KOMATSU 730E DUMP TRUCK Operation & Maintenance Manual (SN:A30539 – A30551) KOMATSU 730E – PDF DOWNLOAD

Description

KOMATSU 730E DUMP TRUCK Operation & Maintenance Manual (SN:A30539 – A30551) KOMATSU 730E

KOMATSU 730E DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30539 – A30551) KOMATSU 730E – PDF DOWNLOAD:

IMAGE PREVIEW:

DESCRIPTION:

KOMATSU 730E DUMP TRUCK Operation & Maintenance Manual (SN:A30539 – A30551) KOMATSU 730E

• This manual is written for use by the operator and/or the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel must read and understand the materials in this manual before operating the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings, and cautions must be understood and followed when operating or repairing the truck.
• A product identification plate is located on the frame in front of the right side front wheel and designates the truck model number, product identification number (vehicle serial number), and maximum GVW (Gross Vehicle Weight) rating.
• The Komatsu truck model designation consists of three numbers and one letter (i.e. 930E).
  The three numbers represent the basic truck model.
  The letter E, when present, designates an electrical wheel motor drive system.
• The product identification number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.

TABLE OF CONTENTS:

KOMATSU 730E DUMP TRUCK Operation & Maintenance Manual (SN:A30539 – A30551) KOMATSU 730E

COVER
.......................................................................................................................................................................................................................................................................  1
INTRODUCTION.................................................................................................................................................................................................................................................................  5
	FOREWORD.................................................................................................................................................................................................................................................................  5
	TRUCK MODEL ILLUSTRATION.................................................................................................................................................................................................................................................  6
	ABOUT THIS MANUAL........................................................................................................................................................................................................................................................  7
	ALERTS PAGE..............................................................................................................................................................................................................................................................  8
TABLE OF CONTENTS............................................................................................................................................................................................................................................................  9
TORQUE TABLES AND CONVERSION CHARTS.......................................................................................................................................................................................................................................... 19
	EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values..................................................................................................................................................................................................... 20
	STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts.................................................................................................................................................................................................... 20
	STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws....................................................................................................................................................................................................... 21
	STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws................................................................................................................................................................................................................... 22
GENERAL SAFETY............................................................................................................................................................................................................................................................... 29
	PERSONAL SAFETY.......................................................................................................................................................................................................................................................... 29
		Safety Rules......................................................................................................................................................................................................................................................... 29
		Truck Safety Features................................................................................................................................................................................................................................................ 29
		Clothing And Personal Items.......................................................................................................................................................................................................................................... 29
		Unauthorized Modification............................................................................................................................................................................................................................................ 29
		Leaving The Operator’s Seat.......................................................................................................................................................................................................................................... 29
		Mounting And Dismounting............................................................................................................................................................................................................................................. 29
		Fire Extinguishers And First Aid Kits................................................................................................................................................................................................................................ 30
		Precautions For High Temperature Fluids.............................................................................................................................................................................................................................. 30
		Asbestos Dust Hazard Prevention...................................................................................................................................................................................................................................... 30
		Fire Prevention For Fuel And Oil..................................................................................................................................................................................................................................... 30
		ROPS Precautions..................................................................................................................................................................................................................................................... 31
		Preventing Injury From Work Equipment................................................................................................................................................................................................................................ 31
		Precautions For Optional Attachments................................................................................................................................................................................................................................. 31
		Precautions When Starting The Machine................................................................................................................................................................................................................................ 31
	PRECAUTIONS FOR TRUCK OPERATION.......................................................................................................................................................................................................................................... 32
		Safety Is Thinking Ahead............................................................................................................................................................................................................................................. 32
		Safety At The Work Site.............................................................................................................................................................................................................................................. 32
		Fire Prevention...................................................................................................................................................................................................................................................... 32
		Preparing For Operation.............................................................................................................................................................................................................................................. 32
		Ventilation For Enclosed Areas....................................................................................................................................................................................................................................... 32
		Mirrors, Windows, And Lights......................................................................................................................................................................................................................................... 32
		In The Operator’s Cab - Before Starting The Engine................................................................................................................................................................................................................... 33
		Seat Belts........................................................................................................................................................................................................................................................... 33
	OPERATING THE MACHINE.................................................................................................................................................................................................................................................... 33
		Starting The Engine.................................................................................................................................................................................................................................................. 33
		Truck Operation - General............................................................................................................................................................................................................................................ 33
		Traveling In The Truck............................................................................................................................................................................................................................................... 34
		Precautions When Traveling In Reverse................................................................................................................................................................................................................................ 34
		Traveling On Slopes.................................................................................................................................................................................................................................................. 34
		Ensuring Good Visibility............................................................................................................................................................................................................................................. 35
		Operating On Snow.................................................................................................................................................................................................................................................... 35
		Avoid Damage To The Dump Body........................................................................................................................................................................................................................................ 35
		Driving Near High-Voltage Cables..................................................................................................................................................................................................................................... 35
		When Loading The Truck............................................................................................................................................................................................................................................... 35
		When Dumping......................................................................................................................................................................................................................................................... 35
		Working On Loose Ground.............................................................................................................................................................................................................................................. 35
		Parking The Machine.................................................................................................................................................................................................................................................. 36
	TOWING................................................................................................................................................................................................................................................................... 36
	WORKING NEAR BATTERIES................................................................................................................................................................................................................................................... 36
		Battery Hazard Prevention............................................................................................................................................................................................................................................ 36
		Jump-Starting With Booster Cables.................................................................................................................................................................................................................................... 37
		Jump Starting With Receptacles....................................................................................................................................................................................................................................... 37
	PRECAUTIONS FOR MAINTENANCE.............................................................................................................................................................................................................................................. 38
		BEFORE PERFORMING MAINTENANCE........................................................................................................................................................................................................................................ 38
			Stopping The Engine Before Service............................................................................................................................................................................................................................... 38
			Warning Tag...................................................................................................................................................................................................................................................... 38
			Proper Tools..................................................................................................................................................................................................................................................... 38
			Securing The Dump Body........................................................................................................................................................................................................................................... 38
		DURING MAINTENANCE................................................................................................................................................................................................................................................... 39
			Personnel........................................................................................................................................................................................................................................................ 39
			Attachments...................................................................................................................................................................................................................................................... 39
			Working Under The Machine........................................................................................................................................................................................................................................ 39
			Keeping The Machine Clean........................................................................................................................................................................................................................................ 39
			Rules To Follow When Adding Fuel Or Oil.......................................................................................................................................................................................................................... 39
			Radiator Coolant Level........................................................................................................................................................................................................................................... 39
			Use Of Lighting.................................................................................................................................................................................................................................................. 39
			Precautions With The Battery..................................................................................................................................................................................................................................... 40
			Handling High-Pressure Hoses..................................................................................................................................................................................................................................... 40
			Precautions With High-Pressure Oil............................................................................................................................................................................................................................... 40
			Maintenance Near High Temperatures And High Pressures............................................................................................................................................................................................................ 40
			Rotating Fan And Belts........................................................................................................................................................................................................................................... 40
			Waste Materials.................................................................................................................................................................................................................................................. 40
		TIRES................................................................................................................................................................................................................................................................ 41
			Handling Tires................................................................................................................................................................................................................................................... 41
			Tire Maintenance................................................................................................................................................................................................................................................. 42
			Storing Tires After Removal...................................................................................................................................................................................................................................... 42
	ADDITIONAL JOB SITE RULES................................................................................................................................................................................................................................................ 43
	WHEN REPAIRS ARE NECESSARY............................................................................................................................................................................................................................................... 44
WARNINGS AND CAUTIONS........................................................................................................................................................................................................................................................ 47
OPERATING INSTRUCTIONS....................................................................................................................................................................................................................................................... 55
	PREPARING FOR OPERATION.................................................................................................................................................................................................................................................. 55
	SAFETY IS THINKING AHEAD................................................................................................................................................................................................................................................. 55
	WALK AROUND INSPECTION................................................................................................................................................................................................................................................... 55
	ENGINE START-UP.......................................................................................................................................................................................................................................................... 60
	AFTER ENGINE HAS STARTED................................................................................................................................................................................................................................................. 61
	EMERGENCY STEERING SYSTEM................................................................................................................................................................................................................................................ 62
		Operation............................................................................................................................................................................................................................................................ 62
		Pre-Operation Testing................................................................................................................................................................................................................................................ 62
		Additional Guidelines................................................................................................................................................................................................................................................ 63
	MACHINE OPERATION SAFETY PRECAUTIONS..................................................................................................................................................................................................................................... 63
	LOADING.................................................................................................................................................................................................................................................................. 64
	HAULING.................................................................................................................................................................................................................................................................. 64
	PASSING.................................................................................................................................................................................................................................................................. 65
	DUMPING.................................................................................................................................................................................................................................................................. 65
		To Raise The Dump Body:.............................................................................................................................................................................................................................................. 65
		To Lower The Dump Body: (When dumping over a berm or into a crusher):................................................................................................................................................................................................ 66
		To Lower The Dump Body (When dumping on flat ground):................................................................................................................................................................................................................ 66
	SAFE PARKING PROCEDURES.................................................................................................................................................................................................................................................. 67
	ENGINE SHUTDOWN PROCEDURE................................................................................................................................................................................................................................................ 67
	DELAYED ENGINE SHUTDOWN PROCEDURE........................................................................................................................................................................................................................................ 68
	SUDDEN LOSS OF POWER..................................................................................................................................................................................................................................................... 68
	DISABLED TRUCK DUMPING PROCEDURE......................................................................................................................................................................................................................................... 69
		Hookup............................................................................................................................................................................................................................................................... 69
		Raising the Body..................................................................................................................................................................................................................................................... 69
		Lowering the Body.................................................................................................................................................................................................................................................... 69
	TOWING................................................................................................................................................................................................................................................................... 70
OPERATOR CONTROLS............................................................................................................................................................................................................................................................ 71
	STEERING WHEEL AND CONTROLS.............................................................................................................................................................................................................................................. 72
		STEERING WHEEL....................................................................................................................................................................................................................................................... 72
		HORN BUTTON.......................................................................................................................................................................................................................................................... 72
		TILT/TELESCOPE LEVER................................................................................................................................................................................................................................................. 72
		MULTI-FUNCTION TURN SIGNAL SWITCH.................................................................................................................................................................................................................................... 72
			Turn Signal Operation............................................................................................................................................................................................................................................ 72
			High Beam Headlight Operation.................................................................................................................................................................................................................................... 72
			Windshield Wiper Operation....................................................................................................................................................................................................................................... 72
	PEDALS................................................................................................................................................................................................................................................................... 73
		SERVICE BRAKE PEDAL.................................................................................................................................................................................................................................................. 73
		DYNAMIC RETARDER PEDAL............................................................................................................................................................................................................................................... 73
			Optional - Dual Function/Single Pedal............................................................................................................................................................................................................................ 73
		THROTTLE PEDAL....................................................................................................................................................................................................................................................... 73
	CAB CLIMATE CONTROL...................................................................................................................................................................................................................................................... 74
		HEATER/AIR CONDITIONER VENTS......................................................................................................................................................................................................................................... 74
		HEATER/AIR CONDITIONER CONTROLS AND VENTS............................................................................................................................................................................................................................ 74
			Defroster Vent Control Switch.................................................................................................................................................................................................................................... 74
			Heat Control Switch.............................................................................................................................................................................................................................................. 74
			Temperature Control Knob......................................................................................................................................................................................................................................... 74
			Fan Control Knob................................................................................................................................................................................................................................................. 75
			Heater/Air Conditioner Selector Switch........................................................................................................................................................................................................................... 75
			Heater/Air Conditioner Vents..................................................................................................................................................................................................................................... 75
	OVERHEAD PANEL CONTROLS AND COMPONENTS................................................................................................................................................................................................................................... 76
		GRADE/SPEED WARNING CHART............................................................................................................................................................................................................................................ 76
		RADIO SPEAKERS....................................................................................................................................................................................................................................................... 76
		WARNING ALARM BUZZER................................................................................................................................................................................................................................................. 76
		CAB RADIO............................................................................................................................................................................................................................................................ 76
		WARNING LIGHTS DIMMER CONTROL........................................................................................................................................................................................................................................ 76
		WARNING/STATUS INDICATOR LIGHT PANEL................................................................................................................................................................................................................................. 76
		AIR CLEANER VACUUM GAUGES............................................................................................................................................................................................................................................ 76
		WINDSHIELD WIPERS.................................................................................................................................................................................................................................................... 76
		TRUCK CONTROLS....................................................................................................................................................................................................................................................... 77
			F-N-R Selector Switch............................................................................................................................................................................................................................................ 77
			Hoist Control Lever.............................................................................................................................................................................................................................................. 78
		CENTER CONSOLE
...................................................................................................................................................................................................................................................... 77
		CONSOLE SWITCHES AND CONTROLS........................................................................................................................................................................................................................................ 78
			Ashtray.......................................................................................................................................................................................................................................................... 78
			Cigarette Lighter................................................................................................................................................................................................................................................ 78
			Left-Hand Window Control Switch.................................................................................................................................................................................................................................. 78
			Right-Hand Window Control Switch................................................................................................................................................................................................................................. 78
			Engine Shutdown Switch........................................................................................................................................................................................................................................... 78
			Override Switch.................................................................................................................................................................................................................................................. 78
			Retard Speed Control (RSC) Switch................................................................................................................................................................................................................................ 79
			Retard Speed Control (RSC) Dial.................................................................................................................................................................................................................................. 79
			Statex III Download Port......................................................................................................................................................................................................................................... 80
			Engine Diagnostic Port (CENSE)................................................................................................................................................................................................................................... 80
			Modular Mining Port.............................................................................................................................................................................................................................................. 80
			Modular mining port (15, Figure 32-7) is used if the optional modular mining system is installed on the truck.................................................................................................................................................... 80
			Passenger Seat................................................................................................................................................................................................................................................... 80
			Engine Diagnostic Connectors..................................................................................................................................................................................................................................... 80
			Engine Diagnostics Connector..................................................................................................................................................................................................................................... 80
			Data Storage Button.............................................................................................................................................................................................................................................. 80
		PAYLOAD METER........................................................................................................................................................................................................................................................ 80
			Payload Meter Download Connector................................................................................................................................................................................................................................. 80
	OPERATOR SEAT............................................................................................................................................................................................................................................................ 81
		ADJUSTMENT........................................................................................................................................................................................................................................................... 81
	INSTRUMENT PANEL......................................................................................................................................................................................................................................................... 82
		CONTROL SYMBOLS...................................................................................................................................................................................................................................................... 82
		CONTROL SWITCHES AND GAUGES.......................................................................................................................................................................................................................................... 83
			Key Switch....................................................................................................................................................................................................................................................... 83
			Engine Shutdown Switch With Timer Delay.......................................................................................................................................................................................................................... 84
			Fog Light Switch................................................................................................................................................................................................................................................. 84
			Ladder Light Switch.............................................................................................................................................................................................................................................. 84
			Backup Light Switch.............................................................................................................................................................................................................................................. 84
			Backup light switch (5, Figure 32-11) allows the backup lights to be turned ON providing added visibility and safety when the selector switch (see operator controls) is not in the REV position. When the switch is pressed toward the ON position, manua....... 84
			Panel Illumination Lights........................................................................................................................................................................................................................................ 84
			Cab Air Conditioner/Heater Vents................................................................................................................................................................................................................................. 84
			Engine Cold Weather Starting Aid Switch.......................................................................................................................................................................................................................... 84
			Rotating Beacon Light Switch..................................................................................................................................................................................................................................... 84
			Heated Mirror Switch............................................................................................................................................................................................................................................. 84
			Wheel Brake Lock Switch.......................................................................................................................................................................................................................................... 85
			Parking Brake Switch............................................................................................................................................................................................................................................. 85
			Digital Tachometer............................................................................................................................................................................................................................................... 85
			Right Turn Signal Indicator Light................................................................................................................................................................................................................................ 86
			High Beam Headlight Indicator Light.............................................................................................................................................................................................................................. 86
			Left Turn Signal Indicator Light................................................................................................................................................................................................................................. 86
			Digital Speedometer/Payload Meter Display........................................................................................................................................................................................................................ 86
			Voltmeter Gauge.................................................................................................................................................................................................................................................. 86
			Engine Oil Pressure Gauge........................................................................................................................................................................................................................................ 86
			Engine Water Temperature Gauge................................................................................................................................................................................................................................... 86
			Fuel Gauge....................................................................................................................................................................................................................................................... 86
			Engine Hourmeter................................................................................................................................................................................................................................................. 86
			Headlight Switch................................................................................................................................................................................................................................................. 87
			Panel Illumination Lights Dimmer Rheostat........................................................................................................................................................................................................................ 87
			Payload Meter Switch............................................................................................................................................................................................................................................. 87
	OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL............................................................................................................................................................................................................................ 88
		DESCRIPTION OF INDICATOR SYMBOLS..................................................................................................................................................................................................................................... 88
		INDICATOR LIGHT FUNCTIONS............................................................................................................................................................................................................................................ 89
			A1. High Hydraulic Oil Temperature............................................................................................................................................................................................................................... 89
			B1. Low Steering Pressure........................................................................................................................................................................................................................................ 89
			C1. Low Accumulator Precharge Pressure........................................................................................................................................................................................................................... 90
			D1. Electric System Fault........................................................................................................................................................................................................................................ 90
			E1. Low Brake Pressure........................................................................................................................................................................................................................................... 90
			A2. Low Hydraulic Tank Level..................................................................................................................................................................................................................................... 90
			B2. Automatic Lubrication System Pressure........................................................................................................................................................................................................................ 90
			C2. Circuit Breaker Tripped...................................................................................................................................................................................................................................... 90
			D2. Hydraulic Oil Filter Monitor................................................................................................................................................................................................................................. 91
			E2. Low Fuel..................................................................................................................................................................................................................................................... 91
			A3. Parking Brake................................................................................................................................................................................................................................................ 91
			B3. Service Brake................................................................................................................................................................................................................................................ 91
			C3. Body Up...................................................................................................................................................................................................................................................... 91
			D3. Dynamic Retarding............................................................................................................................................................................................................................................ 91
			E3. Stop Engine.................................................................................................................................................................................................................................................. 91
			A4. Not Used..................................................................................................................................................................................................................................................... 92
			B4. Manual Backup Lights......................................................................................................................................................................................................................................... 92
			C4. Engine Shutdown Timer........................................................................................................................................................................................................................................ 92
			D4. Retard Speed Control (RSC)................................................................................................................................................................................................................................... 92
			E4. Check Engine................................................................................................................................................................................................................................................. 92
			A5. Service Engine Indicator (AEM)............................................................................................................................................................................................................................... 92
			B5. High Wheel Motor Temperature................................................................................................................................................................................................................................. 92
			C5. Blower Fault................................................................................................................................................................................................................................................. 92
			D5, E5, A6, B6, and C6. Not Used................................................................................................................................................................................................................................. 92
			D6. Service Engine (CENSE)....................................................................................................................................................................................................................................... 92
			E6. Not Used..................................................................................................................................................................................................................................................... 92
			Komatsu Engines with Centry™ Fuel Control........................................................................................................................................................................................................................ 93
			Hazard Warning Light Switch...................................................................................................................................................................................................................................... 93
			Lamp Test Switch/Centry™ Diagnostic Test Switch.................................................................................................................................................................................................................. 93
	CENTRY™ FUEL SYSTEM DIAGNOSTICS.......................................................................................................................................................................................................................................... 94
		GENERAL OPERATION.................................................................................................................................................................................................................................................... 94
		DETERMINING FAULT CODES.............................................................................................................................................................................................................................................. 94
		EXITING THE DIAGNOSTICS MODE......................................................................................................................................................................................................................................... 95
LUBRICATION AND SERVICE...................................................................................................................................................................................................................................................... 97
	GENERAL INFORMATION...................................................................................................................................................................................................................................................... 97
	HYDRAULIC TANK SERVICE................................................................................................................................................................................................................................................... 97
		Adding Oil........................................................................................................................................................................................................................................................... 97
	COOLING SYSTEM SERVICE................................................................................................................................................................................................................................................... 98
		Radiator Filling Procedure........................................................................................................................................................................................................................................... 98
	RESERVE ENGINE OIL SYSTEM - (IF EQUIPPED)................................................................................................................................................................................................................................ 98
		Reserve Oil Tank Filling Procedure (Remote Fill)..................................................................................................................................................................................................................... 98
	LEFT-HAND FUEL RECEIVER - OPTIONAL (WIGGINS QUICK FILL).................................................................................................................................................................................................................. 99
	LUBRICATION CHART........................................................................................................................................................................................................................................................100
	10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS..............................................................................................................................................................................................................................101
	10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS (Continued)..................................................................................................................................................................................................................102
	50 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................................................................................................................................................................................103
	100 HOUR LUBRICATION AND MAINTENANCE CHECKS..............................................................................................................................................................................................................................103
	250 HOUR LUBRICATION AND MAINTENANCE CHECKS..............................................................................................................................................................................................................................104
	250 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)..................................................................................................................................................................................................................105
	500 HOUR LUBRICATION AND MAINTENANCE CHECKS..............................................................................................................................................................................................................................106
	500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)..................................................................................................................................................................................................................107
	1000 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................................................................................................................................................................................................108
	1500 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................................................................................................................................................................................................109
	2500 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................................................................................................................................................................................................109
	5000 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................................................................................................................................................................................................110
	10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS...........................................................................................................................................................................................................................111
AUTOMATIC LUBRICATION SYSTEM.................................................................................................................................................................................................................................................113
	GENERAL DESCRIPTION......................................................................................................................................................................................................................................................113
	SYSTEM COMPONENTS........................................................................................................................................................................................................................................................114
		Filter Assembly......................................................................................................................................................................................................................................................114
		Hydraulic Motor and Grease Pump......................................................................................................................................................................................................................................114
		Reservoir............................................................................................................................................................................................................................................................114
		Fixed Pressure Reducing Valve........................................................................................................................................................................................................................................114
		Flow Control Valve...................................................................................................................................................................................................................................................114
		Solenoid Valve.......................................................................................................................................................................................................................................................116
		Vent Valve...........................................................................................................................................................................................................................................................116
		Time Delay Module....................................................................................................................................................................................................................................................116
		Pump Cutoff Pressure Switch..........................................................................................................................................................................................................................................116
		Unloader Valve.......................................................................................................................................................................................................................................................116
		Pressure Switch......................................................................................................................................................................................................................................................116
		Pressure Gauge.......................................................................................................................................................................................................................................................116
		Manual Override Button...............................................................................................................................................................................................................................................116
		Injectors............................................................................................................................................................................................................................................................116
	SYSTEM OPERATION.........................................................................................................................................................................................................................................................118
		Normal Operation.....................................................................................................................................................................................................................................................118
		Pressure Failure Detection Circuits..................................................................................................................................................................................................................................119
	GENERAL INSTRUCTIONS.....................................................................................................................................................................................................................................................120
		LUBRICANT REQUIRED FOR SYSTEM........................................................................................................................................................................................................................................120
		SYSTEM PRIMING.......................................................................................................................................................................................................................................................120
		LUBRICANT PUMP.......................................................................................................................................................................................................................................................120
			Pump Housing Oil Level...........................................................................................................................................................................................................................................120
			Pump Pressure Control............................................................................................................................................................................................................................................120
			Filter And Reservoir.............................................................................................................................................................................................................................................121
			Filter Assembly Element..........................................................................................................................................................................................................................................121
		INJECTORS (SL-1 Series H)............................................................................................................................................................................................................................................122
			Injector Specifications..........................................................................................................................................................................................................................................122
			Injector Adjustment..............................................................................................................................................................................................................................................122
		INJECTOR OPERATION...................................................................................................................................................................................................................................................123
		SYSTEM CHECKOUT......................................................................................................................................................................................................................................................124
			Lubrication Cycle Timer Check....................................................................................................................................................................................................................................124
			Lubrication Cycle Timer Adjustment...............................................................................................................................................................................................................................125
		PREVENTIVE MAINTENANCE INSPECTION....................................................................................................................................................................................................................................125
			10 Hour Lubrication System Inspection............................................................................................................................................................................................................................125
			250 Hour Inspection..............................................................................................................................................................................................................................................125
			1000 Hour Inspection.............................................................................................................................................................................................................................................126
		SYSTEM TROUBLESHOOTING CHART.........................................................................................................................................................................................................................................127
MAJOR COMPONENT DESCRIPTION..................................................................................................................................................................................................................................................129
	SPECIFICATIONS...........................................................................................................................................................................................................................................................131
PAYLOAD METER III............................................................................................................................................................................................................................................................133
	PAYLOAD METER III........................................................................................................................................................................................................................................................137
		Introduction.........................................................................................................................................................................................................................................................137
			Data Summary.....................................................................................................................................................................................................................................................137
			Data Gathering...................................................................................................................................................................................................................................................137
		COMPONENT DESCRIPTION................................................................................................................................................................................................................................................138
			System Diagram...................................................................................................................................................................................................................................................138
			Suspension Pressure Sensors......................................................................................................................................................................................................................................138
			Inclinometer.....................................................................................................................................................................................................................................................138
			Operator Display.................................................................................................................................................................................................................................................138
			Payload Operator Switch..........................................................................................................................................................................................................................................139
			Speed Input......................................................................................................................................................................................................................................................139
			Body-Up Switch...................................................................................................................................................................................................................................................139
			Brake Lock Switch................................................................................................................................................................................................................................................139
			Payload Meter....................................................................................................................................................................................................................................................139
			Communications Ports.............................................................................................................................................................................................................................................139
			Key Switch Input.................................................................................................................................................................................................................................................140
			Payload Meter Power..............................................................................................................................................................................................................................................140
			Load Lights......................................................................................................................................................................................................................................................140
			Wiring and Termination...........................................................................................................................................................................................................................................141
			TCI Outputs......................................................................................................................................................................................................................................................141
		OPERATOR’S DISPLAY AND SWITCH........................................................................................................................................................................................................................................142
			Reading the Speedometer..........................................................................................................................................................................................................................................142
			Reading the Load Display.........................................................................................................................................................................................................................................142
			Using the Operator ID............................................................................................................................................................................................................................................142
			Using the Load and Ton Counter...................................................................................................................................................................................................................................142
			Total Ton Counter................................................................................................................................................................................................................................................142
			Total Load Counter...............................................................................................................................................................................................................................................143
			Clearing the Counters............................................................................................................................................................................................................................................143
			Viewing Live Sensor Data.........................................................................................................................................................................................................................................143
			Other Display Messages...........................................................................................................................................................................................................................................143
		PAYLOAD OPERATION AND CALCULATION....................................................................................................................................................................................................................................144
			Description of Haul Cycle States.................................................................................................................................................................................................................................144
			Haul Cycle Description...........................................................................................................................................................................................................................................144
			Load Calculation.................................................................................................................................................................................................................................................145
			Carry Back.......................................................................................................................................................................................................................................................145
			Measurement Accuracy.............................................................................................................................................................................................................................................145
		SOURCES FOR PAYLOAD ERROR............................................................................................................................................................................................................................................145
			Payload Error....................................................................................................................................................................................................................................................145
			Loading Conditions...............................................................................................................................................................................................................................................146
			Pressure Sensors.................................................................................................................................................................................................................................................146
			Swingloads.......................................................................................................................................................................................................................................................146
			Speed and Distance...............................................................................................................................................................................................................................................146
		HAUL CYCLE DATA......................................................................................................................................................................................................................................................146
			Haul Cycle Data..................................................................................................................................................................................................................................................147
			Haul Cycle Warning Flags.........................................................................................................................................................................................................................................148
			M: Haul Cycle Too Long...........................................................................................................................................................................................................................................149
			N: Sensor Input Error............................................................................................................................................................................................................................................149
			Frame Torque Data................................................................................................................................................................................................................................................149
			Sprung Weight Data...............................................................................................................................................................................................................................................149
			Maximum Speed Data...............................................................................................................................................................................................................................................149
			Alarm Records....................................................................................................................................................................................................................................................149
			Fault Code Data..................................................................................................................................................................................................................................................150
		PC SOFTWARE OVERVIEW.................................................................................................................................................................................................................................................151
			PC Overview......................................................................................................................................................................................................................................................151
			System Configuration.............................................................................................................................................................................................................................................151
			Installing the PLM III Software..................................................................................................................................................................................................................................151
		DOWNLOADING DATA.....................................................................................................................................................................................................................................................152
		PLM III SYSTEM CONFIGURATION.........................................................................................................................................................................................................................................153
			Starting Communications..........................................................................................................................................................................................................................................153
			Displayed Payload Units..........................................................................................................................................................................................................................................153
			Time Units.......................................................................................................................................................................................................................................................153
			Connection Menu..................................................................................................................................................................................................................................................153
			Connecting to the Payload Meter..................................................................................................................................................................................................................................154
			Configure the Payload Meter......................................................................................................................................................................................................................................154
			Setting the Date and Time........................................................................................................................................................................................................................................154
			Setting the Truck Type...........................................................................................................................................................................................................................................155
			Setting the Gauge Display Units..................................................................................................................................................................................................................................155
			Setting the Frame Serial Number..................................................................................................................................................................................................................................155
			Setting the Truck Number.........................................................................................................................................................................................................................................155
			Setting the Komatsu Distributor..................................................................................................................................................................................................................................155
			Setting the Komatsu Customer.....................................................................................................................................................................................................................................155
			Clean Truck Tare.................................................................................................................................................................................................................................................156
			Inclinometer Calibration.........................................................................................................................................................................................................................................156
		DATA ANALYSIS........................................................................................................................................................................................................................................................157
			Creating a Query.................................................................................................................................................................................................................................................157
			Sorting on Truck Unit Number.....................................................................................................................................................................................................................................157
			Sorting on Truck Type............................................................................................................................................................................................................................................157
			Sorting on Date Range............................................................................................................................................................................................................................................158
			Sorting on Time Range............................................................................................................................................................................................................................................158
			Payload Detail Screen............................................................................................................................................................................................................................................159
			Creating Reports.................................................................................................................................................................................................................................................159
			Summary - One Page Report........................................................................................................................................................................................................................................160
			Detailed - Multi-Page Report.....................................................................................................................................................................................................................................160
			Creating Graphs..................................................................................................................................................................................................................................................161
			Exporting Data...................................................................................................................................................................................................................................................161
			CSV Export.......................................................................................................................................................................................................................................................161
			Compressed.......................................................................................................................................................................................................................................................163
			Importing Data...................................................................................................................................................................................................................................................163
			Deleting Haul Cycle Records......................................................................................................................................................................................................................................163
			Viewing Alarms...................................................................................................................................................................................................................................................164
			Deleting Alarm Records...........................................................................................................................................................................................................................................164
AM/FM RADIO / CD PLAYER......................................................................................................................................................................................................................................................165
	GENERAL RADIO RECEIVER FUNCTIONS.........................................................................................................................................................................................................................................165
		Turning On the Power.................................................................................................................................................................................................................................................165
		One-Hour Timer.......................................................................................................................................................................................................................................................165
		Display..............................................................................................................................................................................................................................................................166
		Setting a Default Display............................................................................................................................................................................................................................................166
		Adjusting the Brightness of the Display..............................................................................................................................................................................................................................166
		Auxiliary Mode.......................................................................................................................................................................................................................................................166
		Adjusting the Receiver Settings......................................................................................................................................................................................................................................166
	USING THE CLOCK..........................................................................................................................................................................................................................................................167
		Setting the Clock....................................................................................................................................................................................................................................................167
	USING THE ALARM..........................................................................................................................................................................................................................................................167
		Setting the Alarm....................................................................................................................................................................................................................................................167
		Turning the Alarm Off................................................................................................................................................................................................................................................167
		Activating Snooze....................................................................................................................................................................................................................................................167
		Setting Alarm Volume.................................................................................................................................................................................................................................................167
	USING THE RADIO..........................................................................................................................................................................................................................................................168
		Finding a Station....................................................................................................................................................................................................................................................168
		Setting the Presets..................................................................................................................................................................................................................................................168
	USING THE WEATHERBAND....................................................................................................................................................................................................................................................169
	USING THE COMPACT DISC PLAYER............................................................................................................................................................................................................................................169
		Playing a Compact Disc...............................................................................................................................................................................................................................................169
		Button Functions.....................................................................................................................................................................................................................................................169
	PLAYING AN MP3 DISC......................................................................................................................................................................................................................................................170
		MP3 Format Compatibility.............................................................................................................................................................................................................................................170
		Root Directory.......................................................................................................................................................................................................................................................170
		Empty Directory or Folder............................................................................................................................................................................................................................................170
		No Folder............................................................................................................................................................................................................................................................170
		File Name Display....................................................................................................................................................................................................................................................170
		Pre-Programmed Playlists.............................................................................................................................................................................................................................................171
		Playing MP3 Files....................................................................................................................................................................................................................................................171
		Button Functions.....................................................................................................................................................................................................................................................171
	TROUBLESHOOTING..........................................................................................................................................................................................................................................................172

PLEASE NOTE:

⦁ This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
⦁ The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
⦁ Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer