KOMATSU 730E TROLLEY DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30474, A30512 – A30517, & A30546 – A30549) – PDF DOWNLOAD

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KOMATSU 730E TROLLEY DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30474, A30512 – A30517, & A30546 – A30549)

KOMATSU 730E TROLLEY DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30474, A30512 – A30517, & A30546 – A30549) – PDF DOWNLOAD:

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KOMATSU 730E TROLLEY DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30474, A30512 – A30517, & A30546 – A30549)

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

TABLE OF CONTENTS:

KOMATSU 730E TROLLEY DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30474, A30512 – A30517, & A30546 – A30549)

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

PLEASE NOTE:

⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.