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

Trolley, dump truck
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Operation & Maintenance
Manual
DUMP TRUCK
SERIAL NUMBERS
Trolley
A30431, A30432, A30460,
A30461, A30463, A30464, &
A30467 - A30469
CEAM020701
®

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  • Page 1 CEAM020701 Operation & Maintenance Manual Trolley DUMP TRUCK A30431, A30432, A30460, A30461, A30463, A30464, & SERIAL NUMBERS A30467 - A30469 ®...
  • 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 products whenever it is possible and practical to do so. The...
  • 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 05/08 OM1060 Page 10-2 TRUCK MODEL ILLUSTRATION KOMATSU MODEL 730E DUMP TRUCK...

  • 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 05/08 OM1060 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

    OM1060 05/08 Introduction - Section 10 Page 10-5 TABLE OF CONTENTS SUBJECT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION/PAGE INTRODUCTION .
  • Page 10 Introduction - Section 10 05/08 OM1060 Page 10-6 SUBJECT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION/PAGE WORKING NEAR BATTERIES .
  • Page 11 OM1060 05/08 Introduction - Section 10 Page 10-7 SUBJECT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION/PAGE SAFE PARKING PROCEDURES .
  • Page 12 Introduction - Section 10 05/08 OM1060 Page 10-8 SUBJECT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION/PAGE Windshield Wiper Operation .
  • Page 13 OM1060 05/08 Introduction - Section 10 Page 10-9 SUBJECT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION/PAGE PAYLOAD METER .
  • Page 14 Introduction - Section 10 05/08 OM1060 Page 10-10 SUBJECT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION/PAGE Left Turn Signal Indicator Light .
  • Page 15 Komatsu Engines w/Centry™ Fuel Control ........
  • Page 16 Introduction - Section 10 05/08 OM1060 Page 10-12 SUBJECT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION/PAGE 250 HOUR LUBRICATION AND MAINTENANCE CHECKS .
  • Page 17 OM1060 05/08 Introduction - Section 10 Page 10-13 SUBJECT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION/PAGE SYSTEM PRIMING .
  • Page 18 Introduction - Section 10 05/08 OM1060 Page 10-14 SUBJECT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION/PAGE Setting a Default Display .
  • 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 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 • 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: Operating The Machine

    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 • 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. Use of these anchors and thick gloves.

  • 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 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 OM2232 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 OM2232 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 OM2232 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 OM2232 Safety - Section 22 Warnings and Cautions Page 22-5 The parking brake is spring-applied and hydraulically Before arc welding on the truck, disconnect the posi- released. It is designed to hold a stationary truck tive and negative battery cables of the vehicle. Fail- when the engine is off.
  • Page 52 Safety - Section 22 OM2232 Page 22-6 Warnings and Cautions This plate warns the technician to stop the engine, before loosening or disconnecting a brake line. Turn A decal plate is located on top of the center cross the key switch off, and open the drain valves on all tube.
  • Page 53 OM2232 Safety - Section 22 Warnings and Cautions Page 22-7 A wheel motor oil level decal is attached to the gear cover on both the electric wheel motors. This decal stresses that the truck must be on a level surface and parked for 20 minutes prior to checking the oil level.
  • Page 54 Safety - Section 22 OM2232 Page 22-8 Warnings and Cautions The lubrication chart is located on the right-hand side of the radiator grille. The chart specifies some of the critical maintenance items to be checked. Component location and service intervals are specified on the chart. The lube key lists the proper lubricants to be used.

  • 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: Machine Operation Safety Precautions

    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 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

    OM3241 Operation - Section 32 Operator Cab and Controls Page 32-1 OPERATOR CONTROLS FIGURE 32-1. CAB INTERIOR - OPERATOR VIEW 1. Steering Wheel and Controls 6. Heater/Air Conditioner and 11. Radio, AM/FM, CD Player 2. Service Brake Pedal Controls 12. Warning Lights Dimmer Control 3.

  • Page 80: Steering Wheel And Controls

    Operation - Section 32 OM3241 Page 32-2 Operator Cab and Controls STEERING WHEEL AND CONTROLS MULTI-FUNCTION TURN SIGNAL SWITCH STEERING WHEEL 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.

  • Page 81: Pedals

    OM3241 Operation - Section 32 Operator Cab and Controls Page 32-3 PEDALS DYNAMIC RETARDER PEDAL Dynamic retarder pedal (3, Figure 32-4) is a foot- operated pedal which allows the operator to slow the truck and maintain a safe productive speed without the use of the service brakes.

  • Page 82: Overhead Panel Controls And Components

    Operation - Section 32 OM3241 Page 32-4 Operator Cab and Controls OVERHEAD PANEL CONTROLS AND WARNING ALARM BUZZER COMPONENTS Warning alarm buzzer (10, Figure 32-1) will sound when activated by any one of several truck functions. GRADE/SPEED WARNING CHART Refer to Instrument Panel in this chapter for a detailed description of the functions and indicators Grade/Speed Warning chart (Figure 32-5) provides that will activate this alarm.

  • Page 83: Center Console

    OM3241 Operation - Section 32 Operator Cab and Controls Page 32-5 CENTER CONSOLE FIGURE 32-6. CENTER CONSOLE 1. Data Storage Button 8. Engine Shutdown Switch 2. Trolley Master Control Lever 9. Window Control Switches 3. F-N-R Selector Switch 10. Cigarette Lighter 4.

  • Page 84: Truck Controls

    Operation - Section 32 OM3241 Page 32-6 Operator Cab and Controls TRUCK CONTROLS CONSOLE SWITCHES AND CONTROLS F-N-R Selector Switch Cigarette Lighter F-N-R selector switch 3, Figure 32-6) is mounted on a Cigarette lighter (10, Figure 32-6) may be used for console to the right of the operator's seat.

  • Page 85: Override Switch

    OM3241 Operation - Section 32 Operator Cab and Controls Page 32-7 Override Switch Retard Speed Control (RSC) Switch Override switch Retard speed control (7, Figure 32-6) switch (6, Figure 32-6) is spring-loaded turns the system off or to the OFF posi- on.

  • Page 86: Statex Iii Download Port

    Operation - Section 32 OM3241 Page 32-8 Operator Cab and Controls With the RSC switch in the ON position and the dial Data Storage Button adjusted, the system will function as follows: As the Data storage button (1, Figure 32-6) is used to record truck speed increases to the set speed and the throt- a snapshot of the Statex III drive system.

  • Page 87: Cab Climate Control

    OM3241 Operation - Section 32 Operator Cab and Controls Page 32-9 CAB CLIMATE CONTROL Fan Control Knob Fan control knob (4, Figure 32-8) controls the 3-speed HEATER/AIR CONDITIONER VENTS heater/air conditioner internal fan unit. Full counter- The operator has complete control of the air flow in the clockwise is the off position.

  • Page 88: Operator Seat

    Operation - Section 32 OM3241 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. ADJUSTMENT The following adjustments must be made while sitting in the seat. 1. Headrest: Move up, down, fore, or aft by mov- ing headrest (1, Figure 32-9) to the desired position.

  • Page 89: Instrument Panels

    OM3241 Operation - Section 32 Operator Cab and Controls Page 32-11 INSTRUMENT PANEL FIGURE 32-10. PANEL, GAUGES, INDICATORS, AND CONTROLS 1. Key Switch 16. High Beam Headlight Indicator Light 2. Timer Delayed Engine Shutdown Switch 17. Left Turn Signal Indicator Light 3.

  • Page 90: General Information

    Operation - Section 32 OM3241 Page 32-12 Operator Cab and Controls GENERAL INFORMATION The operator must understand the function and oper- This symbol, when it appears on ation of each instrument and control (Figure 32-10). an indicator or control, identifies Control functions are identified with international that this indicator or control is not symbols that the operator must learn to recognize...

  • Page 91: Key Switch

    OM3241 Operation - Section 32 Operator Cab and Controls Page 32-13 Key Switch Ladder Light Switch Key switch (1, Figure 32-10) is a three-position (OFF, Ladder light switch (4, Figure 32- RUN, START) switch. When the switch is rotated one 10) turns the ladder lights on and position clockwise, it is in the RUN position and all off.

  • Page 92: Cab Air Conditioner/Heater Vents

    Operation - Section 32 OM3241 Page 32-14 Operator Cab and Controls Cab Air Conditioner/Heater Vents Wheel Brake Lock Switch Cab air conditioner/heater vents (7, Figure 32-10) are Wheel brake lock switch (12, Figure 32- spherically mounted and may be directed by the oper- 10) must only be used when the engine ator to provide the most comfortable cabin air flow.

  • Page 93: Digital Tachometer

    OM3241 Operation - Section 32 Operator Cab and Controls Page 32-15 Digital Tachometer Voltmeter Gauge Digital tachometer (14, Figure 32-10) displays the Voltmeter gauge (19, Figure 32- engine crankshaft speed in revolutions per minute 10) indicates the voltage of the (rpm).

  • Page 94: Fuel Gauge

    Operation - Section 32 OM3241 Page 32-16 Operator Cab and Controls Fuel Gauge Payload Meter Switch Fuel gauge (22, Figure 32-10) Payload meter switch (29, Figure indicates how much diesel fuel is 32-10) is a two-way, momentary in the fuel tank. switch.

  • Page 95: Overhead Status / Warning Indicator Light Panel

    OM3241 Operation - Section 32 Operator Cab and Controls Page 32-17 OVERHEAD STATUS / WARNING INDICATOR LIGHT PANEL FIGURE 32-11. INDICATOR LIGHT PANEL Row / Indicator Indicator Color Wire Row / Indicator Indicator Color Wire Column Description Index Column Description Index Hydraulic Oil Temp.

  • Page 96: Indicator Light Functions

    Operation - Section 32 OM3241 Page 32-18 Operator Cab and Controls INDICATOR LIGHT FUNCTIONS Amber indicator lights alert the operator the indicated truck function requires some precaution when lighted. If the low steering warning light continues to illu- minate and the alarm continues to sound, low Red indicator lights alert the operator the indicated steering pressure is indicated.

  • Page 97: Electric System Fault Warning

    OM3241 Operation - Section 32 Operator Cab and Controls Page 32-19 Electric System Fault Warning Low Automatic Lubrication System Pressure Electric system fault warning light (D1) will flash on and off when a Amber low automatic lubrica- malfunction occurs in the electri- tion system pressure light (B2) cal system.

  • Page 98: Low Fuel Indicator

    Operation - Section 32 OM3241 Page 32-20 Operator Cab and Controls Low Fuel Indicator Stop Engine Warning Amber low fuel indicator light Red stop engine warning light (E2) will illuminate when the fuel (E3) will illuminate if a serious remaining in the tank is below engine malfunction is detected in 95 liters (25 gallons).

  • Page 99: Check Engine

    Centry™ fuel control sys- tem, alert maintenance personnel as soon as possi- ble. Service Engine Komatsu Engines w/Centry™ Fuel Control Indicator (AEM) This indicator monitors the Centry™ fuel system. Amber service engine indicator During engine operation, if a fault is detected in the...

  • Page 100: Lamp Test Switch/Centry™ Diagnostic Test Switch

    OFF position. automatically switched to use For diagnostic tests of a Komatsu engine equipped from the trolley line power. When the amber indicator with the Centry™ fuel control, refer to Centry™ Diag- light is on, it means that the sequence has been com- nostics at the end of this chapter.
  • Page 101 OM3241 Operation - Section 32 Operator Cab and Controls Page 32-23 Trolley Fault Indicator Max Speed Indicator The trolley fault indicator (D7) The max speed indicator (A8) lights when a trolley fault occurs lights when the operator has while the master control switch is selected the fourth, and last, in the TROLLEY position.
  • Page 102 Operation - Section 32 OM3241 Page 32-24 Operator Cab and Controls Med Speed Indicator Right Limit Indicator (Optional) The medium speed indicator When on trolley, the right limit (C8) lights when the operator indicator (E8) will light if the over- has selected the second detent head power cables make contact position of the master control...

  • Page 103: Rear Axle Light Bar

    OM3241 Operation - Section 32 Operator Cab and Controls Page 32-25 REAR AXLE LIGHT BAR FIGURE 32-1. REAR AXLE LIGHT BAR 1. Backup Lights 3. Brake Lights 2. Retard Lights 4. Backup Alarm Brake Light NOTE: The brake light is functional at all times Brake light (3) will illuminate when the operator regardless of key switch position.

  • Page 104: Centry™ Fuel System Diagnostics

    Operation - Section 32 OM3241 Page 32-26 Operator Cab and Controls CENTRY™ FUEL SYSTEM Lamp test/diagnostic test switch (8, Figure 32-11) may be used to activate the Centry™ fuel system DIAGNOSTICS diagnostic codes. When the Centry™ fuel system detects a fault and service engine indicator light (D6, GENERAL OPERATION Figure 32-11) illuminates, this switch will permit iden- Service engine indicator light (D6, Figure 32-11)

  • Page 105: Exiting The Diagnostics Mode

    OM3241 Operation - Section 32 Operator Cab and Controls Page 32-27 EXITING THE DIAGNOSTICS MODE 3. If there is an active fault after releasing the switch, there will be a short pause, followed by Starting the engine or turning the key switch to the OFF the first fault code.
  • Page 106 Operation - Section 32 OM3241 Page 32-28 Operator Cab and Controls NOTES...

  • Page 107: 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 108: 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 109 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 110: 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 111: Left-Hand Fuel Receiver - Optional

    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 112: Lubrication Chart

    Maintenance - Section 40 OM4064 06/11 Page 40-6 Lubrication and Service LUBRICATION CHART...
  • Page 113 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 114 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 115: Hour Lube 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 116 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 117 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 118 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 119 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 120: 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 121: 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 122: 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 123: 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 124 Maintenance - Section 40 OM4064 06/11 Page 40-18 Lubrication and Service NOTES...

  • Page 125: 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 126: 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 127: 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 128: 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 129 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 130: 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 131: 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 132: 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 133: 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 134: 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 135: 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 136: 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 137: 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 138: 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 139: 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 140 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 141: 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 142 Specifications - Section 50 03/11 OM5037 Page 50-2 730E MAJOR COMPONENTS...
  • Page 143 Number of Cylinders ..... . . 16 Komatsu ....223... . .59 Operating Cycle.
  • Page 144 Capacity: Standard Komatsu Body . 25,612 ..(56,464) Struck ....77 m³ ..101 yds³...
  • Page 145 OM6008 08/06 Payload Meter III - Section 60 Page 60-1 PAYLOAD METER III SECTION 60 INDEX PAYLOAD METER III ............. . .60-5 Introduction .
  • Page 146 Setting the Komatsu Distributor ........
  • Page 147 OM6008 08/06 Payload Meter III - Section 60 Page 60-3 Sorting on Date Range ............60-26 Sorting on Time Range .
  • Page 148 Payload Meter III - Section 60 08/06 OM6008 Page 60-4 NOTES...

  • Page 149: Payload Meter Iii

    OM6008 08/06 Payload Meter III - Section 60 Page 60-5 PAYLOAD METER III INTRODUCTION Data Gathering Windows 95/98/NT software is available to down- Payload Meter III (PLM III) measures, displays and load, store, and view payload and fault information. records the weight of material being carried by an off- The PC software will download an entire truck fleet highway truck.
  • Page 150 Payload Meter III - Section 60 08/06 OM6008 Page 60-6 COMPONENT DESCRIPTION System Diagram Suspension Pressure Sensors Operator Display PLM III uses a two-wire pressure sensor. The range The speedometer/display gauge is used as a speed- for the pressure sensor is 281 kPa (4000 psi) and the ometer and payload display.
  • Page 151 Connections flag the haul cycle record. All other functions will be to this serial port need to be approved by Komatsu. normal regardless of brake lock usage. The brake Several protocol options are available and detailed...
  • Page 152 Payload Meter III - Section 60 08/06 OM6008 Page 60-8 Key Switch Input Load Lights PLM III monitors the status of the key switch. 24VDC PLM III 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 153 OM6008 08/06 Payload Meter III - Section 60 Page 60-9 Wiring and Termination TCI Outputs Most of the PLM III truck connections use a heavy- The GE drive system on the 930E/960E requires duty cable. This yellow multi-conductor cable uses a information from the payload meter regarding the 16awg, finely stranded wire designed for continuous loaded condition of the truck.
  • Page 154 Payload Meter III - Section 60 08/06 OM6008 Page 60-10 OPERATOR’S DISPLAY AND SWITCH Using the Operator ID The current operator ID number is recorded with Reading the Speedometer each haul cycle. The number can be between 0 and The top window of the speedometer/display gauge is 9999.
  • Page 155 OM6008 08/06 Payload Meter III - Section 60 Page 60-11 Total Load Counter The inclinometer displays whole degrees of incline. Positive incline is truck nose up. The gauge will The total load counter records the number of loads quickly display the type of information shown every hauled since the last time it was cleared.
  • Page 156 Payload Meter III - Section 60 08/06 OM6008 Page 60-12 PAYLOAD OPERATION AND The payload meter switches from loading to maneu- vering as soon as the truck begins moving. The CALCULATION maneuvering zone is 160m and is designed to allow Description of Haul Cycle States the operator to reposition the truck under the shovel.
  • Page 157 OM6008 08/06 Payload Meter III - Section 60 Page 60-13 SOURCES FOR PAYLOAD ERROR Load Calculation The final load calculation is different from the last Payload Error swingload calculation. The accuracy of the swing load The number one source of error in payload calcula- calculation depends on loading conditions and the tion is improperly serviced suspensions.
  • Page 158 The payload meter does not compensate for these changes. NOTE: Earlier 730E and 830E models are subject to incorrect speed data due to electrical interference. The incorrect speeds are generated while the truck is stopped.
  • Page 159 OM6008 08/06 Payload Meter III - Section 60 Page 60-15 Haul Cycle Data The following information is recorded for each haul cycle: 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 the numeric truck number.
  • Page 160 Payload Meter III - Section 60 08/06 OM6008 Page 60-16 Haul Cycle Warning Flags F: Final Zone to Dumping Transition The payload meter expects haul cycles to progress in This message is generated when the payload meter a particular way. When something unexpected takes senses a body-up while it is calculating the final pay- place, the system records a warning flag.
  • Page 161 OM6008 08/06 Payload Meter III - Section 60 Page 60-17 M: Haul Cycle Too Long Sprung Weight Data The haul_cycle_too_long flag indicates that the haul The payload meter is constantly monitoring the live cycle took longer than 18.2 hours to complete. The payload calculation.
  • Page 162 Payload Meter III - Section 60 08/06 OM6008 Page 60-18 Fault Code Data Table 2: Fault Code Name Description Left front pressure high Input current > 22 ma Left front pressure low Input current < 2 ma Right front pressure high Input current >...
  • Page 163 OM6008 08/06 Payload Meter III - Section 60 Page 60-19 PC SOFTWARE OVERVIEW Installing the PLM III Software The CD ROM containing the Payload Data Manage- PC Overview ment (PDM) Software will automatically begin instal- The PC software has several basic functions: lation when it is inserted into the drive on the PC.
  • Page 164 Payload Meter III - Section 60 08/06 OM6008 Page 60-20 DOWNLOADING DATA To download the payload meter: 1. Connect to the payload meter and start the PC PLM III records many types of data. The PLM III PC software. software is designed to download the data from a whole truck fleet.
  • Page 165 OM6008 08/06 Payload Meter III - Section 60 Page 60-21 PLM III SYSTEM CONFIGURATION Short Tons: Payload is displayed in short tons, dis- tances and speeds will be displayed in Miles. Starting Communications Metric Tons: Payload is displayed in metric tons, dis- The PDM software allows users to download and tances and speeds are displayed in Kilometers.
  • Page 166 Payload Meter III - Section 60 08/06 OM6008 Page 60-22 There are also many configuration and download Setting the Date and Time options available from this screen. The connection menu is updated only when the connection is first made. It does not update automatically. To view changes made while connected, the user must close the window and reconnect to the payload meter.
  • Page 167 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 sys- changed from metric to short tons or long tons using tem. Komatsu also assigns a distributor number to the truck configuration screen.
  • Page 168 Payload Meter III - Section 60 08/06 OM6008 Page 60-24 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 169 The truck type is the size of the truck from the family can be narrowed by selecting which trucks or types of Komatsu trucks. This allows the user to quickly to view and for what dates and times. view results from different types of trucks on the property.
  • Page 170 Payload Meter III - Section 60 08/06 OM6008 Page 60-26 Sorting on Date Range 2. Change the From date to January 5, 2000. The default query starts in 1995 and runs through the current date on the PC. To narrow the range to a spe- cific date, change the From and To dates.
  • Page 171 OM6008 08/06 Payload Meter III - Section 60 Page 60-27 Creating Reports Reports can be generated and viewed on the screen Date Time Jan 5, 2000 Jan 6, 2000 Jan 7, 2000 Jan 8, 2000 Jan 9, 2000 or printed. These reports are generated from the 0:00 query displayed on the payload summary screen.
  • Page 172 Payload Meter III - Section 60 08/06 OM6008 Page 60-28 NOTE: Some haul cycles may contain the sensor input warning flag. This indicates that one of the four pressure sensors or inclinometer was not functioning properly during the haul cycle. Haul cycles with this warning are displayed in red on the payload summary window and are not included in the summary statistics for reports or display.
  • Page 173 OM6008 08/06 Payload Meter III - Section 60 Page 60-29 Creating Graphs Exporting Data The PLM III 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 screen.
  • Page 174 Payload Meter III - Section 60 08/06 OM6008 Page 60-30 • Maximum - frame torque • Time when the maximum - frame torque occurred • Maximum sprung weight calculation • Time when maximum sprung weight calculation occurred • Left front tire-kilometer-hour •...
  • Page 175 OM6008 08/06 Payload Meter III - Section 60 Page 60-31 Compressed Deleting Haul Cycle Records To delete haul cycle records from the main database, press the "Delete" button at the bottom of the pay- load summary screen. The program will display a summary of the records from the displayed query.
  • Page 176 Payload Meter III - Section 60 08/06 OM6008 Page 60-32 Viewing Alarms Deleting Alarm Records From the payload summary screen, click the To delete alarm records from the main database, “Alarms” button to display the alarm screen. The press the "Delete" button at the bottom of the alarm alarms are sorted by the query settings from the pay- display screen.
  • Page 177 OM7006 03/10 Radio / CD Player - Section 70 Page 70-1 AM/FM RADIO / CD PLAYER FIGURE 70-1. AM/FM RADIO / CD PLAYER 1. Ejects CD 7. Push Buttons 1-6 Pre-set stations/CD/MP3 func- tions 2. BAND Switches between AM, FM1, FM2, FM3, WX (Weatherband) and Auxiliary Mode 8.
  • Page 178 Radio / CD Player - Section 70 03/10 OM7006 Page 70-2 Display Auxiliary Mode The receiver will display the time of day when it is off. When in Auxiliary mode, the radio can play an audio Momentarily pressing the TMSET/DSPL (3) button source from an iPOD or an MP3 player that is con- when the receiver is on allows to toggle between dis- nected via the auxiliary radio lines.
  • Page 179 OM7006 03/10 Radio / CD Player - Section 70 Page 70-3 USING THE ALARM SEEK SENSITIVITY: To adjust seek sensitivity, press the AUDIO knob until SEEK and the sensitivity Momentarily pressing the ALARM (10) button will dis- level appear. Rotate the AUDIO knob to the desired play the alarm set time.
  • Page 180 Radio / CD Player - Section 70 03/10 OM7006 Page 70-4 After 5 seconds of inactivity, the receiver will return to the default display and the volume level at which the SCAN: Press SCAN/DIM (9) to scan all stations on receiver was previously playing.
  • Page 181 OM7006 03/10 Radio / CD Player - Section 70 Page 70-5 USING THE WEATHERBAND USING THE COMPACT DISC PLAYER NOAA Weather Radio is a service of the National The integral CD player plays full size CDs and MP3 Weather Service. It provides continuous broadcasts discs.
  • Page 182 Radio / CD Player - Section 70 03/10 OM7006 Page 70-6 5/FF: Press and hold FF to fast-forward. Upon Root Directory release, the CD will play at normal speed. The dis- The root directory is treated as a folder. If the root play will show the track number and elapsed time.
  • Page 183 OM7006 03/10 Radio / CD Player - Section 70 Page 70-7 Pre-Programmed Playlists Button Functions Pre-programmed playlist function like folders contain- 1/FLD (NEXT FOLDER): Press this button to go to ing compressed audio song files. This radio plays the first track in the next folder or playlist. Pressing pls, m3u, and rmp playlist formats.
  • Page 184 Radio / CD Player - Section 70 03/10 OM7006 Page 70-8 TROUBLESHOOTING DSPL/TM SET: Pressing this button toggles between the ID3 tag (song title, artist and album title) and time The following error messages may appear while of day. There are 3 display types that can be set as playing a CD or MP3 disc: default: track, folder/playlist, and time of day.
  • Page 186 ® www.komatsuamerica.com Copyright 2011 Komatsu Printed in U.S.A. Komatsu America Corp.

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