KOMATSU 730E TROLLEY DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30489 & A30490) KOMATSU 730E – PDF DOWNLOAD

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KOMATSU 730E TROLLEY DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30489 & A30490) KOMATSU 730E

KOMATSU 730E TROLLEY DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30489 & A30490) KOMATSU 730E – PDF DOWNLOAD:

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KOMATSU 730E TROLLEY DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30489 & A30490) KOMATSU 730E

• This manual is written for use by the operator and/or the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel must read and understand the materials in this manual before operating the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings, and cautions must be understood and followed when operating or repairing the truck.
• A product identification plate is located on the frame in front of the right side front wheel and designates the truck model number, product identification number (vehicle serial number), and maximum GVW (Gross Vehicle Weight) rating.
• The Komatsu truck model designation consists of three numbers and one letter (i.e. 930E).
  The three numbers represent the basic truck model.
  The letter E, when present, designates an electrical wheel motor drive system.
• The product identification number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.
• 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:A30489 & A30490) KOMATSU 730E

COVER
...................................................................................................................................................................................................................................................................  1
INTRODUCTION.............................................................................................................................................................................................................................................................  5
	FOREWORD.............................................................................................................................................................................................................................................................  5
	ABOUT THIS MANUAL....................................................................................................................................................................................................................................................  7
	ALERTS PAGE..........................................................................................................................................................................................................................................................  8
TABLE OF CONTENTS........................................................................................................................................................................................................................................................  9
TORQUE TABLES AND CONVERSION CHARTS...................................................................................................................................................................................................................................... 19
	EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values................................................................................................................................................................................................. 20
	STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts................................................................................................................................................................................................ 20
	STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws................................................................................................................................................................................................... 21
	STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws............................................................................................................................................................................................................... 22
GENERAL SAFETY........................................................................................................................................................................................................................................................... 29
	PERSONAL SAFETY...................................................................................................................................................................................................................................................... 29
		Safety Rules..................................................................................................................................................................................................................................................... 29
		Truck Safety Features............................................................................................................................................................................................................................................ 29
		Clothing And Personal Items...................................................................................................................................................................................................................................... 29
		Unauthorized Modification........................................................................................................................................................................................................................................ 29
		Leaving The Operator’s Seat...................................................................................................................................................................................................................................... 29
		Mounting And Dismounting......................................................................................................................................................................................................................................... 29
		Fire Extinguishers And First Aid Kits............................................................................................................................................................................................................................ 30
		Precautions For High Temperature Fluids.......................................................................................................................................................................................................................... 30
		Asbestos Dust Hazard Prevention.................................................................................................................................................................................................................................. 30
		Fire Prevention For Fuel And Oil................................................................................................................................................................................................................................. 30
		ROPS Precautions................................................................................................................................................................................................................................................. 31
		Preventing Injury From Work Equipment............................................................................................................................................................................................................................ 31
		Precautions For Optional Attachments............................................................................................................................................................................................................................. 31
		Precautions When Starting The Machine............................................................................................................................................................................................................................ 31
	PRECAUTIONS FOR TRUCK OPERATION...................................................................................................................................................................................................................................... 32
		Safety Is Thinking Ahead......................................................................................................................................................................................................................................... 32
		Safety At The Work Site.......................................................................................................................................................................................................................................... 32
		Fire Prevention.................................................................................................................................................................................................................................................. 32
		Preparing For Operation.......................................................................................................................................................................................................................................... 32
		Ventilation For Enclosed Areas................................................................................................................................................................................................................................... 32
		Mirrors, Windows, And Lights..................................................................................................................................................................................................................................... 32
		In The Operator’s Cab - Before Starting The Engine............................................................................................................................................................................................................... 33
		Seat Belts....................................................................................................................................................................................................................................................... 33
	OPERATING THE MACHINE................................................................................................................................................................................................................................................ 33
		Starting The Engine.............................................................................................................................................................................................................................................. 33
		Truck Operation - General........................................................................................................................................................................................................................................ 33
		Traveling In The Truck........................................................................................................................................................................................................................................... 34
		Precautions When Traveling In Reverse............................................................................................................................................................................................................................ 34
		Traveling On Slopes.............................................................................................................................................................................................................................................. 34
		Ensuring Good Visibility......................................................................................................................................................................................................................................... 35
		Operating On Snow................................................................................................................................................................................................................................................ 35
		Avoid Damage To The Dump Body.................................................................................................................................................................................................................................... 35
		Driving Near High-Voltage Cables................................................................................................................................................................................................................................. 35
		When Loading The Truck........................................................................................................................................................................................................................................... 35
		When Dumping..................................................................................................................................................................................................................................................... 35
		Working On Loose Ground.......................................................................................................................................................................................................................................... 35
		Parking The Machine.............................................................................................................................................................................................................................................. 36
	TOWING............................................................................................................................................................................................................................................................... 36
	WORKING NEAR BATTERIES............................................................................................................................................................................................................................................... 36
		Battery Hazard Prevention........................................................................................................................................................................................................................................ 36
		Jump-Starting With Booster Cables................................................................................................................................................................................................................................ 37
		Jump Starting With Receptacles................................................................................................................................................................................................................................... 37
	PRECAUTIONS FOR MAINTENANCE.......................................................................................................................................................................................................................................... 38
		BEFORE PERFORMING MAINTENANCE.................................................................................................................................................................................................................................... 38
			Stopping The Engine Before Service........................................................................................................................................................................................................................... 38
			Warning Tag.................................................................................................................................................................................................................................................. 38
			Proper Tools................................................................................................................................................................................................................................................. 38
			Securing The Dump Body....................................................................................................................................................................................................................................... 38
		DURING MAINTENANCE............................................................................................................................................................................................................................................... 39
			Personnel.................................................................................................................................................................................................................................................... 39
			Attachments.................................................................................................................................................................................................................................................. 39
			Working Under The Machine.................................................................................................................................................................................................................................... 39
			Keeping The Machine Clean.................................................................................................................................................................................................................................... 39
			Rules To Follow When Adding Fuel Or Oil...................................................................................................................................................................................................................... 39
			Radiator Coolant Level....................................................................................................................................................................................................................................... 39
			Use Of Lighting.............................................................................................................................................................................................................................................. 39
			Precautions With The Battery................................................................................................................................................................................................................................. 40
			Handling High-Pressure Hoses................................................................................................................................................................................................................................. 40
			Precautions With High-Pressure Oil........................................................................................................................................................................................................................... 40
			Maintenance Near High Temperatures And High Pressures........................................................................................................................................................................................................ 40
			Rotating Fan And Belts....................................................................................................................................................................................................................................... 40
			Waste Materials.............................................................................................................................................................................................................................................. 40
			Use of Tie-Off Anchor During Maintenance and Repair.......................................................................................................................................................................................................... 40
		TIRES............................................................................................................................................................................................................................................................ 41
			Handling Tires............................................................................................................................................................................................................................................... 41
			Tire Maintenance............................................................................................................................................................................................................................................. 42
			Storing Tires After Removal.................................................................................................................................................................................................................................. 42
	ADDITIONAL JOB SITE RULES............................................................................................................................................................................................................................................ 43
	WHEN REPAIRS ARE NECESSARY........................................................................................................................................................................................................................................... 44
WARNINGS AND CAUTIONS.................................................................................................................................................................................................................................................... 47
OPERATING INSTRUCTIONS................................................................................................................................................................................................................................................... 55
	PREPARING FOR OPERATION.............................................................................................................................................................................................................................................. 55
	SAFETY IS THINKING talkAHEAD......................................................................................................................................................................................................................................... 55
	WALK AROUND INSPECTION............................................................................................................................................................................................................................................... 55
	ENGINE START-UP...................................................................................................................................................................................................................................................... 59
	AFTER ENGINE HAS STARTED............................................................................................................................................................................................................................................. 60
	EMERGENCY STEERING SYSTEM............................................................................................................................................................................................................................................ 61
		Operation........................................................................................................................................................................................................................................................ 61
		Pre-Operation Testing............................................................................................................................................................................................................................................ 61
		Additional Guidelines............................................................................................................................................................................................................................................ 62
	MACHINE OPERATION SAFETY PRECAUTIONS................................................................................................................................................................................................................................. 62
	LOADING.............................................................................................................................................................................................................................................................. 63
	HAULING.............................................................................................................................................................................................................................................................. 63
	PASSING.............................................................................................................................................................................................................................................................. 64
	DUMPING.............................................................................................................................................................................................................................................................. 64
		To Raise The Dump Body:.......................................................................................................................................................................................................................................... 64
		To Lower The Dump Body: (When dumping over a berm or into a crusher):............................................................................................................................................................................................ 65
		To Lower The Dump Body (When dumping on flat ground):............................................................................................................................................................................................................ 65
	SAFE PARKING PROCEDURES.............................................................................................................................................................................................................................................. 66
	ENGINE SHUTDOWN PROCEDURE............................................................................................................................................................................................................................................ 66
	DELAYED ENGINE SHUTDOWN PROCEDURE.................................................................................................................................................................................................................................... 67
	SUDDEN LOSS OF POWER................................................................................................................................................................................................................................................. 67
	DISABLED TRUCK OPERATION............................................................................................................................................................................................................................................. 68
	GENERAL.............................................................................................................................................................................................................................................................. 68
	STEERING AND BRAKE SYSTEM............................................................................................................................................................................................................................................ 68
		Components Required.............................................................................................................................................................................................................................................. 68
		Hookup........................................................................................................................................................................................................................................................... 69
	DISABLED TRUCK DUMPING PROCEDURE..................................................................................................................................................................................................................................... 70
		Hookup........................................................................................................................................................................................................................................................... 70
		Raising the Body................................................................................................................................................................................................................................................. 70
		Lowering the Body................................................................................................................................................................................................................................................ 70
	TOWING............................................................................................................................................................................................................................................................... 71
	TROLLEY OPERATING INSTRUCTIONS....................................................................................................................................................................................................................................... 71
		AFTER THE ENGINE HAS STARTED..................................................................................................................................................................................................................................... 71
		OPERATING IN DIESEL MODE......................................................................................................................................................................................................................................... 72
		OPERATING IN TROLLEY LINE MODE................................................................................................................................................................................................................................... 72
		GETTING ON LINE.................................................................................................................................................................................................................................................. 73
			Operating On Trolley......................................................................................................................................................................................................................................... 74
		GETTING OFF LINE................................................................................................................................................................................................................................................. 76
		LINE STATUS SIGNALS.............................................................................................................................................................................................................................................. 76
		LINE STATUS SIGNAL MARKINGS...................................................................................................................................................................................................................................... 77
		TRAFFIC CONSIDERATION FOR TROLLEY LINE OPERATION................................................................................................................................................................................................................. 77
		APPROACHING SLOW MOVING VEHICLES IN A TROLLEY ASSISTED TRUCK..................................................................................................................................................................................................... 77
		OPERATING SLOW MOVING VEHICLES ON TROLLEY ASSIST RAMPS........................................................................................................................................................................................................... 78
		TRUCK FAILURE WHILE ON TROLLEY................................................................................................................................................................................................................................... 78
OPERATOR CAB AND CONTROLS................................................................................................................................................................................................................................................ 79
	STEERING WHEEL AND CONTROLS.......................................................................................................................................................................................................................................... 80
		Horn Button...................................................................................................................................................................................................................................................... 80
		Multi-Function Turn Signal Switch................................................................................................................................................................................................................................ 80
	SERVICE BRAKE PEDAL.................................................................................................................................................................................................................................................. 81
	DYNAMIC RETARDER PEDAL............................................................................................................................................................................................................................................... 81
		Optional - Dual Function / Single Pedal.......................................................................................................................................................................................................................... 81
	THROTTLE PEDAL....................................................................................................................................................................................................................................................... 81
	HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS.................................................................................................................................................................................................................... 82
		HEATER / AIR CONDITIONER VENTS................................................................................................................................................................................................................................... 81
		Defroster Vent Control Switch.................................................................................................................................................................................................................................... 82
		Heat Control Switch.............................................................................................................................................................................................................................................. 82
		Temperature Control Knob......................................................................................................................................................................................................................................... 82
		Fan Control Knob................................................................................................................................................................................................................................................. 82
		Heater / Air Conditioner Selector Switch......................................................................................................................................................................................................................... 82
		Heater / Air Conditioner Vents................................................................................................................................................................................................................................... 82
	INSTRUMENT PANEL..................................................................................................................................................................................................................................................... 83
	GRADE / SPEED WARNING CHART.......................................................................................................................................................................................................................................... 83
	RADIO SPEAKERS....................................................................................................................................................................................................................................................... 83
	WARNING ALARM BUZZER................................................................................................................................................................................................................................................. 83
	CAB RADIO............................................................................................................................................................................................................................................................ 83
	WARNING LIGHTS DIMMER CONTROL........................................................................................................................................................................................................................................ 83
	WARNING INDICATOR LIGHT PANEL........................................................................................................................................................................................................................................ 83
	AIR CLEANER VACUUM GAUGES............................................................................................................................................................................................................................................ 83
	WINDSHIELD WIPERS.................................................................................................................................................................................................................................................... 83
	CENTER CONSOLE....................................................................................................................................................................................................................................................... 84
		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
	Introduction.........................................................................................................................................................................................................................................................143
		Data Summary.....................................................................................................................................................................................................................................................143
		Data Gathering...................................................................................................................................................................................................................................................143
	COMPONENT DESCRIPTION................................................................................................................................................................................................................................................144
		System Diagram...................................................................................................................................................................................................................................................144
		Suspension Pressure Sensors......................................................................................................................................................................................................................................144
		Inclinometer.....................................................................................................................................................................................................................................................144
		Speedometer/Load Display.........................................................................................................................................................................................................................................144
		Operator Switches................................................................................................................................................................................................................................................145
		Speed Input......................................................................................................................................................................................................................................................145
		Body-Up Switch...................................................................................................................................................................................................................................................145
		Brake Lock Switch................................................................................................................................................................................................................................................145
		Payload Meter....................................................................................................................................................................................................................................................145
		Communications Ports.............................................................................................................................................................................................................................................145
		Key Switch Input.................................................................................................................................................................................................................................................146
		Payload Meter Power..............................................................................................................................................................................................................................................146
		Load Lights......................................................................................................................................................................................................................................................146
		Wiring and Termination...........................................................................................................................................................................................................................................147
		TCI Outputs......................................................................................................................................................................................................................................................147
	LOAD DISPLAY AND OPERATOR SWITCHES...................................................................................................................................................................................................................................148
		Setting the Operator ID..........................................................................................................................................................................................................................................148
		Total Ton and Total Load Counters................................................................................................................................................................................................................................148
		Viewing Live Sensor Data.........................................................................................................................................................................................................................................148
	PAYLOAD OPERATION & CALCULATION......................................................................................................................................................................................................................................149
		Description of Haul Cycles.......................................................................................................................................................................................................................................149
		Load Calculation.................................................................................................................................................................................................................................................150
		Carry Back.......................................................................................................................................................................................................................................................150
		Measurement Accuracy.............................................................................................................................................................................................................................................150
	SOURCES FOR PAYLOAD ERROR............................................................................................................................................................................................................................................150
		Suspensions......................................................................................................................................................................................................................................................150
		Loading Conditions...............................................................................................................................................................................................................................................151
		Pressure Sensors.................................................................................................................................................................................................................................................151
		Swingloads.......................................................................................................................................................................................................................................................151
		Speed and Distance...............................................................................................................................................................................................................................................151
	HAUL CYCLE DATA......................................................................................................................................................................................................................................................151
		Haul Cycle Warning Flags.........................................................................................................................................................................................................................................151
		Frame Torque Data................................................................................................................................................................................................................................................154
		Sprung Weight Data...............................................................................................................................................................................................................................................154
		Maximum Speed Data...............................................................................................................................................................................................................................................154
		Alarm Records....................................................................................................................................................................................................................................................155
	PDM SOFTWARE OVERVIEW................................................................................................................................................................................................................................................156
		System Configuration.............................................................................................................................................................................................................................................156
		Installing the PDM Software......................................................................................................................................................................................................................................156
	DOWNLOADING DATA.....................................................................................................................................................................................................................................................156
	PLM III SYSTEM CONFIGURATION.........................................................................................................................................................................................................................................157
		Starting Communications..........................................................................................................................................................................................................................................157
		Connection Menu..................................................................................................................................................................................................................................................157
		Connecting to the Payload Meter..................................................................................................................................................................................................................................158
		Configuring the Payload Meter....................................................................................................................................................................................................................................158
		Setting the Date and Time........................................................................................................................................................................................................................................158
		Setting the Truck Type...........................................................................................................................................................................................................................................159
		Setting the Display Units........................................................................................................................................................................................................................................159
		Setting the Frame Serial Number..................................................................................................................................................................................................................................159
		Setting the Truck Number.........................................................................................................................................................................................................................................159
		Setting the Komatsu Distributor..................................................................................................................................................................................................................................159
		Setting the Komatsu Customer.....................................................................................................................................................................................................................................159
		Clean Truck Tare.................................................................................................................................................................................................................................................160
		Inclinometer Calibration.........................................................................................................................................................................................................................................160
	DATA ANALYSIS........................................................................................................................................................................................................................................................161
		Creating a Query.................................................................................................................................................................................................................................................161
		Sorting on Truck Unit Number.....................................................................................................................................................................................................................................161
		Sorting on Truck Type............................................................................................................................................................................................................................................161
		Sorting on Date Range............................................................................................................................................................................................................................................162
		Sorting on Time Range............................................................................................................................................................................................................................................162
		Payload Detail Screen............................................................................................................................................................................................................................................163
		Creating Reports.................................................................................................................................................................................................................................................164
		Creating Graphs..................................................................................................................................................................................................................................................165
		Exporting Data...................................................................................................................................................................................................................................................165
		Importing Data...................................................................................................................................................................................................................................................167
		Deleting Haul Cycle Records......................................................................................................................................................................................................................................167
		Viewing Alarms...................................................................................................................................................................................................................................................167
		Deleting Alarm Records...........................................................................................................................................................................................................................................167
AM/FM RADIO / CD / MP3 / USB / iPOD™ / AUX PLAYER........................................................................................................................................................................................................................169
	OPERATING INSTRUCTIONS...............................................................................................................................................................................................................................................169
		GENERAL RADIO RECEIVER FUNCTIONS.................................................................................................................................................................................................................................169
			Turning On the Power.........................................................................................................................................................................................................................................169
			One-Hour Timer...............................................................................................................................................................................................................................................169
			Adjusting the Volume.........................................................................................................................................................................................................................................170
			Display......................................................................................................................................................................................................................................................170
			Radio Mode Displays..........................................................................................................................................................................................................................................170
			CD Mode Displays.............................................................................................................................................................................................................................................170
			MP3/USB/iPod Mode Displays...................................................................................................................................................................................................................................170
			AUX Input Displays...........................................................................................................................................................................................................................................171
			CLOCK/ALARM Button...........................................................................................................................................................................................................................................171
			Front Auxiliary Mode.........................................................................................................................................................................................................................................171
			Rear Auxiliary Mode..........................................................................................................................................................................................................................................171
			Adjusting the Receiver Audio Settings........................................................................................................................................................................................................................171
			Adjusting the Receiver Menu Settings.........................................................................................................................................................................................................................172
		USING THE RADIO..................................................................................................................................................................................................................................................173
			Finding a Station............................................................................................................................................................................................................................................173
			Setting the Presets..........................................................................................................................................................................................................................................173
		USING THE CLOCK..................................................................................................................................................................................................................................................174
			Setting the Clock............................................................................................................................................................................................................................................174
		USING THE ALARM..................................................................................................................................................................................................................................................174
			Setting the Alarm............................................................................................................................................................................................................................................174
			Turning the Alarm Off........................................................................................................................................................................................................................................175
			Activating Snooze............................................................................................................................................................................................................................................175
		USING THE WEATHERBAND (USA Only).................................................................................................................................................................................................................................175
		USING THE COMPACT DISC PLAYER/USB................................................................................................................................................................................................................................176
			Playing A Compact Disc.......................................................................................................................................................................................................................................176
			Button Functions.............................................................................................................................................................................................................................................176
		PLAYING AN MP3 DISC/USB..........................................................................................................................................................................................................................................177
			Root Directory...............................................................................................................................................................................................................................................177
			Empty Directory or Folder....................................................................................................................................................................................................................................177
			No Folder....................................................................................................................................................................................................................................................177
			File Name Display............................................................................................................................................................................................................................................177
		PLAYING MP3 FILES................................................................................................................................................................................................................................................177
			Button Functions.............................................................................................................................................................................................................................................177
		USING AN iPOD®...................................................................................................................................................................................................................................................178
			Playing an iPod..............................................................................................................................................................................................................................................178
			Button Functions.............................................................................................................................................................................................................................................178
		OPERATING TIPS...................................................................................................................................................................................................................................................179
			Tips About The Audio System..................................................................................................................................................................................................................................179
			Understanding Radio Reception................................................................................................................................................................................................................................179
			Care of The Compact Discs....................................................................................................................................................................................................................................179
		TROUBLESHOOTING..................................................................................................................................................................................................................................................180

PLEASE NOTE:

⦁ This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
⦁ You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
⦁ Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted