Komatsu 730E Operation & Maintenance Manual
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Komatsu 730E Operation & Maintenance Manual

Dump truck
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CEAM024900
Operation & Maintenance
Manual
Trolley
DUMP TRUCK
A30489 & A30490
SERIAL NUMBERS
®

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Summary of Contents for Komatsu 730E

  • Page 1 CEAM024900 Operation & Maintenance Manual Trolley DUMP TRUCK A30489 & A30490 SERIAL NUMBERS ®...
  • Page 3 This material is proprietary to Komatsu America Corp (KAC), and is not to be reproduced, used, or disclosed except in accordance with written autho- rization from KAC. It is the policy of the Company to improve prod- ucts whenever it is possible and practical to do so.
  • Page 4 Komatsu is also aware of repair companies that will rework or modify an OEM part for reuse in critical systems. Komatsu does not generally authorize such repairs or modifications for the same reasons as noted above.

  • Page 5: Introduction

    (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.

  • Page 6: Truck Model Illustration

    Introduction - Section 10 OM1095 Page 10-2 TRUCK MODEL ILLUSTRATION KOMATSU MODEL 730E DUMP TRUCK WITH TROLLEY ASSIST...

  • Page 7: About This Manual

    The front cover of this manual includes a form number. This form number must be referenced when ordering addi- tional copies of this manual, or for any other correspondence regarding the coverage in this manual. Direct all inquiries to: Komatsu America Corp. Datakom, Peoria Technical Publications P.O. Box 240...

  • Page 8: Alerts Page

    Introduction - Section 10 OM1095 Page 10-4 ALERTS PAGE This ALERT symbol is used in this manual, along with the signal words CAUTION, DANGER, and WARNING, to alert the reader to hazards arising from improper operat- ing and maintenance practices. DANGER identifies a specific potential hazard WHICH WILL RESULT in either INJURY OR DEATH...

  • Page 9: Table Of Contents

    OM1095 Introduction - Section 10 Page 10-5 TABLE OF CONTENTS INTRODUCTION ..............10-1 FOREWORD .

  • Page 10: Table Of Contents

    Introduction - Section 10 OM1095 Page 10-6 TABLE OF CONTENTS (cont.) Ensuring Good Visibility ............20-7 Operating On Snow .
  • Page 11 OM1095 Introduction - Section 10 Page 10-7 TABLE OF CONTENTS (cont.) WARNINGS AND CAUTIONS ............22-1 OPERATING INSTRUCTIONS .
  • Page 12 Introduction - Section 10 OM1095 Page 10-8 TABLE OF CONTENTS (cont.) TRAFFIC CONSIDERATION FOR TROLLEY LINE OPERATION ..... . . 30-23 APPROACHING SLOW MOVING VEHICLES IN A TROLLEY ASSISTED TRUCK .
  • Page 13 OM1095 Introduction - Section 10 Page 10-9 TABLE OF CONTENTS (cont.) Statex III Download Port ............32-8 Engine Diagnostic Port (CENSE) .
  • Page 14 Komatsu Engines w/Centry™ Fuel Control ........
  • Page 15 OM1095 Introduction - Section 10 Page 10-11 TABLE OF CONTENTS (cont.) REAR AXLE LIGHT BAR ............32-23 CENTRY™...
  • Page 16 Introduction - Section 10 OM1095 Page 10-12 TABLE OF CONTENTS (cont.) Fixed Pressure Reducing Valve ..........42-2 Flow Control Valve .
  • Page 17 OM1095 Introduction - Section 10 Page 10-13 TABLE OF CONTENTS (cont.) AM/FM RADIO / CD PLAYER ............70-1 OPERATING INSTRUCTIONS .
  • Page 18 Introduction - Section 10 OM1095 Page 10-14 NOTES...
  • Page 19 OM1200 02/11 Torque Tables And Conversion Charts - Section 12 Page 12-1 TORQUE TABLES AND CONVERSION CHARTS This manual provides dual dimensioning for many specifications. Metric units are specified first, with References throughout the manual to standard U.S. standard units in parentheses. When torque val- torques or other standard values will be to one of ues are not specified in the assembly instructions the following tables.
  • Page 20 N•m ft lb kg•m NOTE: This list represents the current engineering M6 x1 1.22 approved sources for use in Komatsu manufacture. It M8 x 1.25 3.06 is not exclusive. Other products may meet the same M10 x 1.5 5.61 specifications of this list.
  • Page 21 OM1200 02/11 Torque Tables And Conversion Charts - Section 12 Page 12-3 STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws The following specifications apply to required assem- • The maximum torque tolerance shall be ±10% of bly torques for all grade 5 and grade 8 cap screws.
  • Page 22 Torque Tables And Conversion Charts - Section 12 02/11 OM1200 Page 12-4 STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws The following specifications apply to required assem- bly torques for all 12-point, grade 9 (170,000 psi min- imum tensile), cap screws. •...
  • Page 23 OM1200 02/11 Torque Tables And Conversion Charts - Section 12 Page 12-5 TABLE 4. Tightening Torque For T-Bolt Type Hose Clamp (SAE J1508 Type TB) Newton meters Inch Pounds Thread Size Band Width (N·m) (in. lb) 0.25-28 UNF 19.05 mm (0.75 in.) 8.5 ±...
  • Page 24 Torque Tables And Conversion Charts - Section 12 02/11 OM1200 Page 12-6 TABLE 7. Torque Chart For JIC 37° Swivel NutS With Or Without O-ring Seals Size Tube Size Threads UNF-2B Newton meters Foot Pounds Code (OD) (N·m) (ft lb) –...
  • Page 25 OM1200 02/11 Torque Tables And Conversion Charts - Section 12 Page 12-7 TABLE 9. Torque Chart For O-ring Boss Fittings Foot Pounds Newton meters Size Tube Size Threads UNF-2B (ft lb) (N·m) Code (OD) – 2 0.125 0.312 – 24 4 ±...
  • Page 26 Torque Tables And Conversion Charts - Section 12 02/11 OM1200 Page 12-8 TABLE11. Common Conversion Multipliers Metric To English Multiply To Convert From millimeter (mm) inch (in.) 0.0394 centimeter (cm) inch (in.) 0.3937 meter (m) foot (ft) 3.2808 meter (m) yard (yd) 1.0936 kilometer (km)
  • Page 27 OM1200 02/11 Torque Tables And Conversion Charts - Section 12 Page 12-9 TABLE 12. Common Conversion Multipliers English to Metric To Convert Multiply From inch (in.) millimeter (mm) 25.40 inch (in.) centimeter (cm) 2.54 foot (ft) meter (m) 0.3048 yard (yd) meter (m) 0.914 mile (mi)
  • Page 28 Torque Tables And Conversion Charts - Section 12 02/11 OM1200 Page 12-10 TABLE 13. Temperature Conversions Formula: F° - 32  1.8 = C° or C° x 1.8 + 32 = F° Celsius Fahrenheit Celsius Fahrenheit Celsius Fahrenheit C° F° C°...

  • Page 29: General Safety

    Read and follow all safety precautions. Failure to do so may result in serious injury or death. • Before making any modification, consult your authorized regional Komatsu America Corp. PERSONAL SAFETY distributor. Komatsu will not be responsible for injury damage caused Safety Rules unauthorized modification.

  • Page 30: Fire Extinguishers And First Aid Kits

    Safety - Section 20 08/11 OM2036 Page 20-2 Use the handrails and steps marked by arrows • To prevent hot engine oil spray: in the diagram below when climbing on or off 1. Stop the engine. the machine. 2. Wait for the oil temperature to cool. 3.

  • Page 31: Rops Precautions

    • DO NOT use attachments that are not authorized absorb the energy of the impact. by Komatsu America Corp., or the authorized regional Komatsu distributor. Use of unauthorized • ROPS structures,...

  • Page 32: Precautions For Truck Operation

    Only qualified opera- Preparing For Operation tors or technicians may attempt to operate or main- tain a Komatsu truck. • Mount and dismount while facing the truck. DO NOT attempt to mount or dismount the truck Safe practices start before the operator gets to the while it is in motion.

  • Page 33: In The Operator's Cab - Before Starting The Engine

    OM2036 08/11 Safety - Section 20 Page 20-5 OPERATING THE MACHINE In The Operator’s Cab - Before Starting The Engine Starting The Engine • DO NOT leave tools or spare parts lying around • DO NOT attempt to start the machine by shorting or allow trash to accumulate in the cab of the across the starter terminals.

  • Page 34: Traveling In The Truck

    Safety - Section 20 08/11 OM2036 Page 20-6 • Check for flat tires periodically during a shift. If • If the engine stops while the truck is in motion, the truck has been operating on a flat, DO NOT the steering and brakes will continue to operate, park indoors until the tire cools.

  • Page 35: Ensuring Good Visibility

    OM2036 08/11 Safety - Section 20 Page 20-7 Ensuring Good Visibility The following actions are effective in preventing acci- dents while working near high voltages: • When working in dark places, install work lamps and headlamps. • Wear shoes with rubber or leather soles. •...

  • Page 36: Parking The Machine

    Safety - Section 20 08/11 OM2036 Page 20-8 WORKING NEAR BATTERIES Parking The Machine • Choose a horizontal road surface to park the Battery Hazard Prevention machine. If the machine has to be parked on a • Battery electrolyte contains sulfuric acid and can slope, install wheel chocks to prevent the quickly burn the skin and eat holes in clothing.

  • Page 37: Jump-Starting With Booster Cables

    OM2036 08/11 Safety - Section 20 Page 20-9 Jump-Starting With Booster Cables Jump Starting With Receptacles • Always wear safety glasses or goggles when • Always wear safety glasses or goggles when starting the machine with booster cables. starting the machine with booster cables. •...

  • Page 38: Precautions For Maintenance

    Install wheel chocks. position. • If the engine must be operated during service, The Komatsu body-up safety cable can only be move the selector switch to the NEUTRAL used with a Komatsu body. Non-OEM body may position, and apply the parking brake. Perform not accommodate the Komatsu body-up safety this work with two people.

  • Page 39: During Maintenance

    OM2036 08/11 Safety - Section 20 Page 20-11 DURING MAINTENANCE Rules To Follow When Adding Fuel Or Oil • Spilled fuel and oil may cause slipping. Clean up Personnel spills immediately. • Only authorized personnel may service and • Tighten the fuel cap and the oil cap securely. repair the machine.

  • Page 40: Precautions With The Battery

    • Small, high-pressure pinhole leaks are extremely dangerous. The jet of high-pressure oil can Komatsu anchor (58B-98-75190) is available for use pierce the skin and eyes. Wear safety glasses with fall protection harnesses. Carefully read and and thick gloves. Use a piece of cardboard or a understand the harness maker’s instructions before...

  • Page 41: Tires

    OM2036 08/11 Safety - Section 20 Page 20-13 TIRES The tire inflation pressure and permissible speeds, given in this manual, are general values. The actual Handling Tires values may differ, depending on the type of tire and the specific operating conditions. For details, please Rim and tire maintenance can be hazardous unless the consult the tire manufacturer.

  • Page 42: Tire Maintenance

    No Entry and other warning signs. injury, or even death. When performing such mainte- nance, consult your authorized regional Komatsu dis- • Stand the tire on level ground, and block it tributor, or the tire manufacturer.

  • Page 43: Additional Job Site Rules

    OM2036 08/11 Safety - Section 20 Page 20-15 ADDITIONAL JOB SITE RULES • Use this space to add any additional job site rules not covered in any of the previous discussions. • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ •...

  • Page 44: When Repairs Are Necessary

    Operating Instructions - Towing. attempt repairs. 10. Drain, clean, and ventilate the fuel tanks and/or 2. Many components on the Komatsu truck are hydraulic tanks before welding. large and heavy. Ensure that the lifting equip- ment - hoists, slings, chains, lifting eyes - are of NOTE: If it is necessary to weld the hydraulic tank or adequate capacity.
  • Page 45 OM2036 08/11 Safety - Section 20 Page 20-17...
  • Page 46 Safety - Section 20 08/11 OM2036 Page 20-18 NOTES...

  • Page 47: Warnings And Cautions

    (CL). The CL is used to verify the accuracy of the individual PIN. FC - Character positions 10 and 11 identify the Fac- tory Code (FC). The FC identifies the Komatsu fac- tory in charge of claims for the product. The FC for electric drive trucks is 61.
  • Page 48 Safety - Section 22 OM2231 Page 22-2 Warnings and Cautions A warning decal surrounds the key switch. The warn- ing stresses the importance of reading the operator's manual before operation. Warning plates are attached to the hydraulic tank and the fuel tank. The decals alert technicians not to work on the truck with the body raised unless the body-up retention cable is in position.
  • Page 49 OM2231 Safety - Section 22 Warnings and Cautions Page 22-3 A warning plate is mounted on top of the radiator A plate on the side of the hydraulic tank provides surge tank cover near the radiator cap. The engine instructions for filling the hydraulic tank. cooling system is pressurized when the engine is on and/or when the system is hot.
  • Page 50 Safety - Section 22 OM2231 Page 22-4 Warnings and Cautions A warning plate is attached to the frame above the hydraulic system Auxiliary Power Unit (APU) quick Attached to the exterior of the battery compartment is disconnect fittings. The plate alerts technicians that a danger plate.
  • Page 51 OM2231 Safety - Section 22 Warnings and Cautions Page 22-5 The parking brake is spring-applied and hydraulically of the Alarm Indicating Device (AID) circuit control released. It is designed to hold a stationary truck cards. when the engine is off. The truck must be completely Fasten the welding machine ground (-) lead to the stopped before applying the parking brake, or dam- piece being welded.
  • Page 52 Safety - Section 22 OM2231 Page 22-6 Warnings and Cautions Warning and danger plates are located inside the door of the brake system cabinet behind the cab. This plate alerts technicians to read the warning labels attached to the accumulators prior to releasing internal nitrogen pressure, or disconnecting any hydraulic lines or hardware.
  • Page 53 OM2231 Safety - Section 22 Warnings and Cautions Page 22-7 seconds of time to pass before opening (disconnect- ing) the battery disconnect switch. This time period allows hydraulic pressure to be released from the steering accumulators. A warning plate is located above the hydraulic sys- tem (APU) quick disconnect fittings in front of the hydraulic tank.
  • Page 54 Safety - Section 22 OM2231 Page 22-8 Warnings and Cautions This decal is placed on deck mounted cabinets, housings, and structures that must be lifted from specific points in order to safely move them. If any of these decals is damaged or defaced so it is no longer legible, it should be replaced immediately.

  • Page 55: Operating Instructions

    Operators or technicians must be qualified to operate or maintain a Komatsu truck. 3. Move behind the front left tire. Check the hub and brake assemblies for leaks, and any abnor- Safe practices start before the operator gets to the mal wear or signs of damage.
  • Page 56 Operation - Section 30 OM3070 Page 30-2 Operating Instructions FIGURE 30-1. Component Location 1. Cab 8. Cooling Blower 15.Drive Motors 2. Radiator 9. Cooling Duct 16.Rear Hydrair II® Suspension 3. Reserve Oil 10.Steering Circuit Filter 17.Tires 4. Auto Lube 11.Hoist Circuit Filter 18.Hydraulic Tank 5.
  • Page 57 OM3070 Operation - Section 30 Operating Instructions Page 30-3 8. Move behind the rear of the front wheel. Ensure 14. Move to the rear of the dual tires. Check for and the suspension protective boot is in good condi- remove any rocks lodged between the dual tion.
  • Page 58 Operation - Section 30 OM3070 Page 30-4 Operating Instructions 19. Move behind the rear right side dual tires. 24. Move outboard of the front wheel, and inspect Check for and remove any rocks lodged the attaching lugs/wedges to ensure they are between the dual tires.

  • Page 59: Engine Start-Up

    OM3070 Operation - Section 30 Operating Instructions Page 30-5 ENGINE START-UP 30. Check the coolant in the radiator using the coolant level sight gauge, or observe the coolant level through the opening in the end of the hood. If it is necessary to remove the radiator cap, shut the engine off, allow the engine to cool, and slowly Never attempt to start the engine by shorting remove the radiator cap.

  • Page 60: After Engine Has Started

    Operation - Section 30 OM3070 Page 30-6 Operating Instructions AFTER ENGINE HAS STARTED NOTE: If the truck is equipped with an engine prelube system, a noticeable time delay will occur (while the engine lube oil passages are being filled) before the starter engages. The colder the engine oil temperature, the longer the time delay.

  • Page 61: Emergency Steering System

    DO NOT operate the truck until the problem Pre-Operation Testing is corrected. NOTE: Komatsu recommends that operators perform 5. Start the engine and allow the steering this test to verify that the steering accumulator accumulators to fully charge. Turn the steering precharge pressure is adequate at the beginning of wheel so that the front wheels are straight.

  • Page 62: Additional Guidelines

    Operation - Section 30 OM3070 Page 30-8 Operating Instructions MACHINE OPERATION SAFETY 7. Shut the engine off by using the engine stop PRECAUTIONS button located on the center console. Leave the key switch in the ON position. This allows the After the truck engine is started and all the systems are steering accumulators to retain their hydraulic functioning properly, the operator must follow all the...

  • Page 63: Loading

    OM3070 Operation - Section 30 Operating Instructions Page 30-9 HAULING 1. Stay alert! Drive with extreme caution. Cab doors must remain closed at all times if the truck is in motion or unattended. 2. Obey all road signs. Operate the truck in a con- DO NOT use the brake lock for parking.

  • Page 64: Passing

    Operation - Section 30 OM3070 Page 30-10 Operating Instructions 11. When the maximum truck speed is reached, To Raise The Dump Body: haul trucks equipped with Statex III w/fuel enhancement (fuel saver) system will experi- ence a decrease in engine rpm. NOTE: This is different from trucks equipped with Dumping certain types of material can result in Statex II or Statex III without fuel enhancement,...

  • Page 65: To Lower The Dump Body (When Dumping Over A Berm Or Into A Crusher)

    OM3070 Operation - Section 30 Operating Instructions Page 30-11 To Lower The Dump Body: To Lower The Dump Body (When dumping over a berm or into a crusher): (When dumping on flat ground): 7. Move the hoist lever forward to the DOWN posi- 8.

  • Page 66: Safe Parking Procedures

    Operation - Section 30 OM3070 Page 30-12 Operating Instructions SAFE PARKING PROCEDURES ENGINE SHUTDOWN PROCEDURE The operator must continue the use of safety precau- The following procedure must be followed at each tions when preparing for parking and engine shut- engine shutdown.

  • Page 67: Delayed Engine Shutdown Procedure

    OM3070 Operation - Section 30 Operating Instructions Page 30-13 DELAYED ENGINE SHUTDOWN 9. Close and lock all windows, remove the key PROCEDURE from the key switch, and lock the cab to prevent possible unauthorized truck operation. Dis- Refer to Section 32, Operator Cab and Controls, for mount the truck properly.

  • Page 68: Disabled Truck Operation

    Operation - Section 30 OM3070 Page 30-14 Operating Instructions DISABLED TRUCK OPERATION 3. Remove the plug and install the necessary QD return fittings listed in Table 2 into the QD GENERAL Return port on the bleeddown manifold. Refer to the shop manual for repair and troubleshoot- ing procedures for the hoist system components and Table 2: QD Return Fittings steering system components.

  • Page 69: Hookup

    OM3070 Operation - Section 30 Operating Instructions Page 30-15 Hookup 5. To disconnect the hoses, stop the engine(s) on both trucks. Wait two minutes for the hydraulic 1. When the good truck is in position, stop the systems on both trucks to bleed down. Ensure engine and wait two minutes to allow the all hydraulic pressure has been relieved before hydraulic system to bleed down.

  • Page 70: Disabled Truck Dumping Procedure

    2. Connect another hose from power down quick disconnect (2) to the power up circuit of the dis- abled truck. NOTE: If both trucks are a model 730E, the hoses will be installed at the quick disconnects shown in Figure 30-3 and will be crossed when connected.

  • Page 71: Towing

    OM3070 Operation - Section 30 Operating Instructions Page 30-17 TOWING TROLLEY OPERATING INSTRUCTIONS Prior to towing a truck, many factors must be care- fully considered. Serious personal injury and/or sig- The instructions provided here are specifically for nificant property damage may result if important trolley use.

  • Page 72: Operating In Diesel Mode

    Operation - Section 30 OM3070 Page 30-18 Operating Instructions OPERATING IN DIESEL MODE OPERATING IN TROLLEY LINE MODE Operating a truck equipped with trolley assist is Only trucks that are loaded will travel on the trolley nearly identical to operating a standard truck. line.

  • Page 73: Getting On Line

    OM3070 Operation - Section 30 Operating Instructions Page 30-19 GETTING ON LINE 3. Once aligned and moving 6 mph or faster, move the master control lever forward to one of the When operating a trolley truck, follow the procedure four speed control positions. This will start the listed below to get on the trolley line.

  • Page 74: Operating On Trolley

    Operation - Section 30 OM3070 Page 30-20 Operating Instructions TROLLEY SPEED BASED ON LINE VOLTAGE INPUT Master Control Overhead Trolley Speed With Trolley Speed With Trolley Speed With Lever Position Panel Light 1400 VDC Input 1500 VDC Input 1600 VDC Input 7.6 - 8.1 mph 8.6 - 9.1 mph 9 - 10.0 mph...
  • Page 75 OM3070 Operation - Section 30 Operating Instructions Page 30-21 4. The propel direction selector must remain in the the truck drifts too far to either side, an auto- forward position and the throttle pedal fully matic switch will lower the pantograph, and the pressed at all times while on trolley.

  • Page 76: Getting Off Line

    Operation - Section 30 OM3070 Page 30-22 Operating Instructions GETTING OFF LINE LINE STATUS SIGNALS As the truck approaches the end of the trolley line, it Line status signals are lights (much like traffic lights) must exit the line properly. There will be signs or sig- that advise operators whether segments of trolley nals near the end of the line indicating to the operator lines are energized and ready to accept haulage traf-...

  • Page 77: Line Status Signal Markings

    OM3070 Operation - Section 30 Operating Instructions Page 30-23 LINE STATUS SIGNAL MARKINGS TRAFFIC CONSIDERATION FOR TROLLEY LINE OPERATION The line status signals will show the following colors to indicate line status: Trucks operating on trolley assist will travel faster than trucks unable to operate on trolley, most support Ready for haul traffic - green equipment and some maintenance equipment.

  • Page 78: Operating Slow Moving Vehicles On Trolley Assist Ramps

    Operation - Section 30 OM3070 Page 30-24 Operating Instructions OPERATING SLOW MOVING VEHICLES TRUCK FAILURE WHILE ON TROLLEY ON TROLLEY ASSIST RAMPS If the truck fails while on trolley, perform the following: Personnel operating any vehicle on a trolley assist 1.

  • Page 79: Operator Cab And Controls

    OM3223 Operation - Section 32 Operator Cab and Controls Page 32-1 OPERATOR CAB AND CONTROLS FIGURE 32-1. CAB INTERIOR - OPERATOR VIEW 1. Steering Wheel 7. Instrument Panel 13. Warning / Status Indicator Lights 2. Service Brake Pedal 8. Grade / Speed Chart 14.

  • Page 80: Steering Wheel And Controls

    Operation - Section 32 OM3223 Page 32-2 Operator Cab and Controls STEERING WHEEL AND CONTROLS Multi-Function Turn Signal Switch Steering wheel (1, Figure 32-2) will telescope in and out and adjust through a tilt angle to provide a com- fortable wheel position for most operators. Horn Button Horn (2, Figure 32-2) is actuated by pushing the but- ton in the center of the steering wheel.

  • Page 81: Service Brake Pedal

    OM3223 Operation - Section 32 Operator Cab and Controls Page 32-3 SERVICE BRAKE PEDAL THROTTLE PEDAL Service brake pedal (2, Figure 32-4) is a foot-oper- Throttle pedal (4, Figure 32-4) is a foot-operated ated pedal which applies the service brakes. pedal which allows the operator to control engine rpm, depending on pedal angle.
  • Page 82 Operation - Section 32 OM3223 Page 32-4 Operator Cab and Controls HEATER / AIR CONDITIONER Heater / Air Conditioner Selector Switch COMPARTMENT AND CONTROLS Selector switch (5, Figure 32-5) allows the operator to select heat or air conditioning, or neither. The left The heater/air conditioner compartment contains position of the switch activates the air conditioning heater/air conditioner controls (6, Figure 32-1) and...

  • Page 83: Grade/Speed Warning Chart

    Proper tion: use of dynamic retarding will maintain a safe speed. Komatsu Engine: ..25 inches of H2O vacuum. DO NOT exceed these recommended maximum NOTE: After service, push the reset button on the speeds when descending grades with a loaded truck.

  • Page 84: Center Console

    Operation - Section 32 OM3223 Page 32-6 Operator Cab and Controls CENTER CONSOLE The center console contains: 1. Data Storage Button 2. Trolley Master Control Lever 3. F-N-R Selector 4. Hoist Control Lever 5. Retarder Speed Control Dial 6. RSC ON / OFF Switch 7.
  • Page 85 OM3223 Operation - Section 32 Operator Cab and Controls Page 32-7 Hoist Control Lever Retard Speed Control (RSC) Adjust Dial Hoist control (4, Figure 32-7) is a four position hand- RSC adjust dial (5, Figure 32-7) allows the operator operated lever located between the operator seat to vary the downhill truck speed that the retard speed and the center console.

  • Page 86: Retard Speed Control (Rsc) Switch

    Operation - Section 32 OM3223 Page 32-8 Operator Cab and Controls Retard Speed Control (RSC) Off / On Switch Engine Shutdown Switch Retard speed control switch (6, Engine shutdown switch (8, Figure 32-7) “IN” “OFF” Figure 32-7) turns the system is used to turn the engine off.

  • Page 87: Payload Meter

    Engine diagnostics port (12) is used by qualified per- complete description of the payload meter and its sonnel to access engine diagnostic information. functions. Komatsu Engine CENSE Connector Payload Meter Download Connector CENSE Connector (13) is a three-pin connector is for Payload meter download connector (2, Figure 32-9)

  • Page 88: Operator Seat

    Operation - Section 32 OM3223 Page 32-10 Operator Cab and Controls OPERATOR SEAT The operator's seat provides a fully adjustable cush- ioned ride for the driver's comfort and ease of opera- tion. Adjustment The following adjustments must be made while sitting in the seat.

  • Page 89: Instrument Panel

    OM3223 Operation - Section 32 Operator Cab and Controls Page 32-11 INSTRUMENT PANEL AND INDICATOR LIGHTS CONTROL SYMBOLS Many control functions are identified with international symbols that the operator is to learn to recognize immedi- ately. The operator must understand the function and operation of each instrument and control. This knowledge is essential for proper and safe operation of the machine.

  • Page 90: Key Switch

    Operation - Section 32 OM3223 Page 32-12 Operator Cab and Controls FIGURE 32-11. PANEL, GAUGES, INDICATORS, AND CONTROLS 1. Keyswitch 16. High Beam Headlight Indicator Light 2. Engine Shutdown Switch with Timer Delay 17. Left Turn Signal Indicator Light 3. Fog Light Switch (N./O.) (Optional) 18.
  • Page 91 OM3223 Operation - Section 32 Operator Cab and Controls Page 32-13 Engine Shut down Switch with Timer Delay If the engine does not turn off with key switch, use the engine shutdown switch on the operator Engine shut down switch (2) is a three-position cab center console.
  • Page 92 Operation - Section 32 OM3223 Page 32-14 Operator Cab and Controls Engine Cold Weather Start- Wheel Brake Lock Control ing Aid (Optional) Wheel brake lock (12) is to be used with Engine starting aid switch (8) is the engine on for dumping and loading spring-loaded to the OFF posi- operations only.

  • Page 93: Engine Oil Pressure Gauge

    (rpm). age of the 24v battery system. Normal indicated voltage at high Governed rpm (Komatsu Engine): rpm is 27 to 28 volts with batter- Low Idle - 750 rpm ies in the fully charged condition.

  • Page 94: Payload Meter Switch

    Operation - Section 32 OM3223 Page 32-16 Operator Cab and Controls Light Switch instrument panel lights, clearance lights, and the head- lights are controlled by this three position light switch (27). The OFF position is selected by pressing the bottom of switch.

  • Page 95: Overhead Status/Warning Indicator Light Panel

    OM3223 Operation - Section 32 Operator Cab and Controls Page 32-17 OVERHEAD STATUS / WARNING INDICATOR LIGHT PANEL FIGURE 32-12. STATUS / INDICATOR LIGHTS Row / Indicator Indicator Color Row / Indicator Indicator Color Column Description Wire Index Column Description Wire Index Hydraulic Oil Temp.
  • Page 96 Operation - Section 32 OM3223 Page 32-18 Operator Cab and Controls INDICATOR LIGHT SYMBOLS Indicator Lights which are amber in color alert the operator that the indicated truck function requires some precaution when lighted. If the low steering warning light continues to illu- Indicator Lights which are red in color alert the opera- minate and the alarm continues to sound, low tor that the indicated truck function requires immedi-...
  • Page 97 OM3223 Operation - Section 32 Operator Cab and Controls Page 32-19 D1. Electric System Fault C2. Circuit Breaker Tripped The electric system fault warning This light will illuminate if any of light will flash on and off when a the circuit breakers in the relay malfunction occurs in the electri- circuit control boards are tripped.
  • Page 98 Operation - Section 32 OM3223 Page 32-20 Operator Cab and Controls C3. Body Up A4. Not Used This amber body up indicator, Reserved for future use or when illuminated, shows that the options. body is not completely down on the frame. The truck is not to be driven until body is down and light is off.
  • Page 99 Komatsu Engines w/Centry™ Fuel Control - in the cooling air circuit for the alternator and motorized wheels. This indicator monitors the Centry™ fuel system.
  • Page 100 Operation - Section 32 OM3223 Page 32-22 Operator Cab and Controls TROLLEY INDICATOR LIGHTS If a trolley fault occurs while operating in the diesel mode, switch the master control switch to the TROL- The following indicator lights are used only when the LEY position for a minimum of one second, and then truck is equipped with the trolley option.
  • Page 101 OM3223 Operation - Section 32 Operator Cab and Controls Page 32-23 C8. Med Speed (Green) Right Limit (Amber) Optional The medium overhead indicator light, when on, indicates the When on trolley, this light will turn operator has selected the sec- on if the overhead power cables ond detent position of the master make contact too far to the right...
  • Page 102 Releasing the spring-loaded switch will allow the switch to return to the OFF position. For diagnostic tests of a Komatsu engine equipped with Centry™ Fuel Control, refer to Centry™ Diag- nostics at the end of this section.

  • Page 103: Centry™ Fuel System Diagnostics

    Operator Cab and Controls Page 32-25 CENTRY™ FUEL SYSTEM DIAGNOSTICS If the truck is equipped with a Komatsu engine and Centry™ Fuel Control system, service engine indica- tor light (D6, Figure 32-12) monitors the Centry™ fuel system. When the key switch is turned ON, this light should illuminate for about two seconds and then turn off, if no faults are detected in the system.

  • Page 104: Exiting The Diagnostics Mode

    Operation - Section 32 OM3223 Page 32-26 Operator Cab and Controls 2. Turn the key switch to the ON position (engine not on) and press lamp test switch to the bottom (position for one - two seconds, then release (switch is spring-loaded to the top, OFF posi- tion).

  • Page 105: Lubrication And Service

    Komatsu trucks are equipped with an automatic lubri- cation system. The system is designed to automatically deliver the proper amount of lubricant to a specified lubrication point such as a steering cylinder pin or body pivot pin.

  • Page 106: Cooling System Service

    Because of the wide vari- ety of factors involved, it is necessary to consult your area Komatsu representative for all wheel motor ser- vice intervals and instructions. General intervals for oil service and sampling are listed in the interval charts.

  • Page 107: Reserve Engine Oil System (If Equipped)

    OM4064 06/11 Maintenance - Section 40 Lubrication and Service Page 40-3 RESERVE ENGINE OIL SYSTEM (IF Oil should always be visible in the bottom sight gauge. If not, add oil to the reserve oil tank until oil is visible in EQUIPPED) the top sight gauge.

  • Page 108: Quick Fill Service Center

    Maintenance - Section 40 OM4064 06/11 Page 40-4 Lubrication and Service QUICK FILL SERVICE CENTER FIGURE 40-4. SERVICE CENTER 1. Hydraulic Oil 3. Engine Oil 2. Radiator Coolant 4. Grease The service center can be located on either side of the machine and is used to fill system fluids.

  • Page 109: Left-Hand Fuel Receiver -Optional (Wiggins Quick Fill)

    OM4064 06/11 Maintenance - Section 40 Lubrication and Service Page 40-5 LEFT-HAND FUEL RECEIVER - OPTIONAL If fuel spills from the fuel tank (1) breather valve, or if (WIGGINS QUICK FILL) the tank does not completely fill, check the breather- valve to see whether the float balls are in place and the Left-Hand Quick...

  • Page 110: Lubrication Chart

    Maintenance - Section 40 OM4064 06/11 Page 40-6 Lubrication and Service LUBRICATION CHART...

  • Page 111: 10 Hour (Daily) Lube And Maintenance Checks

    OM4064 06/11 Maintenance - Section 40 Lubrication and Service Page 40-7 10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS MACHINE - Inspect the entire truck for leaks, worn parts, and damage.

  • Page 112: Hour (Daily) Lube And Maintenance Checks (Continued)

    The air cleaner(s) must be serviced if the gauge(s) shows the following maxi- mum restriction: Komatsu SSA16V159 Engine: ....6.2 kPa (25 in.) of H O vacuum.

  • Page 113: 50 Hour Lubrication And Maintenance Checks

    OM4064 06/11 Maintenance - Section 40 Lubrication and Service Page 40-9 50 HOUR LUBRICATION AND MAINTENANCE CHECKS Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS FUEL FILTERS - Change the fuel filters, (fuel separators).

  • Page 114: 250 Hour Lubrication And Maintenance Checks

    Maintenance - Section 40 OM4064 06/11 Page 40-10 Lubrication and Service 250 HOUR LUBRICATION AND MAINTENANCE CHECKS Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS ENGINE - Refer to the engine operation and mainte- nance manual for the complete specifications regard- ing the engine lube oil specifications.

  • Page 115: Hour Lubrication And Maintenance Checks (Continued)

    OM4064 06/11 Maintenance - Section 40 Lubrication and Service Page 40-11 250 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued) Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS HYDRAULIC PUMP DRIVESHAFT & U-JOINTS - Add one or two applications of grease to each grease fitting.

  • Page 116: 500 Hour Lubrication And Maintenance Checks

    Maintenance - Section 40 OM4064 06/11 Page 40-12 Lubrication and Service 500 HOUR LUBRICATION AND MAINTENANCE CHECKS Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS FINAL DRIVE CASE BREATHERS - Remove the breather elements from the motorized wheels.

  • Page 117: Hour Lubrication And Maintenance Checks (Continued)

    OM4064 06/11 Maintenance - Section 40 Lubrication and Service Page 40-13 500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued) Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS 11. WHEEL MOTOR OIL (Initial 500 hours only) - Change or filter wheel motor gear oil only after initial 500 hours or operation.

  • Page 118: 1000 Hour Lubrication And Maintenance Checks

    Maintenance - Section 40 OM4064 06/11 Page 40-14 Lubrication and Service 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS HYDRAULIC TANK - Drain the hydraulic tank and clean the inlet strainer.

  • Page 119: 1500 Hour Lubrication And Maintenance Checks

    OM4064 06/11 Maintenance - Section 40 Lubrication and Service Page 40-15 1500 HOUR LUBRICATION AND MAINTENANCE CHECKS Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS WHEEL MOTORS - Change oil. Clean sump mag- netic plugs.

  • Page 120: 5000 Hour Lubrication And Maintenance Checks

    Maintenance - Section 40 OM4064 06/11 Page 40-16 Lubrication and Service 5000 HOUR LUBRICATION AND MAINTENANCE CHECKS Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS AIR CLEANERS - Clean the Donaclone tubes in the pre-cleaner section of the air filter.

  • Page 121: 10,000 Hour Lubrication And Maintenance Checks

    OM4064 06/11 Maintenance - Section 40 Lubrication and Service Page 40-17 10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS WHEEL MOTORS - Clean the area around the grease ports to prevent dirt or other contaminates from entering.
  • Page 122 Maintenance - Section 40 OM4064 06/11 Page 40-18 Lubrication and Service NOTES...

  • Page 123: Automatic Lubrication System

    OM4211 07/09 Maintenance - Section 42 Automatic Lubrication System Page 42-1 AUTOMATIC LUBRICATION SYSTEM GENERAL DESCRIPTION During the down stroke, the pump cylinder is The automatic lubrication system is a pressurized extended into the grease. Through the combination of lubricant delivery system which delivers a controlled shovel action and vacuum generated in the pump cyl- amount of lubricant to designated lubrication points.

  • Page 124: System Components

    Maintenance - Section 42 07/09 0M4211 Page 42-2 Automatic Lubrication System Hydraulic inlet pressure must not exceed 20685 kPa (3000 psi). Exceeding the rated pressure may result in damage to system components and pos- sible personal injury. Specifications are as follows: Maximum hydraulic oil inlet pressure: .

  • Page 125: 23. Flow Control Valve

    OM4211 07/09 Maintenance - Section 42 Automatic Lubrication System Page 42-3 FIGURE 42-3. AUTO LUBRICATION SYSTEM (FRONT AND REAR VIEW) 1. Vent Valve 7. Reservoir Vent Tube 13. Dirty Filter Indicator 19. Solenoid Valve 2. Vent Valve/Vent Hose 8. Hydraulic Oil Return 14.

  • Page 126: Solenoid Valve

    Maintenance - Section 42 07/09 0M4211 Page 42-4 Automatic Lubrication System Solenoid Valve Unloader Valve Solenoid valve (19), when energized, allows oil to Unloader valve (20) is mounted on a tee fitting with flow to the hydraulic motor. pump cutoff pressure switch (21). This valve will relieve grease pressure in the pump if pressure Vent Valve exceeds 27 580 kPa (4,000 psi).
  • Page 127 OM4211 07/09 Maintenance - Section 42 Automatic Lubrication System Page 42-5 FIGURE 42-4. REAR LUBRICATION INJECTORS 1. LH Lower Suspension 7. RH Anti-Sway Bar 13. RH Lower Suspension 2. LH Top Suspension 8. Rear Axle Pivot Pin 14. Grease Supply 3.

  • Page 128: System Operation

    Maintenance - Section 42 07/09 0M4211 Page 42-6 Automatic Lubrication System SYSTEM OPERATION 6. When 20 685 kPa (3,000 psi) grease pressure reaches pressure switch (4, Figure 42-6) set- Normal Operation ting, the switch contacts will close and energize relay K1 (12), removing power from grease Refer to Figure 42-5 and 42-6: pump solenoid valve (5) and the pump will stop.

  • Page 129: Pressure Failure Detection Circuits

    OM4211 07/09 Maintenance - Section 42 Automatic Lubrication System Page 42-7 Pressure Failure Detection Circuits 3. If a problem occurs and the system is not able to attain 13 790 kPa (2,000 psi), then time delay 1. When the lubrication cycle is initiated, 24VDC module (7) will energize relay RB6-K2 after 60 flows through relay RB6-K4 (8, Figure 42-6) N.C.

  • Page 130: General Instructions

    Maintenance - Section 42 07/09 0M4211 Page 42-8 Automatic Lubrication System GENERAL INSTRUCTIONS LUBRICANT PUMP Pump Housing Oil Level LUBRICANT REQUIRED FOR SYSTEM The pump housing must be filled to the proper level Grease requirements will depend on ambient tem- with SAE 10W-30 motor oil.

  • Page 131: Filter And Reservoir

    OM4211 07/09 Maintenance - Section 42 Automatic Lubrication System Page 42-9 Filter And Reservoir Filter Assembly Element Filter assembly (2, Figure 42-8) is mounted on right Filter assembly element (5, Figure 42-9) must be upright (1) and filters the grease when the grease replaced if bypass indicator (2) shows excessive ele- supply is refilled through the quick fill fittings.

  • Page 132: Injectors (Sl-1 Series H)

    Maintenance - Section 42 07/09 0M4211 Page 42-10 Automatic Lubrication System INJECTORS (SL-1 Series H) Injector Specifications • Each lubrication injector services only one grease point. In case of pump malfunction, each injector is equipped with a covered grease fitting allow external lubricating...

  • Page 133: Injector Operation

    OM4211 07/09 Maintenance - Section 42 Automatic Lubrication System Page 42-11 INJECTOR OPERATION STAGE 1. STAGE 3. Injector piston (2) As injector piston (2) is in its normal or completes its stroke, rest position. Dis- it pushes slide valve charge chamber (5) past passage (4), (3) is filled with lu- cutting off further ad-...

  • Page 134: System Checkout

    Maintenance - Section 42 07/09 0M4211 Page 42-12 Automatic Lubrication System SYSTEM CHECKOUT To check the solid-state timer operation without wait- ing for the normal timer setting, proceed as follows: To check system operation, not including the timer, proceed as follows: NOTE: The timer incorporates a liquid and dust-tight cover which must be in place and secured at all times 1.

  • Page 135: Lubrication Cycle Timer Adjustment

    OM4211 07/09 Maintenance - Section 42 Automatic Lubrication System Page 42-13 Lubrication Cycle Timer Adjustment 250 Hour Inspection 1. Check all grease hoses from the SL-1 injectors The timer is set at the factory for a nominal 2.5 min- to the lubrication points. Refer to Figure 42-2. ute (off time) interval.

  • Page 136: 1000 Hour Inspection

    Maintenance - Section 42 07/09 0M4211 Page 42-14 Automatic Lubrication System d. With the system pressurized, check each NOTE: With the engine on, the lubrication system will SL-1 injector assembly. The cycle indicator activate within five minutes. System pressure will pin will be retracted inside the injector body.

  • Page 137: System Troubleshooting Chart

    OM4211 07/09 Maintenance - Section 42 Automatic Lubrication System Page 42-15 SYSTEM TROUBLESHOOTING CHART NOTE: If the following procedures do not correct the problem, contact a factory authorized service center. PROBLEM POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION Lubrication system not grounded. Correct grounding connections to pump assembly and truck chassis.
  • Page 138 Maintenance - Section 42 07/09 0M4211 Page 42-16 Automatic Lubrication System PROBLEM POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION Pump Pressure Builds No signal at solenoid. Check timer. Very Slowly Or Not At All. Turn on electric power to pump. Power Controller Does Not LED must light, pump on LED must light No electric power to controller.

  • Page 139: Major Component Description

    MAJOR COMPONENT DESCRIPTION The Komatsu model 730E standard dump truck is an electric drive, off-highway, rear dump truck with a gross vehi- cle weight of 324,319 kg (715,000 lbs) that is rated for a nominal payload of 185 t (203 tons). Some Trolley ver- sions may have a higher GVW.
  • Page 140 Specifications - Section 50 OM5060 Page 50-2 730E MAJOR COMPONENTS...
  • Page 141 Number of Cylinders ..... . . 16 Komatsu ....223... . .59 Operating Cycle.
  • Page 142 Capacity: Standard Komatsu Body . 25 612 ..(56,464) Struck ....77 m³ ..101 yds³...
  • Page 143 OM6009 8/11 Payload Meter III - Section 60 Page 60-1 PAYLOAD METER III™ INTRODUCTION Payload Meter III (PLMIII) measures, displays and records the weight of material being carried by an off-highway truck. The system generally consists of a payload meter, a gauge display, deck-mounted lights, and sensors. The primary sensors are four suspension pressures and an inclinometer.
  • Page 144 Payload Meter III - Section 60 OM6009 8/11 Page 60-2 COMPONENT DESCRIPTION System Diagram Suspension Pressure Sensors Speedometer/Load Display PLMIII uses a two-wire pressure sensor. The range The speedometer/load display is used as a speedometer and as a payload information display. for the pressure sensor is 281 kg/cm (4000 psi) and The top display is used for speed and can display...
  • Page 145 The brake lock is used to lock the rear brakes on the uses a 3-wire hardware connection. Connections to truck. It is necessary for the accurate calculation of this serial port need to be approved by Komatsu. swingloads during the loading process. Without the Several protocol options are available and detailed...
  • Page 146 Payload Meter III - Section 60 OM6009 8/11 Page 60-4 Key Switch Input Load Lights PLMIII monitors the status of the key switch. 24VDC PLMIII uses load lights to indicate to the shovel indicates that the key switch is on. Open indicates operator the approximate weight of the material in the key switch is off.
  • Page 147 OM6009 8/11 Payload Meter III - Section 60 Page 60-5 Wiring and Termination Most of the PLMIII truck connections use a heavy- duty cable. This yellow multi-conductor cable uses a 16AWG, finely stranded wire designed for continuous motion operations. The conductors are protected by a foil and braided shield for electronic noise immunity and physical strength.
  • Page 148 Payload Meter III - Section 60 OM6009 8/11 Page 60-6 LOAD DISPLAY AND OPERATOR Total Ton and Total Load Counters SWITCHES PLMIII allows the truck operator to monitor and track the total tons hauled and the number of haul cycles The lower display on the speedometer/load display is during the shift.
  • Page 149 OM6009 8/11 Payload Meter III - Section 60 Page 60-7 PAYLOAD OPERATION & CALCULATION The payload meter switches from loading state to maneuvering state as soon as the truck begins Description of Haul Cycles moving. The maneuvering zone is 160 m (0.1 mile) and is designed to allow the operator to reposition The typical haul cycle can be broken down into eight the truck under the shovel.
  • Page 150 Payload Meter III - Section 60 OM6009 8/11 Page 60-8 SOURCES FOR PAYLOAD ERROR Load Calculation The final load calculation is different from the last Suspensions swingload calculation. The accuracy of the swing The number one source of error in payload load calculation depends on loading conditions and calculation is improperly serviced suspensions.
  • Page 151 OM6009 8/11 Payload Meter III - Section 60 Page 60-9 HAUL CYCLE DATA Loading Conditions The final load calculation of the PLMIII system is not PLMIII records and stores data in its on-board flash sensitive to loading conditions. The final load is memory.
  • Page 152 Payload Meter III - Section 60 OM6009 8/11 Page 60-10 C: No Final Load K: New Tare Not Calculated This message is generated when the payload meter The payload meter was not able to accurately is unable to determine the final payload in the truck. calculate a new empty sprung weight for the truck to Typically, this means that the payload meter switched use as the tare value for the haul cycle.
  • Page 153 OM6009 8/11 Payload Meter III - Section 60 Page 60-11 Table 1: HAUL CYCLE DATA Data Unit Remark Truck # alpha- Up to 22 characters can be stored in this field to identify the truck. Typically this field will be just numeric the truck number.
  • Page 154 Payload Meter III - Section 60 OM6009 8/11 Page 60-12 Frame Torque Data Sprung Weight Data Payload meter records the top five peak positive and The payload meter is constantly monitoring the live negative frame torque values and the time they payload calculation.
  • Page 155 OM6009 8/11 Payload Meter III - Section 60 Page 60-13 Alarm Records code has a specific cause and should lead to an investigation for correction. Some failures can be The payload meter stores alarm records to give overcome by the payload meter. Haul cycle data will service personnel a working history of the system.
  • Page 156 Payload Meter III - Section 60 OM6009 8/11 Page 60-14 PDM SOFTWARE OVERVIEW DOWNLOADING DATA The Payload Data Management (PDM) software has PLMIII records many types of data. The PDM several basic functions: software is designed to download the data from a whole truck fleet.
  • Page 157 OM6009 8/11 Payload Meter III - Section 60 Page 60-15 PLM III SYSTEM CONFIGURATION Click “Done” to return to the main menu. From the main menu, select "Connect to Payload Meter". The Starting Communications computer will try to connect to the payload meter and request basic information from the system.
  • Page 158 Payload Meter III - Section 60 OM6009 8/11 Page 60-16 Connecting to the Payload Meter Setting the Date and Time Communications to the PLMIII requires a laptop computer running the PDM software. The software connects to the payload meter through the meter's serial port #1.
  • Page 159 This field in the haul cycle record can hold the name The payload units on the lower display can be of the Komatsu distributor that helped install the changed from metric to short tons or long tons using system. Komatsu also assigns a distributor number the Truck Configuration screen.
  • Page 160 Payload Meter III - Section 60 OM6009 8/11 Page 60-18 Clean Truck Tare Inclinometer Calibration The payload meter uses the clean truck tare value to The inclinometer calibration procedure is designed to calculate carry-back load for each haul cycle. The compensate for variations in the mounting attitude of carry-back stored in the haul cycle record is the new the inclinometer.
  • Page 161 The truck type is the size of the truck from the family to view and for what dates and times. of Komatsu trucks. This allows the user to quickly The query items are added in the "AND" condition. If view results from different models of trucks on the the user selects a truck # and date range, the query property.
  • Page 162 Payload Meter III - Section 60 OM6009 8/11 Page 60-20 Sorting on Date Range Sorting on Time Range The default query starts in 1995 and runs through the The time range sorts the times of the day for valid current date on the computer. To narrow the range to dates.
  • Page 163 OM6009 8/11 Payload Meter III - Section 60 Page 60-21 This query will display haul cycles from January 5 to Payload Detail Screen January 8, from 6:00 AM to 6:00 PM. The Payload Detail screen gives the details for any Date individual haul cycle.
  • Page 164 Payload Meter III - Section 60 OM6009 8/11 Page 60-22 Creating Reports Reports can be generated and viewed on-screen or printed. These reports are generated from the query displayed on the Payload Summary screen. From the example in Sorting on Time Range, the report printed would only contain data from truck 374 during the month of July 2000, from 8:00 AM to 5:00 PM.
  • Page 165 OM6009 8/11 Payload Meter III - Section 60 Page 60-23 Creating Graphs Exporting Data The PDM software can generate graphs that quickly summarize payload data. These graphs can be customized for printing. Just like the reports, the graphs are generated from the query displayed on the “Payload Summary”...
  • Page 166 Payload Meter III - Section 60 OM6009 8/11 Page 60-24 The second set of data below the haul cycle data is Two sets of data are exported. At the top of the file the alarms. The alarm columns, left to right are: will be the haul cycle data.
  • Page 167 OM6009 8/11 Payload Meter III - Section 60 Page 60-25 Importing Data Viewing Alarms From the Payload Summary screen, click on the This import function allows the data from one “Alarms” button to display the alarm screen. The computer to be transferred to another computer. This alarms are sorted by the query settings from the can be useful when a service laptop is used to Payload Summary screen.
  • Page 168 Payload Meter III - Section 60 OM6009 8/11 Page 60-26 NOTES...
  • Page 169 OM7007 Radio / CD Player - Section 70 Page 70-1 AM/FM RADIO / CD / MP3 / USB / iPOD™ / AUX PLAYER FIGURE 70-1. AM/FM RADIO / CD PLAYER 12. OK - Enables selection on a menu - Turns the radio on or off 13.

  • Page 170: Radio Mode Displays

    Radio / CD Player - Section 70 OM7007 Page 70-2 Adjusting the Volume MP3/USB/iPod Mode Displays To increase volume, rotate the ON/AUDIO knob When playing MP3 or WMA files, press the “i Title/ clockwise. To decrease volume, rotate the knob Menu”...

  • Page 171: Aux Input Displays

    OM7007 Radio / CD Player - Section 70 Page 70-3 If RDM is pressed once, RANDOM FOLDER/PLST CLOCK/ALARM Button will appear and the RDM icon will turn on. Then the In any mode, pressing the CLOCK/ALARM button, display returns to its default. In iPod mode, the dis- the display will show the time for 3 seconds.

  • Page 172: Adjusting The Receiver Menu Settings

    Radio / CD Player - Section 70 OM7007 Page 70-4 TREBLE: Rotate the ON/AUDIO knob clockwise to ADVANCED: Rotate the ON/AUDIO knob or press increase the treble sound and counterclockwise to up/down button to select one of the following options: decrease it.

  • Page 173: Using The Radio

    OM7007 Radio / CD Player - Section 70 Page 70-5 USING THE RADIO SCAN: Press SCAN/PSCAN and release to scan all stations on the band that are being used. When a Finding a Station strong enough frequency is found, the radio will play for 8 seconds before continuing to scan.

  • Page 174: Using The Clock

    Radio / CD Player - Section 70 OM7007 Page 70-6 USING THE CLOCK USING THE ALARM The clock can function in a 12-hour or 24-hour mode. The alarm activates the radio at a set time. Pressing The 12-hour mode distinguishes between AM and the CLOCK/ALARM button for more than 2 seconds PM.

  • Page 175: Turning The Alarm Off

    OM7007 Radio / CD Player - Section 70 Page 70-7 USING THE WEATHERBAND (USA Only) If SET MUS is selected, the alarm sound will be whatever was playing when the radio was turned NOAA Weather Radio is a service of the U.S. OFF.

  • Page 176: Using The Compact Disc Player

    Radio / CD Player - Section 70 OM7007 Page 70-8 USING THE COMPACT DISC PLAYER/USB SEEK : Press for less than 2 seconds to go to the beginning of the current track. If pressed within The integrated CD player plays full size CDs, MP3 the first 10 seconds of the track, the radio goes to the and WMA discs.

  • Page 177: Playing An Mp3 Disc

    OM7007 Radio / CD Player - Section 70 Page 70-9 PLAYING AN MP3 DISC/USB PLAYING MP3 FILES The MP3 player will play files recorded on a CD-R up DISC: Insert a disc partway into the slot, label-side to 700 MB or on a USB stick of up to 1 GB. Files can up.

  • Page 178: Using An Ipod

    Radio / CD Player - Section 70 OM7007 Page 70-10 USING AN iPOD® 5/RDM: Pressing the RDM button activates random folder/playlist. The RDM icon on the display indicates The radio is capable of controlling and playing music that this feature is on. To cancel RANDOM FOLDER/ from some models of iPods.
  • Page 179 OM7007 Radio / CD Player - Section 70 Page 70-11 OPERATING TIPS 1/ESC: Press the ESC button to exit or go back to previous menu when in a menu. Tips About The Audio System 2/PAUSE/PLAY: Press the PAUSE/PLAY button to Hearing damage from loud noise is almost undetect- pause a track.

  • Page 180: Troubleshooting

    Radio / CD Player - Section 70 OM7007 Page 70-12 TROUBLESHOOTING NOTE: Sound quality, skipping, difficulty in finding tracks, and/or difficulty in loading or ejecting a CD-R The following error messages may appear while may be affected by a CD-R’s quality, the method of playing a CD, MP3 disc/USB, iPod: recording, the quality of the music that has been NO CD:...
  • Page 182 ® www.komatsuamerica.com Copyright 2011 Komatsu Printed in U.S.A. Komatsu America Corp.

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