):............................................................................................................................................................................................................ 65 SAFE PARKING PROCEDURES.............................................................................................................................................................................................................................................. 66 ENGINE SHUTDOWN PROCEDURE............................................................................................................................................................................................................................................ 66 DELAYED ENGINE SHUTDOWN PROCEDURE.................................................................................................................................................................................................................................... 67 SUDDEN LOSS OF POWER................................................................................................................................................................................................................................................. 67 DISABLED TRUCK OPERATION............................................................................................................................................................................................................................................. 68 GENERAL.............................................................................................................................................................................................................................................................. 68 STEERING AND BRAKE SYSTEM............................................................................................................................................................................................................................................ 68 Components Required.............................................................................................................................................................................................................................................. 68 Hookup........................................................................................................................................................................................................................................................... 69 DISABLED TRUCK DUMPING PROCEDURE..................................................................................................................................................................................................................................... 70 Hookup........................................................................................................................................................................................................................................................... 70 Raising the Body................................................................................................................................................................................................................................................. 70 Lowering the Body................................................................................................................................................................................................................................................ 70 TOWING............................................................................................................................................................................................................................................................... 71 TROLLEY OPERATING INSTRUCTIONS....................................................................................................................................................................................................................................... 71 AFTER THE ENGINE HAS STARTED..................................................................................................................................................................................................................................... 71 OPERATING IN DIESEL MODE......................................................................................................................................................................................................................................... 72 OPERATING IN TROLLEY LINE MODE................................................................................................................................................................................................................................... 72 GETTING ON LINE.................................................................................................................................................................................................................................................. 73 Operating On Trolley......................................................................................................................................................................................................................................... 74 GETTING OFF LINE................................................................................................................................................................................................................................................. 76 LINE STATUS SIGNALS.............................................................................................................................................................................................................................................. 76 LINE STATUS SIGNAL MARKINGS...................................................................................................................................................................................................................................... 77 TRAFFIC CONSIDERATION FOR TROLLEY LINE OPERATION................................................................................................................................................................................................................. 77 APPROACHING SLOW MOVING VEHICLES IN A TROLLEY ASSISTED TRUCK..................................................................................................................................................................................................... 77 OPERATING SLOW MOVING VEHICLES ON TROLLEY ASSIST RAMPS........................................................................................................................................................................................................... 78 TRUCK FAILURE WHILE ON TROLLEY................................................................................................................................................................................................................................... 78 OPERATOR CAB AND CONTROLS................................................................................................................................................................................................................................................ 79 STEERING WHEEL AND CONTROLS.......................................................................................................................................................................................................................................... 80 Horn Button...................................................................................................................................................................................................................................................... 80 Multi-Function Turn Signal Switch................................................................................................................................................................................................................................ 80 SERVICE BRAKE PEDAL.................................................................................................................................................................................................................................................. 81 DYNAMIC RETARDER PEDAL............................................................................................................................................................................................................................................... 81 Optional - Dual Function / Single Pedal.......................................................................................................................................................................................................................... 81 THROTTLE PEDAL....................................................................................................................................................................................................................................................... 81 HEATER / AIR CONDITIONER VENTS....................................................................................................................................................................................................................................... 81 HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS.................................................................................................................................................................................................................... 82 Defroster Vent Control Switch.................................................................................................................................................................................................................................... 82 Heat Control Switch.............................................................................................................................................................................................................................................. 82 Temperature Control Knob......................................................................................................................................................................................................................................... 82 Fan Control Knob................................................................................................................................................................................................................................................. 82 Heater / Air Conditioner Selector Switch......................................................................................................................................................................................................................... 82 Heater / Air Conditioner Vents................................................................................................................................................................................................................................... 82 CENTER CONSOLE ...................................................................................................................................................................................................................................................... 84 INSTRUMENT PANEL..................................................................................................................................................................................................................................................... 83 GRADE / SPEED WARNING CHART.......................................................................................................................................................................................................................................... 83 RADIO SPEAKERS....................................................................................................................................................................................................................................................... 83 WARNING ALARM BUZZER................................................................................................................................................................................................................................................. 83 CAB RADIO............................................................................................................................................................................................................................................................ 83 WARNING LIGHTS DIMMER CONTROL........................................................................................................................................................................................................................................ 83 WARNING INDICATOR LIGHT PANEL........................................................................................................................................................................................................................................ 83 AIR CLEANER VACUUM GAUGES............................................................................................................................................................................................................................................ 83 WINDSHIELD WIPERS.................................................................................................................................................................................................................................................... 83 Data Storage Button.............................................................................................................................................................................................................................................. 84 Data storage button (1, Figure 32-7) is for use by qualified maintenance personnel to record in memory a “snap-shot” of the Statex III drive system.............................................................................................................. 84 Trolley Master Control Lever..................................................................................................................................................................................................................................... 84 F-N-R Selector Switch............................................................................................................................................................................................................................................ 84 Hoist Control Lever.............................................................................................................................................................................................................................................. 85 Retard Speed Control (RSC) Adjust Dial........................................................................................................................................................................................................................... 85 Retard Speed Control (RSC) Off / On Switch....................................................................................................................................................................................................................... 86 Override Switch.................................................................................................................................................................................................................................................. 86 Engine Shutdown Switch........................................................................................................................................................................................................................................... 86 Window Control Switches.......................................................................................................................................................................................................................................... 86 Ash Tray......................................................................................................................................................................................................................................................... 86 Lighter.......................................................................................................................................................................................................................................................... 86 Passenger Seat................................................................................................................................................................................................................................................... 86 Download Ports and Connectors.................................................................................................................................................................................................................................... 87 Engine Diagnostics Port.......................................................................................................................................................................................................................................... 87 Engine diagnostics port (12) is used by qualified personnel to access engine diagnostic information.............................................................................................................................................................. 87 Komatsu Engine CENSE Connector................................................................................................................................................................................................................................... 87 CENSE Connector (13) is a three-pin connector is for use by qualified personnel to access engine diagnostic information for the CENSE system. Refer to the engine manufacturer’s service publications for troubleshooting information............................ 87 Statex III Downlad Port.......................................................................................................................................................................................................................................... 87 Modular Mining Port (Optional)................................................................................................................................................................................................................................... 87 Modular mining port location is used if the optional Modular Mining System is installed on the truck............................................................................................................................................................. 87 Centry™ Fuel Control............................................................................................................................................................................................................................................. 87 Diagnostics Download Port (Optional)............................................................................................................................................................................................................................. 87 Payload Meter.................................................................................................................................................................................................................................................... 87 Payload Meter Download Connector................................................................................................................................................................................................................................. 87 OPERATOR SEAT........................................................................................................................................................................................................................................................ 88 INSTRUMENT PANEL AND INDICATOR LIGHTS................................................................................................................................................................................................................................ 89 CONTROL SYMBOLS.................................................................................................................................................................................................................................................. 89 INSTRUMENT PANEL................................................................................................................................................................................................................................................. 89 PANEL GAUGES, INDICATORS, AND CONTROLS............................................................................................................................................................................................................................... 90 Key Switch....................................................................................................................................................................................................................................................... 90 Engine Shut down Switch with Timer Delay......................................................................................................................................................................................................................... 91 Fog Lights (Optional)............................................................................................................................................................................................................................................ 91 Ladder Light Switch.............................................................................................................................................................................................................................................. 91 Manual Backup Switch............................................................................................................................................................................................................................................. 91 Manual backup switch (5) allows the backup lights to be turned on providing added visibility and safety when the selector switch is not in the REV position. When the switch is pressed toward the on position, the manual backup light indicator (B4, Ove....... 91 Panel Illumination Lights........................................................................................................................................................................................................................................ 91 Cab Air Conditioner / Heater Vents............................................................................................................................................................................................................................... 91 Engine Cold Weather Starting Aid (Optional)...................................................................................................................................................................................................................... 92 Rotating Beacon Light Switch (Optional).......................................................................................................................................................................................................................... 92 Heated Mirror Switch (Optional).................................................................................................................................................................................................................................. 92 Leakage Test Switch (Trolley Option Only)........................................................................................................................................................................................................................ 92 Wheel Brake Lock Control......................................................................................................................................................................................................................................... 92 Parking Brake Control............................................................................................................................................................................................................................................ 92 Tachometer....................................................................................................................................................................................................................................................... 93 Right Turn Signal Indicator...................................................................................................................................................................................................................................... 93 High Beam Indicator.............................................................................................................................................................................................................................................. 93 Left Turn Signal Indicator....................................................................................................................................................................................................................................... 93 Speedometer / Payload Meter Display.............................................................................................................................................................................................................................. 93 Voltmeter........................................................................................................................................................................................................................................................ 93 Engine Oil Pressure Gauge........................................................................................................................................................................................................................................ 93 Water Temperature Gauge.......................................................................................................................................................................................................................................... 93 Fuel Gauge....................................................................................................................................................................................................................................................... 93 Blank (Not Used)................................................................................................................................................................................................................................................. 93 Hourmeter........................................................................................................................................................................................................................................................ 93 Blank (Not Used)................................................................................................................................................................................................................................................. 93 Blank (Not Used)................................................................................................................................................................................................................................................. 93 Light Switch..................................................................................................................................................................................................................................................... 94 Panel Light Dimmer............................................................................................................................................................................................................................................... 94 Payload Meter Switch............................................................................................................................................................................................................................................. 94 OVERHEAD STATUS / WARNING INDICATOR LIGHT PANEL...................................................................................................................................................................................................................... 95 INDICATOR LIGHT SYMBOLS.............................................................................................................................................................................................................................................. 96 TROLLEY INDICATOR LIGHTS.........................................................................................................................................................................................................................................100 Hazard Warning Light Switch......................................................................................................................................................................................................................................102 Lamp Test Switch / Centry™ Diagnostic Test Switch................................................................................................................................................................................................................102 CENTRY™ FUEL SYSTEM DIAGNOSTICS......................................................................................................................................................................................................................................103 DETERMINING FAULT CODES..........................................................................................................................................................................................................................................103 EXITING THE DIAGNOSTICS MODE.....................................................................................................................................................................................................................................104 LUBRICATION AND SERVICE..................................................................................................................................................................................................................................................105 GENERAL INFORMATION..................................................................................................................................................................................................................................................105 HYDRAULIC TANK SERVICE...............................................................................................................................................................................................................................................105 Adding Oil.......................................................................................................................................................................................................................................................105 COOLING SYSTEM SERVICE...............................................................................................................................................................................................................................................106 Radiator Filling Procedure.......................................................................................................................................................................................................................................106 Coolant Specifications...........................................................................................................................................................................................................................................106 Unacceptable Practices...........................................................................................................................................................................................................................................106 WHEEL MOTOR SERVICE..................................................................................................................................................................................................................................................106 RESERVE ENGINE OIL SYSTEM (IF EQUIPPED)..............................................................................................................................................................................................................................107 Reserve Oil Tank Filling Procedure (Remote fill).................................................................................................................................................................................................................107 Inline Screen....................................................................................................................................................................................................................................................107 QUICK FILL SERVICE CENTER............................................................................................................................................................................................................................................108 LEFT-HAND FUEL RECEIVER - OPTIONAL (WIGGINS QUICK FILL)..............................................................................................................................................................................................................109 LUBRICATION CHART....................................................................................................................................................................................................................................................110 10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS..........................................................................................................................................................................................................................111 10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS (Continued)..............................................................................................................................................................................................................112 50 HOUR LUBRICATION AND MAINTENANCE CHECKS...........................................................................................................................................................................................................................113 100 HOUR LUBRICATION AND MAINTENANCE CHECKS..........................................................................................................................................................................................................................113 250 HOUR LUBRICATION AND MAINTENANCE CHECKS..........................................................................................................................................................................................................................114 250 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)..............................................................................................................................................................................................................115 500 HOUR LUBRICATION AND MAINTENANCE CHECKS..........................................................................................................................................................................................................................116 500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)..............................................................................................................................................................................................................117 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS.........................................................................................................................................................................................................................118 1500 HOUR LUBRICATION AND MAINTENANCE CHECKS.........................................................................................................................................................................................................................119 2500 HOUR LUBRICATION AND MAINTENANCE CHECKS.........................................................................................................................................................................................................................119 5000 HOUR LUBRICATION AND MAINTENANCE CHECKS.........................................................................................................................................................................................................................120 10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS.......................................................................................................................................................................................................................121 AUTOMATIC LUBRICATION SYSTEM.............................................................................................................................................................................................................................................123 GENERAL DESCRIPTION..................................................................................................................................................................................................................................................123 SYSTEM COMPONENTS....................................................................................................................................................................................................................................................124 Filter Assembly..................................................................................................................................................................................................................................................124 Hydraulic Motor and Grease Pump..................................................................................................................................................................................................................................124 Reservoir........................................................................................................................................................................................................................................................124 Fixed Pressure Reducing Valve....................................................................................................................................................................................................................................124 Flow Control Valve...............................................................................................................................................................................................................................................124 Solenoid Valve...................................................................................................................................................................................................................................................126 Vent Valve.......................................................................................................................................................................................................................................................126 Time Delay Module................................................................................................................................................................................................................................................126 Pump Cutoff Pressure Switch......................................................................................................................................................................................................................................126 Unloader Valve...................................................................................................................................................................................................................................................126 Pressure Switch..................................................................................................................................................................................................................................................126 Pressure Gauge...................................................................................................................................................................................................................................................126 Manual Override Button...........................................................................................................................................................................................................................................126 Injectors........................................................................................................................................................................................................................................................126 SYSTEM OPERATION.....................................................................................................................................................................................................................................................128 Normal Operation.................................................................................................................................................................................................................................................128 Pressure Failure Detection Circuits..............................................................................................................................................................................................................................129 GENERAL INSTRUCTIONS.................................................................................................................................................................................................................................................130 LUBRICANT REQUIRED FOR SYSTEM....................................................................................................................................................................................................................................130 SYSTEM PRIMING...................................................................................................................................................................................................................................................130 LUBRICANT PUMP...................................................................................................................................................................................................................................................130 Pump Housing Oil Level.......................................................................................................................................................................................................................................130 Pump Pressure Control........................................................................................................................................................................................................................................130 FILTER AND RESERVOIR.........................................................................................................................................................................................................................................131 Filter Assembly Element......................................................................................................................................................................................................................................131 INJECTORS (SL-1 Series H)........................................................................................................................................................................................................................................132 Injector Specifications......................................................................................................................................................................................................................................132 Injector Adjustment..........................................................................................................................................................................................................................................132 INJECTOR OPERATION...............................................................................................................................................................................................................................................133 SYSTEM CHECKOUT..................................................................................................................................................................................................................................................134 Lubrication Cycle Timer Check................................................................................................................................................................................................................................134 Lubrication Cycle Timer Adjustment...........................................................................................................................................................................................................................135 PREVENTIVE MAINTENANCE INSPECTION................................................................................................................................................................................................................................135 10 Hour Lubrication System Inspection........................................................................................................................................................................................................................135 250 Hour Inspection..........................................................................................................................................................................................................................................135 1000 Hour Inspection.........................................................................................................................................................................................................................................136 SYSTEM TROUBLESHOOTING CHART.....................................................................................................................................................................................................................................137 MAJOR COMPONENT DESCRIPTION..............................................................................................................................................................................................................................................139 SPECIFICATIONS.......................................................................................................................................................................................................................................................141 PAYLOAD METER III........................................................................................................................................................................................................................................................143 PAYLOAD METER III....................................................................................................................................................................................................................................................147 Introduction.....................................................................................................................................................................................................................................................147 Data Summary.................................................................................................................................................................................................................................................147 Data Gathering...............................................................................................................................................................................................................................................147 COMPONENT DESCRIPTION............................................................................................................................................................................................................................................148 System Diagram...............................................................................................................................................................................................................................................148 Suspension Pressure Sensors..................................................................................................................................................................................................................................148 Inclinometer.................................................................................................................................................................................................................................................148 Operator Display.............................................................................................................................................................................................................................................148 Payload Operator Switch......................................................................................................................................................................................................................................149 Speed Input..................................................................................................................................................................................................................................................149 Body-Up Switch...............................................................................................................................................................................................................................................149 Brake Lock Switch............................................................................................................................................................................................................................................149 Payload Meter................................................................................................................................................................................................................................................149 Communications Ports.........................................................................................................................................................................................................................................149 Key Switch Input.............................................................................................................................................................................................................................................150 Payload Meter Power..........................................................................................................................................................................................................................................150 Load Lights..................................................................................................................................................................................................................................................150 Wiring and Termination.......................................................................................................................................................................................................................................151 TCI Outputs..................................................................................................................................................................................................................................................151 OPERATOR’S DISPLAY AND SWITCH....................................................................................................................................................................................................................................152 Reading the Speedometer......................................................................................................................................................................................................................................152 Reading the Load Display.....................................................................................................................................................................................................................................152 Using the Operator ID........................................................................................................................................................................................................................................152 Using the Load and Ton Counter...............................................................................................................................................................................................................................152 Total Ton Counter............................................................................................................................................................................................................................................152 Total Load Counter...........................................................................................................................................................................................................................................153 Clearing the Counters........................................................................................................................................................................................................................................153 Viewing Live Sensor Data.....................................................................................................................................................................................................................................153 Other Display Messages.......................................................................................................................................................................................................................................153 PAYLOAD OPERATION AND CALCULATION................................................................................................................................................................................................................................154 Description of Haul Cycle States.............................................................................................................................................................................................................................154 Haul Cycle Description.......................................................................................................................................................................................................................................154 Load Calculation.............................................................................................................................................................................................................................................155 Carry Back...................................................................................................................................................................................................................................................155 Measurement Accuracy.........................................................................................................................................................................................................................................155 SOURCES FOR PAYLOAD ERROR........................................................................................................................................................................................................................................155 Payload Error................................................................................................................................................................................................................................................155 Loading Conditions...........................................................................................................................................................................................................................................156 Pressure Sensors.............................................................................................................................................................................................................................................156 Swingloads...................................................................................................................................................................................................................................................156 Speed and Distance...........................................................................................................................................................................................................................................156 HAUL CYCLE DATA..................................................................................................................................................................................................................................................156 Haul Cycle Data..............................................................................................................................................................................................................................................157 Haul Cycle Warning Flags.....................................................................................................................................................................................................................................158 M: Haul Cycle Too Long.......................................................................................................................................................................................................................................159 N: Sensor Input Error........................................................................................................................................................................................................................................159 Frame Torque Data............................................................................................................................................................................................................................................159 Sprung Weight Data...........................................................................................................................................................................................................................................159 Maximum Speed Data...........................................................................................................................................................................................................................................159 Alarm Records................................................................................................................................................................................................................................................159 Fault Code Data..............................................................................................................................................................................................................................................160 PC SOFTWARE OVERVIEW.............................................................................................................................................................................................................................................161 PC Overview..................................................................................................................................................................................................................................................161 System Configuration.........................................................................................................................................................................................................................................161 Installing the PLM III Software..............................................................................................................................................................................................................................161 DOWNLOADING DATA.................................................................................................................................................................................................................................................162 PLM III SYSTEM CONFIGURATION.....................................................................................................................................................................................................................................163 Starting Communications......................................................................................................................................................................................................................................163 Displayed Payload Units......................................................................................................................................................................................................................................163 Time Units...................................................................................................................................................................................................................................................163 Connection Menu..............................................................................................................................................................................................................................................163 Connecting to the Payload Meter..............................................................................................................................................................................................................................164 Configure the Payload Meter..................................................................................................................................................................................................................................164 Setting the Date and Time....................................................................................................................................................................................................................................164 Setting the Truck Type.......................................................................................................................................................................................................................................165 Setting the Gauge Display Units..............................................................................................................................................................................................................................165 Setting the Frame Serial Number..............................................................................................................................................................................................................................165 Setting the Truck Number.....................................................................................................................................................................................................................................165 Setting the Komatsu Distributor..............................................................................................................................................................................................................................165 Setting the Komatsu Customer.................................................................................................................................................................................................................................165 Clean Truck Tare.............................................................................................................................................................................................................................................166 Inclinometer Calibration.....................................................................................................................................................................................................................................166 DATA ANALYSIS....................................................................................................................................................................................................................................................167 Creating a Query.............................................................................................................................................................................................................................................167 Sorting on Truck Unit Number.................................................................................................................................................................................................................................167 Sorting on Truck Type........................................................................................................................................................................................................................................167 Sorting on Date Range........................................................................................................................................................................................................................................168 Sorting on Time Range........................................................................................................................................................................................................................................168 Payload Detail Screen........................................................................................................................................................................................................................................169 Creating Reports.............................................................................................................................................................................................................................................169 Summary - One Page Report....................................................................................................................................................................................................................................170 Detailed - Multi-Page Report.................................................................................................................................................................................................................................170 Creating Graphs..............................................................................................................................................................................................................................................171 Exporting Data...............................................................................................................................................................................................................................................171 CSV Export...................................................................................................................................................................................................................................................171 Compressed...................................................................................................................................................................................................................................................173 Importing Data...............................................................................................................................................................................................................................................173 Deleting Haul Cycle Records..................................................................................................................................................................................................................................173 Viewing Alarms...............................................................................................................................................................................................................................................174 Deleting Alarm Records.......................................................................................................................................................................................................................................174 RADIO / CASSETTE PLAYER..................................................................................................................................................................................................................................................175 GENERAL RECEIVER FUNCTIONS...........................................................................................................................................................................................................................................175 Turning The Power On And Off.....................................................................................................................................................................................................................................175 Display..........................................................................................................................................................................................................................................................175 Setting The Default Display......................................................................................................................................................................................................................................175 Adjusting Display Brightness.....................................................................................................................................................................................................................................175 SETTING THE TIME.....................................................................................................................................................................................................................................................176 OPERATING THE RADIO..................................................................................................................................................................................................................................................176 BAND.............................................................................................................................................................................................................................................................176 TUNE/SEEK........................................................................................................................................................................................................................................................176 Manual Tuning....................................................................................................................................................................................................................................................176 SEEK Mode........................................................................................................................................................................................................................................................176 SCAN.............................................................................................................................................................................................................................................................176 AUTO.............................................................................................................................................................................................................................................................176 ADJUSTING THE RECEIVER SETTINGS......................................................................................................................................................................................................................................177 PROGRAMMING PRESET STATIONS..........................................................................................................................................................................................................................................177 OPERATION OF THE WEATHERBAND (U.S.)..................................................................................................................................................................................................................................177 SATELLITE RADIO......................................................................................................................................................................................................................................................178 Operating Satellite Radio........................................................................................................................................................................................................................................178 Program Type Search (PTY)........................................................................................................................................................................................................................................178 CASSETTE PLAYER......................................................................................................................................................................................................................................................179 Playing A Cassette...............................................................................................................................................................................................................................................179 Cassette Functions...............................................................................................................................................................................................................................................179 Programmable Eject Default.......................................................................................................................................................................................................................................179 Bad Tape Detect..................................................................................................................................................................................................................................................180 Cleaning The Cassette Player.....................................................................................................................................................................................................................................180
PLEASE NOTE:
⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.