KOMATSU 730E TROLLEY DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30355, A30392, A30393, A30403 & A30406) – PDF DOWNLOAD

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KOMATSU 730E TROLLEY DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30355, A30392, A30393, A30403 & A30406)

KOMATSU 730E TROLLEY DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30355, A30392, A30393, A30403 & A30406) – PDF DOWNLOAD:

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KOMATSU 730E TROLLEY DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30355, A30392, A30393, A30403 & A30406)

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

TABLE OF CONTENTS:

KOMATSU 730E TROLLEY DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30355, A30392, A30393, A30403 & A30406)

COVER ...................................................................................................................................................................................................................................................................  1
INTRODUCTION.............................................................................................................................................................................................................................................................  5
	FOREWORD.............................................................................................................................................................................................................................................................  5
	ABOUT THIS MANUAL....................................................................................................................................................................................................................................................  7
	ALERTS PAGE..........................................................................................................................................................................................................................................................  8
TABLE OF CONTENTS........................................................................................................................................................................................................................................................  9
TORQUE TABLES AND CONVERSION CHARTS...................................................................................................................................................................................................................................... 19
	EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values................................................................................................................................................................................................. 20
	STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts................................................................................................................................................................................................ 20
	STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws................................................................................................................................................................................................... 21
	STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws............................................................................................................................................................................................................... 22
GENERAL SAFETY........................................................................................................................................................................................................................................................... 29
	PERSONAL SAFETY...................................................................................................................................................................................................................................................... 29
		Safety Rules..................................................................................................................................................................................................................................................... 29
		Truck Safety Features............................................................................................................................................................................................................................................ 29
		Clothing And Personal Items...................................................................................................................................................................................................................................... 29
		Unauthorized Modification........................................................................................................................................................................................................................................ 29
		Leaving The Operator’s Seat...................................................................................................................................................................................................................................... 29
		Mounting And Dismounting......................................................................................................................................................................................................................................... 29
		Fire Extinguishers And First Aid Kits............................................................................................................................................................................................................................ 30
		Precautions For High Temperature Fluids.......................................................................................................................................................................................................................... 30
		Asbestos Dust Hazard Prevention.................................................................................................................................................................................................................................. 30
		Fire Prevention For Fuel And Oil................................................................................................................................................................................................................................. 30
		ROPS Precautions................................................................................................................................................................................................................................................. 31
		Preventing Injury From Work Equipment............................................................................................................................................................................................................................ 31
		Precautions For Optional Attachments............................................................................................................................................................................................................................. 31
		Precautions When Starting The Machine............................................................................................................................................................................................................................ 31
	PRECAUTIONS FOR TRUCK OPERATION...................................................................................................................................................................................................................................... 32
		Safety Is Thinking Ahead......................................................................................................................................................................................................................................... 32
		Safety At The Work Site.......................................................................................................................................................................................................................................... 32
		Fire Prevention.................................................................................................................................................................................................................................................. 32
		Preparing For Operation.......................................................................................................................................................................................................................................... 32
		Ventilation For Enclosed Areas................................................................................................................................................................................................................................... 32
		Mirrors, Windows, And Lights..................................................................................................................................................................................................................................... 32
		In The Operator’s Cab - Before Starting The Engine............................................................................................................................................................................................................... 33
		Seat Belts....................................................................................................................................................................................................................................................... 33
	OPERATING THE MACHINE................................................................................................................................................................................................................................................ 33
		Starting The Engine.............................................................................................................................................................................................................................................. 33
		Truck Operation - General........................................................................................................................................................................................................................................ 33
		Traveling In The Truck........................................................................................................................................................................................................................................... 34
		Precautions When Traveling In Reverse............................................................................................................................................................................................................................ 34
		Traveling On Slopes.............................................................................................................................................................................................................................................. 34
		Ensuring Good Visibility......................................................................................................................................................................................................................................... 35
		Operating On Snow................................................................................................................................................................................................................................................ 35
		Avoid Damage To The Dump Body.................................................................................................................................................................................................................................... 35
		Driving Near High-Voltage Cables................................................................................................................................................................................................................................. 35
		When Loading The Truck........................................................................................................................................................................................................................................... 35
		When Dumping..................................................................................................................................................................................................................................................... 35
		Working On Loose Ground.......................................................................................................................................................................................................................................... 35
		Parking The Machine.............................................................................................................................................................................................................................................. 36
	TOWING............................................................................................................................................................................................................................................................... 36
	WORKING NEAR BATTERIES............................................................................................................................................................................................................................................... 36
		Battery Hazard Prevention........................................................................................................................................................................................................................................ 36
		Jump-Starting With Booster Cables................................................................................................................................................................................................................................ 37
		Jump Starting With Receptacles................................................................................................................................................................................................................................... 37
	PRECAUTIONS FOR MAINTENANCE.......................................................................................................................................................................................................................................... 38
		BEFORE PERFORMING MAINTENANCE.................................................................................................................................................................................................................................... 38
			Stopping The Engine Before Service........................................................................................................................................................................................................................... 38
			Warning Tag.................................................................................................................................................................................................................................................. 38
			Proper Tools................................................................................................................................................................................................................................................. 38
			Securing The Dump Body....................................................................................................................................................................................................................................... 38
		DURING MAINTENANCE............................................................................................................................................................................................................................................... 39
			Personnel.................................................................................................................................................................................................................................................... 39
			Attachments.................................................................................................................................................................................................................................................. 39
			Working Under The Machine.................................................................................................................................................................................................................................... 39
			Keeping The Machine Clean.................................................................................................................................................................................................................................... 39
			Rules To Follow When Adding Fuel Or Oil...................................................................................................................................................................................................................... 39
			Radiator Coolant Level....................................................................................................................................................................................................................................... 39
			Use Of Lighting.............................................................................................................................................................................................................................................. 39
			Precautions With The Battery................................................................................................................................................................................................................................. 40
			Handling High-Pressure Hoses................................................................................................................................................................................................................................. 40
			Precautions With High-Pressure Oil........................................................................................................................................................................................................................... 40
			Maintenance Near High Temperatures And High Pressures........................................................................................................................................................................................................ 40
			Rotating Fan And Belts....................................................................................................................................................................................................................................... 40
			Waste Materials.............................................................................................................................................................................................................................................. 40
			Use of Tie-Off Anchor During Maintenance and Repair.......................................................................................................................................................................................................... 40
		TIRES............................................................................................................................................................................................................................................................ 41
			Handling Tires............................................................................................................................................................................................................................................... 41
			Tire Maintenance............................................................................................................................................................................................................................................. 42
			Storing Tires After Removal.................................................................................................................................................................................................................................. 42
	ADDITIONAL JOB SITE RULES............................................................................................................................................................................................................................................ 43
	WHEN REPAIRS ARE NECESSARY........................................................................................................................................................................................................................................... 44
WARNINGS AND CAUTIONS.................................................................................................................................................................................................................................................... 47
OPERATING INSTRUCTIONS................................................................................................................................................................................................................................................... 55
	PREPARING FOR OPERATION.............................................................................................................................................................................................................................................. 55
	SAFETY IS THINKING talkAHEAD......................................................................................................................................................................................................................................... 55
	WALK AROUND INSPECTION............................................................................................................................................................................................................................................... 55
	ENGINE START-UP...................................................................................................................................................................................................................................................... 59
	AFTER ENGINE HAS STARTED............................................................................................................................................................................................................................................. 60
	EMERGENCY STEERING SYSTEM............................................................................................................................................................................................................................................ 61
		Operation........................................................................................................................................................................................................................................................ 61
		Pre-Operation Testing............................................................................................................................................................................................................................................ 61
		Additional Guidelines............................................................................................................................................................................................................................................ 62
	MACHINE OPERATION SAFETY PRECAUTIONS................................................................................................................................................................................................................................. 62
	LOADING.............................................................................................................................................................................................................................................................. 63
	HAULING.............................................................................................................................................................................................................................................................. 63
	PASSING.............................................................................................................................................................................................................................................................. 64
	DUMPING.............................................................................................................................................................................................................................................................. 64
		To Raise The Dump Body:.......................................................................................................................................................................................................................................... 64
		To Lower The Dump Body: (When dumping over a berm or into a crusher):............................................................................................................................................................................................ 65
		To Lower The Dump Body (When dumping on flat ground):............................................................................................................................................................................................................ 65
	SAFE PARKING PROCEDURES.............................................................................................................................................................................................................................................. 66
	ENGINE SHUTDOWN PROCEDURE............................................................................................................................................................................................................................................ 66
	DELAYED ENGINE SHUTDOWN PROCEDURE.................................................................................................................................................................................................................................... 67
	SUDDEN LOSS OF POWER................................................................................................................................................................................................................................................. 67
	DISABLED TRUCK OPERATION............................................................................................................................................................................................................................................. 68
	GENERAL.............................................................................................................................................................................................................................................................. 68
	STEERING AND BRAKE SYSTEM............................................................................................................................................................................................................................................ 68
		Components Required.............................................................................................................................................................................................................................................. 68
		Hookup........................................................................................................................................................................................................................................................... 69
	DISABLED TRUCK DUMPING PROCEDURE..................................................................................................................................................................................................................................... 70
		Hookup........................................................................................................................................................................................................................................................... 70
		Raising the Body................................................................................................................................................................................................................................................. 70
		Lowering the Body................................................................................................................................................................................................................................................ 70
	TOWING............................................................................................................................................................................................................................................................... 71
	TROLLEY OPERATING INSTRUCTIONS....................................................................................................................................................................................................................................... 71
		AFTER THE ENGINE HAS STARTED..................................................................................................................................................................................................................................... 71
		OPERATING IN DIESEL MODE......................................................................................................................................................................................................................................... 72
		OPERATING IN TROLLEY LINE MODE................................................................................................................................................................................................................................... 72
		GETTING ON LINE.................................................................................................................................................................................................................................................. 73
			Operating On Trolley......................................................................................................................................................................................................................................... 74
		GETTING OFF LINE................................................................................................................................................................................................................................................. 76
		LINE STATUS SIGNALS.............................................................................................................................................................................................................................................. 76
		LINE STATUS SIGNAL MARKINGS...................................................................................................................................................................................................................................... 77
		TRAFFIC CONSIDERATION FOR TROLLEY LINE OPERATION................................................................................................................................................................................................................. 77
		APPROACHING SLOW MOVING VEHICLES IN A TROLLEY ASSISTED TRUCK..................................................................................................................................................................................................... 77
		OPERATING SLOW MOVING VEHICLES ON TROLLEY ASSIST RAMPS........................................................................................................................................................................................................... 78
		TRUCK FAILURE WHILE ON TROLLEY................................................................................................................................................................................................................................... 78
OPERATOR CAB AND CONTROLS................................................................................................................................................................................................................................................ 79
	STEERING WHEEL AND CONTROLS.......................................................................................................................................................................................................................................... 80
		Horn Button...................................................................................................................................................................................................................................................... 80
		Multi-Function Turn Signal Switch................................................................................................................................................................................................................................ 80
	SERVICE BRAKE PEDAL.................................................................................................................................................................................................................................................. 81
	DYNAMIC RETARDER PEDAL............................................................................................................................................................................................................................................... 81
		Optional - Dual Function / Single Pedal.......................................................................................................................................................................................................................... 81
	THROTTLE PEDAL....................................................................................................................................................................................................................................................... 81
	HEATER / AIR CONDITIONER VENTS....................................................................................................................................................................................................................................... 81
	HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS.................................................................................................................................................................................................................... 82
		Defroster Vent Control Switch.................................................................................................................................................................................................................................... 82
		Heat Control Switch.............................................................................................................................................................................................................................................. 82
		Temperature Control Knob......................................................................................................................................................................................................................................... 82
		Fan Control Knob................................................................................................................................................................................................................................................. 82
		Heater / Air Conditioner Selector Switch......................................................................................................................................................................................................................... 82
		Heater / Air Conditioner Vents................................................................................................................................................................................................................................... 82
	INSTRUMENT PANEL..................................................................................................................................................................................................................................................... 83
	GRADE / SPEED WARNING CHART.......................................................................................................................................................................................................................................... 83
	RADIO SPEAKERS....................................................................................................................................................................................................................................................... 83
	WARNING ALARM BUZZER................................................................................................................................................................................................................................................. 83
	CAB RADIO............................................................................................................................................................................................................................................................ 83
	WARNING LIGHTS DIMMER CONTROL........................................................................................................................................................................................................................................ 83
	WARNING INDICATOR LIGHT PANEL........................................................................................................................................................................................................................................ 83
	AIR CLEANER VACUUM GAUGES............................................................................................................................................................................................................................................ 83
	WINDSHIELD WIPERS.................................................................................................................................................................................................................................................... 83
		Data Storage Button.............................................................................................................................................................................................................................................. 84
		Data storage button (1, Figure 32-7) is for use by qualified maintenance personnel to record in memory a “snap-shot” of the Statex III drive system.............................................................................................................. 84
		Trolley Master Control Lever..................................................................................................................................................................................................................................... 84
		F-N-R Selector Switch............................................................................................................................................................................................................................................ 84
		Hoist Control Lever.............................................................................................................................................................................................................................................. 85
		Retard Speed Control (RSC) Adjust Dial........................................................................................................................................................................................................................... 85
		Retard Speed Control (RSC) Off / On Switch....................................................................................................................................................................................................................... 86
		Override Switch.................................................................................................................................................................................................................................................. 86
		Engine Shutdown Switch........................................................................................................................................................................................................................................... 86
		Window Control Switches.......................................................................................................................................................................................................................................... 86
		Ash Tray......................................................................................................................................................................................................................................................... 86
		Lighter.......................................................................................................................................................................................................................................................... 86
		Passenger Seat................................................................................................................................................................................................................................................... 86
		Download Ports and Connectors.................................................................................................................................................................................................................................... 87
		Engine Diagnostics Port.......................................................................................................................................................................................................................................... 87
		Engine diagnostics port (12) is used by qualified personnel to access engine diagnostic information.............................................................................................................................................................. 87
		Komatsu Engine CENSE Connector................................................................................................................................................................................................................................... 87
		CENSE Connector (13) is a three-pin connector is for use by qualified personnel to access engine diagnostic information for the CENSE system. Refer to the engine manufacturer’s service publications for troubleshooting information............................ 87
		Statex III Downlad Port.......................................................................................................................................................................................................................................... 87
		Modular Mining Port (Optional)................................................................................................................................................................................................................................... 87
		Modular mining port location is used if the optional Modular Mining System is installed on the truck............................................................................................................................................................. 87
		Centry™ Fuel Control............................................................................................................................................................................................................................................. 87
		Diagnostics Download Port (Optional)............................................................................................................................................................................................................................. 87
		Payload Meter.................................................................................................................................................................................................................................................... 87
		Payload Meter Download Connector................................................................................................................................................................................................................................. 87
	CENTER CONSOLE ...................................................................................................................................................................................................................................................... 84
	OPERATOR SEAT........................................................................................................................................................................................................................................................ 88
	INSTRUMENT PANEL AND INDICATOR LIGHTS................................................................................................................................................................................................................................ 89
		CONTROL SYMBOLS.................................................................................................................................................................................................................................................. 89
		INSTRUMENT PANEL................................................................................................................................................................................................................................................. 89
	PANEL GAUGES, INDICATORS, AND CONTROLS............................................................................................................................................................................................................................... 90
		Key Switch....................................................................................................................................................................................................................................................... 90
		Engine Shut down Switch with Timer Delay......................................................................................................................................................................................................................... 91
		Fog Lights (Optional)............................................................................................................................................................................................................................................ 91
		Ladder Light Switch.............................................................................................................................................................................................................................................. 91
		Manual Backup Switch............................................................................................................................................................................................................................................. 91
		Manual backup switch (5) allows the backup lights to be turned on providing added visibility and safety when the selector switch is not in the REV position. When the switch is pressed toward the on position, the manual backup light indicator (B4, Ove....... 91
		Panel Illumination Lights........................................................................................................................................................................................................................................ 91
		Cab Air Conditioner / Heater Vents............................................................................................................................................................................................................................... 91
		Engine Cold Weather Starting Aid (Optional)...................................................................................................................................................................................................................... 92
		Rotating Beacon Light Switch (Optional).......................................................................................................................................................................................................................... 92
		Heated Mirror Switch (Optional).................................................................................................................................................................................................................................. 92
		Leakage Test Switch (Trolley Option Only)........................................................................................................................................................................................................................ 92
		Wheel Brake Lock Control......................................................................................................................................................................................................................................... 92
		Parking Brake Control............................................................................................................................................................................................................................................ 92
		Tachometer....................................................................................................................................................................................................................................................... 93
		Right Turn Signal Indicator...................................................................................................................................................................................................................................... 93
		High Beam Indicator.............................................................................................................................................................................................................................................. 93
		Left Turn Signal Indicator....................................................................................................................................................................................................................................... 93
		Speedometer / Payload Meter Display.............................................................................................................................................................................................................................. 93
		Voltmeter........................................................................................................................................................................................................................................................ 93
		Engine Oil Pressure Gauge........................................................................................................................................................................................................................................ 93
		Water Temperature Gauge.......................................................................................................................................................................................................................................... 93
		Fuel Gauge....................................................................................................................................................................................................................................................... 93
		Blank (Not Used)................................................................................................................................................................................................................................................. 93
		Hourmeter........................................................................................................................................................................................................................................................ 93
		Blank (Not Used)................................................................................................................................................................................................................................................. 93
		Blank (Not Used)................................................................................................................................................................................................................................................. 93
		Light Switch..................................................................................................................................................................................................................................................... 94
		Panel Light Dimmer............................................................................................................................................................................................................................................... 94
		Payload Meter Switch............................................................................................................................................................................................................................................. 94
	OVERHEAD STATUS / WARNING INDICATOR LIGHT PANEL...................................................................................................................................................................................................................... 95
	INDICATOR LIGHT SYMBOLS.............................................................................................................................................................................................................................................. 96
		TROLLEY INDICATOR LIGHTS.........................................................................................................................................................................................................................................100
		Hazard Warning Light Switch......................................................................................................................................................................................................................................102
		Lamp Test Switch / Centry™ Diagnostic Test Switch................................................................................................................................................................................................................102
		REAR AXLE LIGHT BAR..............................................................................................................................................................................................................................................103
			Backup Lights................................................................................................................................................................................................................................................103
			Retard Lights................................................................................................................................................................................................................................................103
			Brake Light..................................................................................................................................................................................................................................................103
			Backup Alarm.................................................................................................................................................................................................................................................103
	CENTRY™ FUEL SYSTEM DIAGNOSTICS......................................................................................................................................................................................................................................104
		DETERMINING FAULT CODES..........................................................................................................................................................................................................................................104
		EXITING THE DIAGNOSTICS MODE.....................................................................................................................................................................................................................................105
LUBRICATION AND SERVICE..................................................................................................................................................................................................................................................107
	GENERAL INFORMATION..................................................................................................................................................................................................................................................107
	HYDRAULIC TANK SERVICE...............................................................................................................................................................................................................................................107
		Adding Oil.......................................................................................................................................................................................................................................................107
	COOLING SYSTEM SERVICE...............................................................................................................................................................................................................................................108
		Radiator Filling Procedure.......................................................................................................................................................................................................................................108
		Coolant Specifications...........................................................................................................................................................................................................................................108
		Unacceptable Practices...........................................................................................................................................................................................................................................108
	WHEEL MOTOR SERVICE..................................................................................................................................................................................................................................................108
	RESERVE ENGINE OIL SYSTEM (IF EQUIPPED)..............................................................................................................................................................................................................................109
		Reserve Oil Tank Filling Procedure (Remote fill).................................................................................................................................................................................................................109
		Inline Screen....................................................................................................................................................................................................................................................109
	QUICK FILL SERVICE CENTER............................................................................................................................................................................................................................................110
	LEFT-HAND FUEL RECEIVER - OPTIONAL (WIGGINS QUICK FILL)..............................................................................................................................................................................................................111
	LUBRICATION CHART....................................................................................................................................................................................................................................................112
	10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS..........................................................................................................................................................................................................................113
	10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS (Continued)..............................................................................................................................................................................................................114
	50 HOUR LUBRICATION AND MAINTENANCE CHECKS...........................................................................................................................................................................................................................115
	100 HOUR LUBRICATION AND MAINTENANCE CHECKS..........................................................................................................................................................................................................................115
	250 HOUR LUBRICATION AND MAINTENANCE CHECKS..........................................................................................................................................................................................................................116
	250 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)..............................................................................................................................................................................................................117
	500 HOUR LUBRICATION AND MAINTENANCE CHECKS..........................................................................................................................................................................................................................118
	500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)..............................................................................................................................................................................................................119
	1000 HOUR LUBRICATION AND MAINTENANCE CHECKS.........................................................................................................................................................................................................................120
	1500 HOUR LUBRICATION AND MAINTENANCE CHECKS.........................................................................................................................................................................................................................121
	2500 HOUR LUBRICATION AND MAINTENANCE CHECKS.........................................................................................................................................................................................................................121
	5000 HOUR LUBRICATION AND MAINTENANCE CHECKS.........................................................................................................................................................................................................................122
	10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS.......................................................................................................................................................................................................................123
AUTOMATIC LUBRICATION SYSTEM.............................................................................................................................................................................................................................................125
	GENERAL DESCRIPTION..................................................................................................................................................................................................................................................125
	SYSTEM COMPONENTS....................................................................................................................................................................................................................................................126
		Filter Assembly..................................................................................................................................................................................................................................................126
		Hydraulic Motor and Grease Pump..................................................................................................................................................................................................................................126
		Reservoir........................................................................................................................................................................................................................................................126
		Fixed Pressure Reducing Valve....................................................................................................................................................................................................................................126
		Flow Control Valve...............................................................................................................................................................................................................................................126
		Solenoid Valve...................................................................................................................................................................................................................................................128
		Vent Valve.......................................................................................................................................................................................................................................................128
		Time Delay Module................................................................................................................................................................................................................................................128
		Pump Cutoff Pressure Switch......................................................................................................................................................................................................................................128
		Unloader Valve...................................................................................................................................................................................................................................................128
		Pressure Switch..................................................................................................................................................................................................................................................128
		Pressure Gauge...................................................................................................................................................................................................................................................128
		Manual Override Button...........................................................................................................................................................................................................................................128
		Injectors........................................................................................................................................................................................................................................................128
	SYSTEM OPERATION.....................................................................................................................................................................................................................................................130
		Normal Operation.................................................................................................................................................................................................................................................130
		Pressure Failure Detection Circuits..............................................................................................................................................................................................................................131
	GENERAL INSTRUCTIONS.................................................................................................................................................................................................................................................132
		LUBRICANT REQUIRED FOR SYSTEM....................................................................................................................................................................................................................................132
		SYSTEM PRIMING...................................................................................................................................................................................................................................................132
		LUBRICANT PUMP...................................................................................................................................................................................................................................................132
			Pump Housing Oil Level.......................................................................................................................................................................................................................................132
			Pump Pressure Control........................................................................................................................................................................................................................................132
			FILTER AND RESERVOIR.........................................................................................................................................................................................................................................133
			Filter Assembly Element......................................................................................................................................................................................................................................133
		INJECTORS (SL-1 Series H)........................................................................................................................................................................................................................................134
			Injector Specifications......................................................................................................................................................................................................................................134
			Injector Adjustment..........................................................................................................................................................................................................................................134
		INJECTOR OPERATION...............................................................................................................................................................................................................................................135
		SYSTEM CHECKOUT..................................................................................................................................................................................................................................................136
			Lubrication Cycle Timer Check................................................................................................................................................................................................................................136
			Lubrication Cycle Timer Adjustment...........................................................................................................................................................................................................................137
		PREVENTIVE MAINTENANCE INSPECTION................................................................................................................................................................................................................................137
			10 Hour Lubrication System Inspection........................................................................................................................................................................................................................137
			250 Hour Inspection..........................................................................................................................................................................................................................................137
			1000 Hour Inspection.........................................................................................................................................................................................................................................138
		SYSTEM TROUBLESHOOTING CHART.....................................................................................................................................................................................................................................139
MAJOR COMPONENT DESCRIPTION..............................................................................................................................................................................................................................................141
	SPECIFICATIONS.......................................................................................................................................................................................................................................................143
PAYLOAD METER III........................................................................................................................................................................................................................................................145
	PAYLOAD METER III....................................................................................................................................................................................................................................................149
		Introduction.....................................................................................................................................................................................................................................................149
			Data Summary.................................................................................................................................................................................................................................................149
			Data Gathering...............................................................................................................................................................................................................................................149
		COMPONENT DESCRIPTION............................................................................................................................................................................................................................................150
			System Diagram...............................................................................................................................................................................................................................................150
			Suspension Pressure Sensors..................................................................................................................................................................................................................................150
			Inclinometer.................................................................................................................................................................................................................................................150
			Operator Display.............................................................................................................................................................................................................................................150
			Payload Operator Switch......................................................................................................................................................................................................................................151
			Speed Input..................................................................................................................................................................................................................................................151
			Body-Up Switch...............................................................................................................................................................................................................................................151
			Brake Lock Switch............................................................................................................................................................................................................................................151
			Payload Meter................................................................................................................................................................................................................................................151
			Communications Ports.........................................................................................................................................................................................................................................151
			Key Switch Input.............................................................................................................................................................................................................................................152
			Payload Meter Power..........................................................................................................................................................................................................................................152
			Load Lights..................................................................................................................................................................................................................................................152
			Wiring and Termination.......................................................................................................................................................................................................................................153
			TCI Outputs..................................................................................................................................................................................................................................................153
		OPERATOR’S DISPLAY AND SWITCH....................................................................................................................................................................................................................................154
			Reading the Speedometer......................................................................................................................................................................................................................................154
			Reading the Load Display.....................................................................................................................................................................................................................................154
			Using the Operator ID........................................................................................................................................................................................................................................154
			Using the Load and Ton Counter...............................................................................................................................................................................................................................154
			Total Ton Counter............................................................................................................................................................................................................................................154
			Total Load Counter...........................................................................................................................................................................................................................................155
			Clearing the Counters........................................................................................................................................................................................................................................155
			Viewing Live Sensor Data.....................................................................................................................................................................................................................................155
			Other Display Messages.......................................................................................................................................................................................................................................155
		PAYLOAD OPERATION AND CALCULATION................................................................................................................................................................................................................................156
			Description of Haul Cycle States.............................................................................................................................................................................................................................156
			Haul Cycle Description.......................................................................................................................................................................................................................................156
			Load Calculation.............................................................................................................................................................................................................................................157
			Carry Back...................................................................................................................................................................................................................................................157
			Measurement Accuracy.........................................................................................................................................................................................................................................157
		SOURCES FOR PAYLOAD ERROR........................................................................................................................................................................................................................................157
			Payload Error................................................................................................................................................................................................................................................157
			Loading Conditions...........................................................................................................................................................................................................................................158
			Pressure Sensors.............................................................................................................................................................................................................................................158
			Swingloads...................................................................................................................................................................................................................................................158
			Speed and Distance...........................................................................................................................................................................................................................................158
		HAUL CYCLE DATA..................................................................................................................................................................................................................................................158
			Haul Cycle Data..............................................................................................................................................................................................................................................159
			Haul Cycle Warning Flags.....................................................................................................................................................................................................................................160
			M: Haul Cycle Too Long.......................................................................................................................................................................................................................................161
			N: Sensor Input Error........................................................................................................................................................................................................................................161
			Frame Torque Data............................................................................................................................................................................................................................................161
			Sprung Weight Data...........................................................................................................................................................................................................................................161
			Maximum Speed Data...........................................................................................................................................................................................................................................161
			Alarm Records................................................................................................................................................................................................................................................161
			Fault Code Data..............................................................................................................................................................................................................................................162
		PC SOFTWARE OVERVIEW.............................................................................................................................................................................................................................................163
			PC Overview..................................................................................................................................................................................................................................................163
			System Configuration.........................................................................................................................................................................................................................................163
			Installing the PLM III Software..............................................................................................................................................................................................................................163
		DOWNLOADING DATA.................................................................................................................................................................................................................................................164
		PLM III SYSTEM CONFIGURATION.....................................................................................................................................................................................................................................165
			Starting Communications......................................................................................................................................................................................................................................165
			Displayed Payload Units......................................................................................................................................................................................................................................165
			Time Units...................................................................................................................................................................................................................................................165
			Connection Menu..............................................................................................................................................................................................................................................165
			Connecting to the Payload Meter..............................................................................................................................................................................................................................166
			Configure the Payload Meter..................................................................................................................................................................................................................................166
			Setting the Date and Time....................................................................................................................................................................................................................................166
			Setting the Truck Type.......................................................................................................................................................................................................................................167
			Setting the Gauge Display Units..............................................................................................................................................................................................................................167
			Setting the Frame Serial Number..............................................................................................................................................................................................................................167
			Setting the Truck Number.....................................................................................................................................................................................................................................167
			Setting the Komatsu Distributor..............................................................................................................................................................................................................................167
			Setting the Komatsu Customer.................................................................................................................................................................................................................................167
			Clean Truck Tare.............................................................................................................................................................................................................................................168
			Inclinometer Calibration.....................................................................................................................................................................................................................................168
		DATA ANALYSIS....................................................................................................................................................................................................................................................169
			Creating a Query.............................................................................................................................................................................................................................................169
			Sorting on Truck Unit Number.................................................................................................................................................................................................................................169
			Sorting on Truck Type........................................................................................................................................................................................................................................169
			Sorting on Date Range........................................................................................................................................................................................................................................170
			Sorting on Time Range........................................................................................................................................................................................................................................170
			Payload Detail Screen........................................................................................................................................................................................................................................171
			Creating Reports.............................................................................................................................................................................................................................................171
			Summary - One Page Report....................................................................................................................................................................................................................................172
			Detailed - Multi-Page Report.................................................................................................................................................................................................................................172
			Creating Graphs..............................................................................................................................................................................................................................................173
			Exporting Data...............................................................................................................................................................................................................................................173
			CSV Export...................................................................................................................................................................................................................................................173
			Compressed...................................................................................................................................................................................................................................................175
			Importing Data...............................................................................................................................................................................................................................................175
			Deleting Haul Cycle Records..................................................................................................................................................................................................................................175
			Viewing Alarms...............................................................................................................................................................................................................................................176
			Deleting Alarm Records.......................................................................................................................................................................................................................................176
RADIO / CASSETTE PLAYER..................................................................................................................................................................................................................................................177
	GENERAL RECEIVER FUNCTIONS...........................................................................................................................................................................................................................................177
		Turning The Power On And Off.....................................................................................................................................................................................................................................177
		Display..........................................................................................................................................................................................................................................................177
		Setting The Default Display......................................................................................................................................................................................................................................177
		Adjusting Display Brightness.....................................................................................................................................................................................................................................177
	SETTING THE TIME.....................................................................................................................................................................................................................................................178
	OPERATING THE RADIO..................................................................................................................................................................................................................................................178
		BAND.............................................................................................................................................................................................................................................................178
		TUNE/SEEK........................................................................................................................................................................................................................................................178
		Manual Tuning....................................................................................................................................................................................................................................................178
		SEEK Mode........................................................................................................................................................................................................................................................178
		SCAN.............................................................................................................................................................................................................................................................178
		AUTO.............................................................................................................................................................................................................................................................178
	ADJUSTING THE RECEIVER SETTINGS......................................................................................................................................................................................................................................179
	PROGRAMMING PRESET STATIONS..........................................................................................................................................................................................................................................179
	OPERATION OF THE WEATHERBAND (U.S.)..................................................................................................................................................................................................................................179
	SATELLITE RADIO......................................................................................................................................................................................................................................................180
		Operating Satellite Radio........................................................................................................................................................................................................................................180
		Program Type Search (PTY)........................................................................................................................................................................................................................................180
	CASSETTE PLAYER......................................................................................................................................................................................................................................................181
		Playing A Cassette...............................................................................................................................................................................................................................................181
		Cassette Functions...............................................................................................................................................................................................................................................181
		Programmable Eject Default.......................................................................................................................................................................................................................................181
		Bad Tape Detect..................................................................................................................................................................................................................................................182
		Cleaning The Cassette Player.....................................................................................................................................................................................................................................182

PLEASE NOTE:

⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]