Komatsu 930E-4SE Operation & Maintenance Manual
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Komatsu 930E-4SE Operation & Maintenance Manual

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CEAM021304
Operation & Maintenance
Manual
DUMP TRUCK
A30769 - A30871
SERIAL NUMBERS
®

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  • Page 1 CEAM021304 Operation & Maintenance Manual DUMP TRUCK A30769 - A30871 SERIAL NUMBERS ®...
  • Page 3 This material is proprietary to Komatsu America Corp (KAC), and is not to be reproduced, used, or disclosed except in accordance with written autho- rization from KAC. It is the policy of the Company to improve prod- ucts whenever it is possible and practical to do so.
  • Page 4 Komatsu is also aware of repair companies that will rework or modify an OEM part for reuse in critical systems. Komatsu does not generally authorize such repairs or modifications for the same reasons as noted above.

  • Page 5: Introduction

    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 “M”, when present, designates a Mechanical drive system.

  • Page 6: Truck Model Illustration

    Introduction - Section 10 8/11 OM1074 Page 10-2 TRUCK MODEL ILLUSTRATION KOMATSU MODEL 930E-4SE DUMP TRUCK...

  • Page 7: About This Manual

    The front cover of this manual includes a form number. This form number should be referenced when ordering additional copies of this manual or for any other correspondence regarding the coverage in this manual. Direct all inquiries to: Komatsu America Corp. Datakom, Peoria Technical Publications P.O. Box 240...

  • Page 8: Alerts Page

    Introduction - Section 10 8/11 OM1074 Page 10-4 ALERTS PAGE This ALERT symbol is used in this manual, along with signal words “CAUTION”, “DANGER” “WARNING”, to alert the reader to hazards arising from improper operating and maintenance practices. “DANGER” identifies a specific potential hazard WHICH WILL RESULT in either INJURY OR DEATH if proper precautions are not taken.

  • Page 9: Table Of Contents

    OM1074 8/11 Introduction - Section 10 Page 10-5 TABLE OF CONTENTS INTRODUCTION ..............10-1 FOREWORD .

  • Page 10: Table Of Contents

    Introduction - Section 10 8/11 OM1074 Page 10-6 TABLE OF CONTENTS (cont.) Driving Near High Voltage Cables ..........20-8 When Dumping .
  • Page 11 OM1074 8/11 Introduction - Section 10 Page 10-7 TABLE OF CONTENTS (cont.) WARNINGS AND CAUTIONS ............22-1 OPERATING INSTRUCTIONS .
  • Page 12 Introduction - Section 10 8/11 OM1074 Page 10-8 TABLE OF CONTENTS (cont.) Multi-Function Turn Signal Switch ..........32-2 Turn Signal Operation .
  • Page 13 OM1074 8/11 Introduction - Section 10 Page 10-9 TABLE OF CONTENTS (cont.) HEATER / AIR CONDITIONER CONTROLS ........32-12 Fan Speed Control Knob .
  • Page 14 KOMATSU WIRELESS BRIDGE (Optional) ........
  • Page 15 OM1074 8/11 Introduction - Section 10 Page 10-11 TABLE OF CONTENTS (cont.) LUBRICATION AND SERVICE ............40-1 GENERAL .
  • Page 16 Introduction - Section 10 8/11 OM1074 Page 10-12 TABLE OF CONTENTS (cont.) LUBRICANT PUMP ............42-6 Pump Housing Oil Level .
  • Page 17 OM1074 8/11 Introduction - Section 10 Page 10-13 TABLE OF CONTENTS (cont.) AM/FM RADIO / CD PLAYER ............70-1 OPERATING INSTRUCTIONS .
  • Page 18 Introduction - Section 10 8/11 OM1074 Page 10-14 NOTES...
  • Page 19 OM1200 02/11 Torque Tables And Conversion Charts - Section 12 Page 12-1 TORQUE TABLES AND CONVERSION CHARTS This manual provides dual dimensioning for many specifications. Metric units are specified first, with References throughout the manual to standard U.S. standard units in parentheses. When torque val- torques or other standard values will be to one of ues are not specified in the assembly instructions the following tables.
  • Page 20 N•m ft lb kg•m NOTE: This list represents the current engineering M6 x1 1.22 approved sources for use in Komatsu manufacture. It M8 x 1.25 3.06 is not exclusive. Other products may meet the same M10 x 1.5 5.61 specifications of this list.
  • Page 21 OM1200 02/11 Torque Tables And Conversion Charts - Section 12 Page 12-3 STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws The following specifications apply to required assem- • The maximum torque tolerance shall be ±10% of bly torques for all grade 5 and grade 8 cap screws.
  • Page 22 Torque Tables And Conversion Charts - Section 12 02/11 OM1200 Page 12-4 STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws The following specifications apply to required assem- bly torques for all 12-point, grade 9 (170,000 psi min- imum tensile), cap screws. •...
  • Page 23 OM1200 02/11 Torque Tables And Conversion Charts - Section 12 Page 12-5 TABLE 4. Tightening Torque For T-Bolt Type Hose Clamp (SAE J1508 Type TB) Newton meters Inch Pounds Thread Size Band Width (N·m) (in. lb) 0.25-28 UNF 19.05 mm (0.75 in.) 8.5 ±...
  • Page 24 Torque Tables And Conversion Charts - Section 12 02/11 OM1200 Page 12-6 TABLE 7. Torque Chart For JIC 37° Swivel NutS With Or Without O-ring Seals Size Tube Size Threads UNF-2B Newton meters Foot Pounds Code (OD) (N·m) (ft lb) –...
  • Page 25 OM1200 02/11 Torque Tables And Conversion Charts - Section 12 Page 12-7 TABLE 9. Torque Chart For O-ring Boss Fittings Foot Pounds Newton meters Size Tube Size Threads UNF-2B (ft lb) (N·m) Code (OD) – 2 0.125 0.312 – 24 4 ±...
  • Page 26 Torque Tables And Conversion Charts - Section 12 02/11 OM1200 Page 12-8 TABLE11. Common Conversion Multipliers Metric To English Multiply To Convert From millimeter (mm) inch (in.) 0.0394 centimeter (cm) inch (in.) 0.3937 meter (m) foot (ft) 3.2808 meter (m) yard (yd) 1.0936 kilometer (km)
  • Page 27 OM1200 02/11 Torque Tables And Conversion Charts - Section 12 Page 12-9 TABLE 12. Common Conversion Multipliers English to Metric To Convert Multiply From inch (in.) millimeter (mm) 25.40 inch (in.) centimeter (cm) 2.54 foot (ft) meter (m) 0.3048 yard (yd) meter (m) 0.914 mile (mi)
  • Page 28 Torque Tables And Conversion Charts - Section 12 02/11 OM1200 Page 12-10 TABLE 13. Temperature Conversions Formula: F° - 32  1.8 = C° or C° x 1.8 + 32 = F° Celsius Fahrenheit Celsius Fahrenheit Celsius Fahrenheit C° F° C°...

  • Page 29: Safety

    OM2042 7/11 Safety - Section 20 Page 20-1 SAFETY GENERAL Fire Extinguisher And First Aid Kit • Make sure that fire extinguishers are accessible Safety records from most organizations will show that and proper usage techniques are known. the greatest percentage of accidents are caused by unsafe acts performed by people.

  • Page 30: Leaving The Operator's Seat

    Safety - Section 20 7/11 OM2042 Page 20-2 Leaving The Operator’s Seat Fire Prevention For Fuel And Oil When preparing to leave the operator's seat, do not • Fuel, oil, and antifreeze can be ignited by a flame. Fuel is extremely flammable and can be touch any control lever that is not locked.

  • Page 31: Precautions With High Temperature Fluids

    3. Turn the cap slowly to release the pressure it is modified or repaired without authorization before removing the cap. from Komatsu, or if it is damaged when the truck rolls over, the strength of the structure will be compromised and will not be able to fulfill its intended purpose.

  • Page 32: Precautions For Attachments

    In addition, know the proper use and care of all the safety equipment on the truck. Only • Do not use attachments that are not authorized by Komatsu America Corp. or the authorized qualified operators or technicians should attempt to regional Komatsu distributor. Use of unauthorized operate or maintain a Komatsu machine.

  • Page 33: Fire Prevention

    OM2042 7/11 Safety - Section 20 Page 20-5 Fire Prevention Mirrors, Windows And Lights • Remove wood chips, leaves, paper, and other • Remove any dirt from the surface of the flammable items that have accumulated in the windshield, cab windows, mirrors and lights. engine compartment.

  • Page 34: Operating The Truck

    Safety - Section 20 7/11 OM2042 Page 20-6 OPERATING THE TRUCK When Starting The Engine • Never attempt to start the engine by shorting across cranking motor terminals. This may cause a fire, or serious injury or death to anyone in The tire and rim assembly may explode if truck’s path.

  • Page 35: Traveling

    OM2042 7/11 Safety - Section 20 Page 20-7 Traveling Traveling On Slopes • When traveling on rough ground, travel at low • Traveling on slopes could result in the truck speeds. When changing direction, avoid turning tipping over or slipping. suddenly.

  • Page 36: Driving Near High Voltage Cables

    Safety - Section 20 7/11 OM2042 Page 20-8 Driving Near High Voltage Cables When Loading Driving near high-voltage cables can cause electric • Make sure that the surrounding area is safe. Stop the truck in the correct loading position, then load shock.

  • Page 37: Working Near Batteries

    OM2042 7/11 Safety - Section 20 Page 20-9 WORKING NEAR BATTERIES • Batteries generate hydrogen gas. Hydrogen gas is very explosive and can easily be ignited with a small spark or flame. Battery Hazard Prevention • Before working with batteries, stop the engine •...

  • Page 38: Before Performing Maintenance

    PARK. Always perform this work with two people. One person must sit in the The Komatsu body-up safety sling can only be operator's seat to stop the engine if necessary. used with a Komatsu body. Non-OEM body may...

  • Page 39: While Performing Maintenance

    OM2042 7/11 Safety - Section 20 Page 20-11 WHILE PERFORMING MAINTENANCE Working Under The Truck • Always lower all movable work equipment to the NOTE: Only authorized personnel should service ground or to their lowest position before and repair the truck. performing service or repairs under the truck.

  • Page 40: Adding Fuel Or Oil

    Safety - Section 20 7/11 OM2042 Page 20-12 Adding Fuel Or Oil Handling High Pressure Hoses • Spilled fuel and oil may cause slipping. Always • Do not bend high pressure hoses or hit them with clean up spills immediately. hard objects.

  • Page 41: Tires

    If the proper procedure for performing maintenance or replacement of the wheel or tire is not used, the wheel or tire may burst and cause serious injury or damage. When performing such maintenance, consult your authorized regional Komatsu distributor or the tire manufacturer.

  • Page 42: When Repairs Are Necessary

    Never allow welding current to • Many components on the Komatsu truck are pass through ball bearings, roller bearings, large and heavy. Ensure that lifting equipment - suspensions or hydraulic cylinders.

  • Page 43: Special Precautions For Working On Ac Drive Trucks

    MAINTENANCE Before welding or repairing an AC drive truck, Normal operation of the AC drive system at shutdown maintenance personnel should notify a Komatsu should leave the system safe to service. However, in service representative. Only qualified personnel, the event of a system failure, performing the following...
  • Page 44 The metal panels on the back of the any power cables or use them as hand or foot cabinet are part of capacitors and cannot be holds. heated. Notify your Komatsu service representative 7. Do not weld on the retarding grid exhaust immediately. Only qualified personnel, louvers! They are made of stainless steel.

  • Page 45: Capacitor Discharge System

    Certain drive system failures, • Grounding stick pair (Figure 20-3) (Komatsu p/n PC3299) however, can result in a condition where one or more (HVR Advanced Power Components MAS-...

  • Page 46: Warnings And Cautions

    Safety - Section 20 7/11 OM2042 Page 20-18 Warnings And Cautions All applicable local mine, government, and industry rules for working with high voltage must be followed. Required personal protective equipment, including but not limited to safety shoes, high voltage gloves, Hazardous voltages are present in this equip- and safety glasses must be worn.

  • Page 47: Manual Dc Link Capacitor Discharge Procedure

    OM2042 7/11 Safety - Section 20 Page 20-19 Manual DC Link Capacitor Discharge Procedure Follow any and all local and site specific procedures and requirements for working on off-highway mining equipment. Verify that: • The engine is off and the parking brake is on. FIGURE 20-4.
  • Page 48 Safety - Section 20 7/11 OM2042 Page 20-20 2. Observe both capacitor charge lights (CCL1, CCL2). CCL1 is on the outside of the contactor box. CCL2 is on the switch panel inside the low voltage area. The lights will stay illuminated as long as the voltage on the DC link is greater than 50 VDC.

  • Page 49: Failure Of The Discharge System

    OM2042 7/11 Safety - Section 20 Page 20-21 Failure of the Discharge System 1. Open the high voltage area doors. 2. With a suitable high voltage meter rated for at If the capacitor charge lights remain illuminated, a least 2000 VDC, such as PC3186 or equivalent, failure of the normal (fast) capacitor discharge sys- plus suitable protective equipment, measure the tem (RP discharge path) has likely occurred.

  • Page 50: Manual Discharge Of Capacitors

    Safety - Section 20 7/11 OM2042 Page 20-22 Manual Discharge of Capacitors 3. Discharge the relevant capacitors. Open the door(s) and place one grounding stick on one of If the voltage is greater than 1V on any of the capaci- the positive (+) capacitor terminals and the tors, the capacitor must be manually discharged.
  • Page 51 OM2042 7/11 Safety - Section 20 Page 20-23 4. Measure voltage on all capacitors as described in Failure of the Discharge System on page 30- 21. Discharge any capacitors that show voltage. 5. If all capacitors read discharged, verify that the meter is functioning correctly using site- Voltages in excess of 1500 VDC may be present.

  • Page 52: Short Isolated Capacitor Terminals

    Safety - Section 20 7/11 OM2042 Page 20-24 Short Isolated Capacitor Terminals Any capacitor that is isolated from the DC link and confirmed discharged must have its terminals electri- cally shorted together to prevent static charge build up. Use bare wire to jumper all four terminals on the capacitor.
  • Page 53 OM2042 7/11 Safety - Section 20 Page 20-25...

  • Page 54: Additional Job Site Rules

    Safety - Section 20 7/11 OM2042 Page 20-26 ADDITIONAL JOB SITE RULES Use this space to add any additional job site rules not covered in any of the previous discussions. _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________...

  • Page 55: Warnings And Cautions

    The plates and decals right of the steering column on the instrument panel. listed here are typical of this Komatsu model, but The warning stresses the importance of reading the because of customer options, individual trucks may operator's manual before operation.
  • Page 56 Safety - Section 22 8/11 OM2220 Page 22-2 BATTERIES This decal is placed on the battery box near the battery disconnect switches to indicate that the battery system A danger decal is located on the front exterior of the (24VDC) is a negative (-) ground system. battery box.
  • Page 57 OM2220 8/11 Safety - Section 22 Page 22-3 CRUSHING HAZARD CYLINDER PRESSURE Warning decals are mounted on the frame in front of These danger decals are mounted on the outside of both front tires and to the rear of both front tires. They each frame rail to remind technicians to read the warn that the clearances change when the truck is warning labels attached to the side of each of the...
  • Page 58 Safety - Section 22 8/11 OM2220 Page 22-4 FILLING THE HYDRAULIC TANK HYDRAULIC OIL PRESSURE A decal mounted on the side of the hydraulic tank A warning plate is attached to the hydraulic tank to provides instructions for filling the hydraulic tank. warn technicians that high pressure hydraulic oil is present during operation.
  • Page 59 OM2220 8/11 Safety - Section 22 Page 22-5 HOT OIL SPRAY RADIATOR If equipped, this decal is placed on both front wheel A warning decal is mounted on top of the radiator surge hubs to warn about hot oil inside the wheel hubs. tank cover near the radiator cap.
  • Page 60 Safety - Section 22 8/11 OM2220 Page 22-6 EMERGENCY DUMP PROCEDURE WELDING A decal which provides the operator or technician with This caution decal is placed near the battery the emergency procedure for dumping a loaded, disconnect switches to alert service technicians to disabled truck by using a functional truck for hydraulic always disconnect the battery charging alternator lead power is located on the frame near the left hoist...
  • Page 61 OM2220 8/11 Safety - Section 22 Page 22-7 INFORMATION DISPLAY HIGH VOLTAGE This information decal is placed on the left door of the A high voltage danger decal is attached to the door of control cabinet. the rear hatch cover. High voltage may be present! Only authorized personnel should access this rear housing.
  • Page 62 Safety - Section 22 8/11 OM2220 Page 22-8 LIFTING INSTRUCTIONS This page illustrates a variety of decals which are If any of these decals is damaged or defaced so it is no placed on deck mounted cabinets, housings, and longer legible, it should be replaced immediately. structures that must be lifted in a specific manner and Maintenance personnel must follow these lifting from specific points in order to safely move them.
  • Page 63 (CL). The CL is used to verify the accuracy of the individual PIN. FC - Character positions 10 and 11 identify the Factory Code (FC). The FC identifies the Komatsu factory in charge of claims for the product. The FC for electric drive trucks is 61.
  • Page 64 Safety - Section 22 8/11 OM2220 Page 22-10 LUBRICATION CHART The lubrication chart is mounted on the right hand side of the radiator grille structure. Refer to Section 40, Lubrication and Service, for more complete lubrication instructions.

  • Page 65: Operating Instructions

    “rest”. Komatsu truck. 1. Start at left front of truck. Visually inspect all lights and safety equipment for damage. Make Safe practices start before the operator gets to the sure that the lenses are clean and unbroken.
  • Page 66 Operating Instructions - Section 30 8/11 OM3062 Page 30-2 START HERE...
  • Page 67 OM3062 8/11 Operating Instructions - Section 30 Page 30-3 13. Move around the left side dual tires. Make sure that all wheel nuts/studs are in place and tight. FIGURE 30-1. TOP VIEW Inspect the wheel for any oil that would indicate 1.
  • Page 68 Operating Instructions - Section 30 8/11 OM3062 Page 30-4 22. Move in behind the right front wheel. Make sure that the steering cylinder is properly greased and the mounting hardware is secure. Check suspension mounting hardware suspension extension. Make sure that the suspension protective boot is in good condition.

  • Page 69: Engine Start-Up

    OM3062 8/11 Operating Instructions - Section 30 Page 30-5 ENGINE START-UP Do not crank an electric starter for more than 30 seconds. Allow two minutes for cooling before Never attempt to start the engine by shorting attempting to start the engine again. Severe across the starter terminals.

  • Page 70: After Engine Start-Up

    Page 30-6 AFTER ENGINE START-UP PRE-SHIFT BRAKE CHECK (if equipped) NOTE: Komatsu recommends that operators perform static brake tests to verify that the braking systems are adequate at the beginning of each shift before operating the truck. Do not leave the truck unattended while the The static brake test allows the operator to check the engine is running.

  • Page 71: Operation

    OM3062 8/11 Operating Instructions - Section 30 Page 30-7 OPERATION If the brake check light does not illuminate immedi- ately after pressing the brake test switch, there is The static brake test utilizes a momentary switch and most likely a problem with the setup. Refer to the a check light located in the overhead display panel.

  • Page 72: Performing The Brake Tests

    Operating Instructions - Section 30 8/11 OM3062 Page 30-8 PERFORMING THE BRAKE TESTS Service Brake Test 1. Firmly depress the service brake pedal. Setup 2. Place the directional control lever in the NEU- Before performing any brake test, the following con- TRAL position.
  • Page 73 OM3062 8/11 Operating Instructions - Section 30 Page 30-9 9. Release the accelerator pedal and the torque Parking Brake Test will be reduced, the test will stop and the brake 1. Place the directional control lever in the PARK check light will turn off. position.

  • Page 74: Emergency Steering System

    The DID panel will display: Pre-Operation Testing Retard System Test PASSED NOTE: Komatsu recommends that operators perform this test to verify that the steering accumulator precharge pressure is adequate at the beginning of Retard System Test FAILED or Incomplete each shift before operating the truck.

  • Page 75: Machine Operation Safety Precautions

    OM3062 8/11 Operating Instructions - Section 30 Page 30-11 MACHINE OPERATION SAFETY 4. Turn the key switch to the ON position, but do not start the engine. PRECAUTIONS a. Steering system pressure: Verify that the low After the engine is started and all systems are steering pressure warning...

  • Page 76: Operating On A Haul Road

    Operating Instructions - Section 30 8/11 OM3062 Page 30-12 • Match the truck speed to haul road conditions. 4. When backing up the truck, give a back-up Slow down the truck in congested areas. Keep a signal of three blasts on the horn. When starting firm grip on the steering wheel at all times.

  • Page 77: Starting On A Grade With Aloaded Truck

    OM3062 8/11 Operating Instructions - Section 30 Page 30-13 STARTING ON A GRADE WITH A Overload Speed Limit Function LOADED TRUCK NOTE: This feature can be enabled or disabled at the discretion of site management. The setting for Initial propulsion with a loaded truck should begin payload trigger and speed limits are also adjustable from a level surface whenever possible.

  • Page 78: Dumping

    Operating Instructions - Section 30 8/11 OM3062 Page 30-14 DUMPING Raising The Dump Body 1. Pull into the dump area with extreme caution. Make sure the area is clear of persons and obstructions, including overhead utility lines. Obey signals directed by the spotter, if present. 2.

  • Page 79: Lowering The Dump Body (When Dumping On Flat Ground)

    OM3062 8/11 Operating Instructions - Section 30 Page 30-15 Lowering The Dump Body Lowering The Dump Body (When dumping on flat ground) (When dumping over a berm or into a crusher) 1. Move the hoist lever forward to the DOWN It is very likely when dumping on flat ground that the position.

  • Page 80: Towing

    Operating Instructions - Section 30 8/11 OM3062 Page 30-16 TOWING Special Wiring Harness Before towing, a special wiring harness must be made in order to release the parking brake. The har- ness will require approximately 9 meters (30 ft) of #14 wire, and one ON/OFF switch (capable of carry- ing 2 amps of current) and two ring terminals.
  • Page 81 OM3062 8/11 Operating Instructions - Section 30 Page 30-17 8. The parking brakes must be released before 12. Minimize the tow angle at all times. Never towing. To release the parking brake, follow the exceed 30 degrees. The towed truck must be steps below to install a special wiring harness to steered in the direction of the tow bar.
  • Page 82 Operating Instructions - Section 30 8/11 OM3062 Page 30-18 FIGURE 30-3. PARKING BRAKE WIRING FOR TOWING 1. Switch 3. Harness 2. Ground Wire...

  • Page 83: Safe Parking Procedures

    OM3062 8/11 Operating Instructions - Section 30 Page 30-19 SAFE PARKING PROCEDURES NORMAL ENGINE SHUTDOWN PROCEDURE Continue to use safety precautions when preparing for parking and engine shutdown. Follow this procedure at each engine shutdown: If the truck is being used in consecutive shifts, any 1.

  • Page 84: Sudden Loss Of Engine Power

    Dynamic retarding will not be available. Do not use the service brakes for continuous retarding Allowing the Komatsu truck to operate until fuel purposes. depletion lead unsafe operating...

  • Page 85: Disabled Truck Dumping Procedure

    The disabled truck may be the same truck model or a different 3. Reduce the power down relief valve pressure Komatsu truck model. on the good truck to normal by turning the adjustment counterclockwise the same number Hookup of turns as required in Step 2b of “Raising the...

  • Page 86: Reserve Engine Oil System

    Operating Instructions - Section 30 8/11 OM3062 Page 30-22 RESERVE ENGINE OIL SYSTEM The reserve oil tank for the engine is designed to add more oil capacity to the engine and to allow less frequent servicing of the engine oil. The circulation of oil between the engine sump and reserve tank increases the total volume of working oil.

  • Page 87: Operator Cab And Controls

    OM3245 8/11 Operator Cab And Controls - Section 32 Page 32-1 OPERATOR CAB AND CONTROLS FIGURE 32-1. CAB INTERIOR - OPERATOR VIEW 1. Steering Wheel 6. Heater/Air Conditioner Controls 11. Radio/CD Player 12. Warning Lights Dimmer Control 2. Retarder Lever 7.

  • Page 88: Steering Wheel And Controls

    Operator Cab And Controls - Section 32 8/11 OM3245 Page 32-2 STEERING WHEEL AND CONTROLS Multi-Function Turn Signal Switch Steering wheel (1, Figure 32-2) can be telescoped “in” and “out” and the lilt angle can be adjusted to provide a comfortable steering wheel position for most operators.

  • Page 89: Dynamic Retarding

    OM3245 8/11 Operator Cab And Controls - Section 32 Page 32-3 DYNAMIC RETARDING NOTE: The retarder lever must be rotated back to the OFF position before the truck will resume the Dynamic retarding is a braking torque (not a brake) propel mode of operation.

  • Page 90: Grade/Speed Retard Chart

    Operator Cab And Controls - Section 32 8/11 OM3245 Page 32-4 GRADE/SPEED CHART The “short term” numbers listed on the chart indicate the combination of speeds and grades which the Grade/speed chart (8, Figure 32-1 and shown below) vehicle can safely negotiate for a short duration provides the recommended MAXIMUM retarding before system components reach the maximum limits at various truck speeds and grades with a fully...

  • Page 91: Overhead Panel And Displays

    OM3245 8/11 Operator Cab And Controls - Section 32 Page 32-5 OVERHEAD PANEL AND DISPLAYS Status/Warning Indicator Light Panel Status/ warning indicator panel (13) contains an array The components described below are located on the of indicator lights to provide the operator with overhead panel.

  • Page 92: Center Console

    Operator Cab And Controls - Section 32 8/11 OM3245 Page 32-6 CENTER CONSOLE Directional Control Lever Directional lever (2, Figure 32-3) is mounted on the console to the right of the operator's seat. It is a four position lever that controls the park, reverse, neutral and forward movement of the truck.

  • Page 93: Override/Fault Reset Switch

    OM3245 8/11 Operator Cab And Controls - Section 32 Page 32-7 Override/Fault Reset Switch Hoist Control Lever This push-button switch (3, Figure 32-3) is spring- Hoist control (7, Figure 32-3) is a four position hand- loaded to the OFF position. When pushed in and operated lever located between the operator seat held, this switch may be used for several functions.

  • Page 94: Retard Speed Control (Rsc) Adjustment Dial

    Operator Cab And Controls - Section 32 8/11 OM3245 Page 32-8 Retard Speed Control (RSC) Adjustment Dial With the RSC switch on and dial adjusted, the system will function as follows: RSC adjustment dial (8, Figure 32-3) allows the operator to vary the downhill truck speed that the As the truck speed increases to the “set”...

  • Page 95: Data Store Button

    OM3245 8/11 Operator Cab And Controls - Section 32 Page 32-9 DIAGNOSTIC PORTS Data Store Button Button (10, Figure 32-3) is for use by qualified KOMTRAX Plus Diagnostic Port maintenance personnel to record in memory a Diagnostic port (1) is used to download truck “snapshot”...

  • Page 96: Operator's Seat

    Operator Cab And Controls - Section 32 8/11 OM3245 Page 32-10 OPERATOR’S SEAT 8. Suspension Dampener - Adjust suspension dampener (8) to obtain the desired stiffness of The operator's seat provides a fully adjustable the adjustable shock absorber. Move the lever cushioned ride for driver comfort and easy operation.

  • Page 97: Passenger Seat

    OM3245 8/11 Operator Cab And Controls - Section 32 Page 32-11 PASSENGER SEAT The passenger seat provides a fully adjustable cushioned ride for driver comfort and easy operation. Seat Belts • On both driver and passenger seats, check the seat belt fabric, buckle, all belt retractors and hardware for damage or wear.

  • Page 98: Heater / Air Conditioner Controls

    Operator Cab And Controls - Section 32 8/11 OM3245 Page 32-12 HEATER / AIR CONDITIONER Heater/Air Conditioner Vents CONTROLS Heater/air conditioner vents (6, Figure 32-7) may be rotated 360°. There are three vents in the heater/air The heater/air conditioner compartment contains conditioner compartment, four vents across the top of heater/air conditioner controls and some of the the instrument panel, and one vent each in the RH...

  • Page 99: Instrument Panel

    OM3245 8/11 Operator Cab And Controls - Section 32 Page 32-13 INSTRUMENT PANEL The operator must understand the function and operation of each instrument and control. Control functions are identified with international symbols that the operator should learn to recognize immediately. This knowledge is essential for proper and safe operation.
  • Page 100 Operator Cab And Controls - Section 32 8/11 OM3245 Page 32-14 FIGURE 32-8. PANEL GAUGES, INDICATORS, AND CONTROLS 1. Key Switch 13. Left Turn Signal Indicator Light 2. Rotating Beacon Switch (optional) 14. Coolant Temperature Gauge 3. Heated Mirror Switch (optional) 15.

  • Page 101: Key Switch

    OM3245 8/11 Operator Cab And Controls - Section 32 Page 32-15 Key Switch Heated Mirror Switch (optional) Switch (3, Figure 32-8) controls the operation of the heated mirrors. AC Drive System Rest Switch Rest switch (4, Figure 32-8) is a rocker switch with a locking device for the OFF position.

  • Page 102: Wheel Brake Lock Switch

    Operator Cab And Controls - Section 32 8/11 OM3245 Page 32-16 Wheel Brake Lock Switch Engine Oil Pressure Gauge Wheel brake lock switch (5, Figure Engine oil pressure gauge (8, Figure 32-8) should be used with engine 32-8) indicates pressure in the running for dumping and loading engine lubrication system.

  • Page 103: Left Turn Signal Indicator

    OM3245 8/11 Operator Cab And Controls - Section 32 Page 32-17 Left Turn Signal Indicator Light Switch (3-Way) Indicator (13, Figure 32-8) illuminates to indicate that instrument panel lights, the left turn signals are operating when the turn clearance lights, and the headlights signal lever is moved downward.

  • Page 104: Fog Light Switch

    Operator Cab And Controls - Section 32 8/11 OM3245 Page 32-18 Fog Light Switch Hydraulic Oil Temperature Gauge Pressing the top of fog light switch Hydraulic oil temperature gauge (19, Figure 32-8) turns the lights on. (22, Figure 32-8) indicates the Pressing the bottom of the switch hydraulic oil temperature.

  • Page 105: Overhead Status/Warning Indicators

    OM3245 8/11 Operator Cab And Controls - Section 32 Page 32-19 OVERHEAD STATUS / WARNING INDICATORS FIGURE 32-9. OVERHEAD STATUS / WARNING INDICATOR Row / Indicator Indicator Color Row / Indicator Indicator Color Column Description Wire Index Column Description Wire Index High Brake Oil No Propel/ No Retard Red-12M/75-6P1...

  • Page 106: A1. High Brake Oil Temperature

    Operator Cab And Controls - Section 32 8/11 OM3245 Page 32-20 Indicator lights that are amber (yellow) in color alert B1. Low Steering Pressure the operator that the indicated truck function requires When the key switch is turned ON, some precaution when lighted. this red warning light will illuminate Indicator lights that are red in color alert the operator and the warning buzzer will sound...

  • Page 107: C1. Low Accumulator Precharge Pressure

    OM3245 8/11 Operator Cab And Controls - Section 32 Page 32-21 6. If safe to do so, have maintenance personnel E1. Low Brake Pressure place wheel chocks or other mechanisms in This red warning light indicates a front or behind the wheels to reduce the risk of malfunction within the hydraulic the truck rolling.

  • Page 108: D2. Hydraulic Oil Filter Monitor

    Operator Cab And Controls - Section 32 8/11 OM3245 Page 32-22 D2. Hydraulic Oil Filter Monitor B3. Service Brake This amber indicator light indicates This amber indicator light will a restriction in the high pressure illuminate when the service brake filter assembly either...

  • Page 109: E3. Stop Engine

    OM3245 8/11 Operator Cab And Controls - Section 32 Page 32-23 E3. Stop Engine B4. Backup Lights This red warning light will illuminate This amber indicator light will if a serious engine malfunction is illuminate when backup light switch detected in the electronic engine (18, Figure 32-8) is turned ON.

  • Page 110: A5. No Power

    Operator Cab And Controls - Section 32 8/11 OM3245 Page 32-24 A5. No Power E5. Battery Charging System Failure This red “no retard/no propel” indicator light indicates that a fault The red warning light indicates a has occurred which has eliminated problem has been detected in the retarding propulsion...

  • Page 111: D6. Reduced Propulsion

    OM3245 8/11 Operator Cab And Controls - Section 32 Page 32-25 C6. Propel System Not Ready D7. Brake Test Light This amber indicator light functions This amber indicator light during start-up much like the indicates when the truck is in the hourglass icon on a computer brake test...

  • Page 112: Rear Axle Light Bar

    Operator Cab And Controls - Section 32 8/11 OM3245 Page 32-26 REAR AXLE LIGHT BAR FIGURE 32-10. REAR AXLE LIGHT BAR 1. Backup Light 3. Brake Light 2. Retard Light 4. Backup Alarm NOTE: The brake light is functional at all times regardless of key switch position. All other lights (and the backup alarm) are only functional with the key switch in the RUN position.

  • Page 113: Komtrax Plus

    (PC) or transmitted directly by communications satellite (utilizing the ORBCOMM Proper operation of the system is dependent on controller). This data is then compiled at the Komatsu good reception. Operating in tunnels, mountain computer server. Based on this information, the...
  • Page 114 Operator Cab And Controls - Section 32 8/11 OM3245 Page 32-28 During normal truck operation, the red LED digits on NOTE: The ORBCOMM modem installed from the the KOMTRAX Plus controller will count from 00-99 factory on all new trucks may not be approved for continuously.

  • Page 115: Interface Module

    • Do not get water, dirt or oil on the system controllers. • If there is any abnormality with the KOMTRAX Plus system, please consult the servicing Komatsu distributor. FIGURE 32-13. ORBCOMM ANTENNA 1. ORBCOMM 2. Magnetic Base Antenna...

  • Page 116: Komatsu Wireless Bridge (Optional)

    KWB. It will be necessary to "create a profile" for the General Information new network. Check the wireless adaptor's manual The Komatsu wireless bridge (2, Figure 32-12) for details. allows for the transfer of information from the 3. Configure the new profile as follows: KOMTRAX Plus controller to a laptop computer with •...

  • Page 117: Setting The Computer Subnet Mask And Ip Address

    This is done automatically by selecting the profile. It may be necessary to repeat these steps to restore the computer settings when connecting to another network. FIGURE 32-15. RESET LOCATION 1. Komatsu Wireless 2. Reset Button Hole Bridge...

  • Page 118: Setting Up The Kwb

    Operator Cab And Controls - Section 32 8/11 OM3245 Page 32-32 Setting Up the KWB Adding Encryption The KWB is preset from the factory. It is It is recommend that encryption be added. recommended that the SSID be changed at setup to 1.

  • Page 119: Data Downloading

    Resetting the KWB To obtain the software for data downloading from the It may be necessary to reset the KWB. For example, KOMTRAX Plus controller, go to the Komatsu if the WEP key was incorrectly typed when setting up Extranet (https://www.komatsuamerica.net).

  • Page 120: Fuses And Circuit Breakers

    Operator Cab And Controls - Section 32 8/11 OM3245 Page 32-34 FUSES AND CIRCUIT BREAKERS The fuses are located in four fuse blocks in the auxiliary control cabinet. N050271 FIGURE 32-16. FUSE BLOCKS FUSE BLOCK #1 Location Amps Devices protected Circuit A/C, Heater Blower Motor Windshield Washer / Wiper...
  • Page 121 OM3245 8/11 Operator Cab And Controls - Section 32 Page 32-35 FUSE BLOCK #2 Location Amps Devices protected Circuit Engine Service Lights 11SL Cab Dome, Fog, Ladder Lights, Beacon, Hour Meter Hazard Lights Interface Module 11INT VHMS & Orbcomm Controllers Power Modular Mining Hub Display Module 11DISP...
  • Page 122 Operator Cab And Controls - Section 32 8/11 OM3245 Page 32-36 FUSE BLOCK #4 Location Amps Devices protected Circuit Brake Circuits 71BC Payload Meter Controller 712PL Interface Module VHMS Controller 71VHM Modular Mining Hub 712MM Display Module Hydraulic Bleed Down Power 71BD Switch LED Power 71LS...
  • Page 123 OM3245 8/11 Operator Cab And Controls - Section 32 Page 32-37 The following circuit breakers are located on the relay boards on the left inside wall of the auxiliary control cabinet. Location Amps Devices protected Circuit RB1 - CB13 12.5 Turn Signals / Clearance Lights 11CL RB1 - CB14...
  • Page 124 Operator Cab And Controls - Section 32 8/11 OM3245 Page 32-38 NOTES...

  • Page 125: Lubrication And Service

    Section 42, Automatic Lubrication System. SERVICE CAPACITIES U.S. Component/System Liters Gallons Crankcase (including 4 oil filters) Komatsu SSDA18V170 Engine Cooling System Komatsu SSDA18V170 Engine Hydraulic System 1325 Refer to “Hydraulic Tank Service” FIGURE 40-1. HYDRAULIC TANK SERVICE Wheel Motors (each side) 1.

  • Page 126: Cooling System Service

    Because of the wide variety of factors involved, it is necessary to consult your area Komatsu representative for all wheel motor service intervals and instructions. General intervals for oil service and sampling are listed in the interval charts.

  • Page 127: Reserve Oil Tank Service

    OM4056 7/11 Lubrication and Service - Section 40 Page 40-3 RESERVE OIL TANK SERVICE Oil should always be visible in the bottom sight gauge. If not, add oil to the reserve oil tank until oil is The reserve engine oil system is designed to add visible in the top sight gauge.

  • Page 128: Quick Fill Service Center

    Lubrication and Service - Section 40 7/11 OM4056 Page 40-4 QUICK FILL SERVICE CENTER The service center (Figure 2-4) can be located on TABLE 1: MAXIMUM FIll PRESSURES either side of the truck and is used to fill system flu- Fill System ids.
  • Page 129 OM4056 7/11 Lubrication and Service - Section 40 Page 40-5...

  • Page 130: Lubrication Chart

    Lubrication and Service - Section 40 7/11 OM4056 Page 40-6 10 HOUR (DAILY) INSPECTIONS NOTE: “Lube Key” references are to the Lubrication Chart on page 40-5. Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS 1.
  • Page 131 OM4056 7/11 Lubrication and Service - Section 40 Page 40-7 10 HOUR (DAILY) INSPECTIONS (Cont.) TASK COMMENTS CHECKED INITIALS 7. COOLING AIR DUCTWORK - Inspect the ductwork from the blower to the rear axle. Make sure that the ductwork is secure, undamaged and unrestricted. 8.

  • Page 132: 50 Hour Lubrication And Maintenance Checks

    Lubrication and Service - Section 40 7/11 OM4056 Page 40-8 50 HOUR LUBRICATION AND MAINTENANCE CHECKS Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS *1. FUEL FILTERS - Replace the fuel filters. Refer to the engine operation and maintenance manual for filter replacement instructions.
  • Page 133 OM4056 7/11 Lubrication and Service - Section 40 Page 40-9 250 HOUR LUBRICATION AND MAINTENANCE CHECKS (Cont.) All 10 Hour (Daily) Inspections should also be performed at this time. NOTE: “Lube Key” references are to the Lubrication Chart on page 40-5. Truck Serial Number______________________ Site Unit Number_______________ Date_______________...
  • Page 134 Lubrication and Service - Section 40 7/11 OM4056 Page 40-10 250 HOUR LUBRICATION AND MAINTENANCE CHECKS (Cont.) TASK COMMENTS CHECKED INITIALS STEERING LINKAGE - Check the torque on the pin retaining nuts for the steering cylinders and tie rods. Tighten to 1 017 N•m (750 ft lb). HYDRAULIC PUMP DRIVESHAFT &...

  • Page 135: 500 Hour Lubrication And Maintenance Checks

    OM4056 7/11 Lubrication and Service - Section 40 Page 40-11 250 HOUR LUBRICATION AND MAINTENANCE CHECKS (Cont.) TASK COMMENTS CHECKED INITIALS 17. CAB RECIRCULATION AIR FILTER - Clean the filter element with mild soap and water. Rinse completely and allow to air dry before reinstalling the filter. 18.
  • Page 136 Lubrication and Service - Section 40 7/11 OM4056 Page 40-12 500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Cont.) TASK COMMENTS CHECKED INITIALS RESERVE ENGINE OIL SYSTEM - 1. Check the electrical system connections for tightness, corrosion and damage. Check the battery, oil pressure switch, junction boxes, remote control box and the circuit breakers.

  • Page 137: 1000 Hour Lubrication And Maintenance Checks

    OM4056 7/11 Lubrication and Service - Section 40 Page 40-13 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS All 10 Hour (Daily) Inspections, 250 Hour Lubrication and Maintenance Checks, and 500 Hour Lubrication and Maintenance Checks should also be performed at this time. NOTE: “Lube Key”...
  • Page 138 Lubrication and Service - Section 40 7/11 OM4056 Page 40-14 NOTES...

  • Page 139: Automatic Lubrication System

    OM4213 7/11 Automatic Lubrication System - Section 42 Page 42-1 AUTOMATIC LUBRICATION SYSTEM GENERAL DESCRIPTION The reciprocating action causes the pump cylinder to move up and down. The pump is a positive The automatic lubrication system is a pressurized displacement, double-acting type as grease output lubricant delivery system which delivers a controlled occurs on both the up and the down stroke.
  • Page 140 Automatic Lubrication System - Section 42 7/11 OM4213 Page 42-2 FIGURE 42-2. AUTOMATIC LUBRICATION SYSTEM INSTALLATION NOTE: The above illustration shows the standard location for the lube pump and reservoir (right platform). This assembly may be located on the left platform on some models. 1.

  • Page 141: System Components

    OM4213 7/11 Automatic Lubrication System - Section 42 Page 42-3 SYSTEM COMPONENTS Flow Control Valve Flow control valve (10, Figure 42-1) mounted on the Filter manifold, controls the amount of oil flow to the Filter assembly (21, Figure 42-2) mounted on the hydraulic motor.

  • Page 142: System Operation

    Automatic Lubrication System - Section 42 7/11 OM4213 Page 42-4 SYSTEM OPERATION 6. When grease pressure reaches pressure switch (18, Figure 42-2) setting, the switch contacts Normal Operation will close and energize the relay RB7-K5, removing power from the hydraulic motor/pump 1.

  • Page 143: General Instructions

    OM4213 7/11 Automatic Lubrication System - Section 42 Page 42-5 GENERAL INSTRUCTIONS Lubricant Required For System Grease requirements will depend on ambient temperatures encountered during truck operation: • Above 32°C (90°F) NLGI multipurpose grease (MPG). • -32° to 32°C (-25° to 90°F) - Use NLGI No. 1 multipurpose grease (MPG).

  • Page 144: Lubricant Pump

    Automatic Lubrication System - Section 42 7/11 OM4213 Page 42-6 LUBRICANT PUMP Pump Housing Oil Level The pump housing must be filled to the proper level with SAE 10W-30 motor oil. Oil level should be checked at 1,000 hour intervals. To add oil, remove dipstick (4, Figure 42-5) on top of the pump housing and fill the housing to the proper level marked on the dipstick.

  • Page 145: Injectors (Sl-1 Series H)

    OM4213 7/11 Automatic Lubrication System - Section 42 Page 42-7 INJECTORS (SL-1 Series “H”) Injector Specifications • Each lube injector services only one grease point. In case of pump malfunction, each injector is equipped with a covered grease fitting to allow the use of external lubricating equipment.

  • Page 146: Injector Operation

    Automatic Lubrication System - Section 42 7/11 OM4213 Page 42-8 Injector Operation STAGE 1. The injector piston (2) is in its normal or “rest” position. The discharge chamber (3) is filled with lubricant from the previous cycle. Under the pressure of incoming lubricant (6), the slide valve (5) is about to open the passage (4) leading to the measuring chamber...

  • Page 147: Preventive Maintenance Procedures

    OM4213 7/11 Automatic Lubrication System - Section 42 Page 42-9 PREVENTIVE MAINTENANCE 4. Inspect all bearing points for a bead of lubricant PROCEDURES around the bearing seal. Use the following maintenance procedures to ensure It is good practice to manually lube each bear- proper system operation.

  • Page 148: System Checkout

    Automatic Lubrication System - Section 42 7/11 OM4213 Page 42-10 SYSTEM CHECKOUT The time between lube events is determined by the setting of the Off Time rotary switch (1, Figure 42-7). To check system operation (not including timer), Off time switch is used to select units of time. proceed as follows: Possible time intervals are: 0.5, 1, 2, 4, 8, 15, 24 or 1.
  • Page 149 OM4213 7/11 Automatic Lubrication System - Section 42 Page 42-11 FIGURE 42-7. LUBRICATION CYCLE TIMER 1. Off Time Switch 3. Cover 2. Mode Switch...

  • Page 150: System Troubleshooting Chart

    Automatic Lubrication System - Section 42 7/11 OM4213 Page 42-12 SYSTEM TROUBLESHOOTING CHART NOTE: If the following procedures do not correct the problem, contact a factory authorized service center. TROUBLE POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION Lube system not grounded. Correct grounding connections to pump assembly and truck chassis.
  • Page 151 OM4213 7/11 Automatic Lubrication System - Section 42 Page 42-13 TROUBLE POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION Pump Pressure Builds No signal at solenoid. Check timer. Very Slowly Or Not At All Turn on electric power to pump. “POWER” Controller Does Not LED should light, “PUMP ON”...
  • Page 152 Automatic Lubrication System - Section 42 7/11 OM4213 Page 42-14 NOTES...

  • Page 153: Components & Specifications

    MAJOR COMPONENT DESCRIPTIONS Truck And Engine Operator's Cab The 930E-4SE Dump Truck is an off-highway, rear The operator cab has been engineered for operator dump truck with AC Electric Drive. The gross vehicle comfort and to allow for efficient and safe operation of weight is 505 611 kg (1,114,670 lb).
  • Page 154 Components & Specifications - Section 5 7/11 OM5048 Page 50-2 930E-4SE MAJOR COMPONENTS...

  • Page 155: Specifications

    OM5048 7/11 Components & Specifications - Section 5 Page 50-3 SPECIFICATIONS These specifications are for the standard Komatsu 930E-4SE Dump Truck. Customer options may change this listing. ENGINE Komatsu SSDA18V170 No. of Cylinders ................18 Operating Cycle.

  • Page 156: Hydraulic Systems

    Components & Specifications - Section 5 7/11 OM5048 Page 50-4 HYDRAULIC SYSTEMS Hoist and Brake Cooling Pump ........... . . Tandem Gear Rating .

  • Page 157: Weight Distribution

    Nominal Payload* ..290 302 kg (640,000 lb) Standard Komatsu body ..30 362 kg (66,936 lb) Standard tire weight... 26 127 kg (57,600 lb) * Nominal payload is defined within Komatsu America Corporation’s payload policy documentation.
  • Page 158 Components & Specifications - Section 5 7/11 OM5048 Page 50-6 NOTES...
  • Page 159 OM6009 2/10 Payload Meter III - Section 60 Page 60-1 PAYLOAD METER III™ INDEX INTRODUCTION ............. . .60-3 Data Summary .
  • Page 160 Setting the Komatsu Distributor ........

  • Page 161: Payload Meter Iii

    OM6009 2/10 Payload Meter III - Section 60 Page 60-3 INTRODUCTION Data Gathering Windows 95/98/NT software available Payload Meter III (PLMIII) measures, displays and download, store and view payload and fault records the weight of material being carried by an off- information.
  • Page 162 Payload Meter III - Section 60 OM6009 2/10 Page 60-4 COMPONENT DESCRIPTION System Diagram Suspension Pressure Sensors Operator Display PLMIII uses a two-wire pressure sensor. The range The speedometer/display gauge is used as a speedometer and payload display. The top display is for the pressure sensor is 4000 psi (281 kg/cm ) and used for speed and can display metric (km/h) or...
  • Page 163 3-wire hardware connection. Connections to assume that the truck was loaded using a continuous this serial port need to be approved by Komatsu. loader and flag the haul cycle record. All other Several protocol options are available and detailed...
  • Page 164 Payload Meter III - Section 60 OM6009 2/10 Page 60-6 Key Switch Input Load Lights PLMIII monitors the status of the key switch. 24vdc PLMIII uses load lights to indicate to the shovel indicates that the key switch is on, open indicates the operator the approximate weight of the material in key switch is off.
  • Page 165 OM6009 2/10 Payload Meter III - Section 60 Page 60-7 Wiring and Termination Most of the PLMIII truck connections use a heavy- duty cable. This yellow multi-conductor cable uses a 16awg, finely stranded wire designed for continuous motion operations. The conductors are protected by a foil and braided shield for electronic noise immunity and physical strength.
  • Page 166 Payload Meter III - Section 60 OM6009 2/10 Page 60-8 OPERATOR’S DISPLAY AND SWITCH Using the Operator ID The current operator ID number is recorded with Reading the Speedometer each haul cycle. The number can be between 0 and The top window of the speedometer/display gauge is 9999.
  • Page 167 OM6009 2/10 Payload Meter III - Section 60 Page 60-9 Total Load Counter The total load counter records the number of loads The inclinometer displays whole degrees of incline. hauled since the last time it was cleared. This display Positive incline is truck nose up. The gauge will can be cleared at the beginning of each shift to allow quickly display the type of information shown every the operator to record how many loads have been...
  • Page 168 Payload Meter III - Section 60 OM6009 2/10 Page 60-10 PAYLOAD OPERATION & CALCULATION The payload meter switches from loading to maneuvering as soon as the truck begins moving. Haul Cycle States The maneuvering zone is 160m and is designed to allow the operator to reposition the truck under the The typical haul cycle can be broken down into eight shovel.
  • Page 169 OM6009 2/10 Payload Meter III - Section 60 Page 60-11 SOURCES FOR PAYLOAD ERROR Load Calculation The final load calculation is different from the last Payload Error swingload calculation. The accuracy of the swing The number one source of error in payload load calculation depends on loading conditions and calculation is improperly serviced suspensions.
  • Page 170 Payload Meter III - Section 60 OM6009 2/10 Page 60-12 HAUL CYCLE DATA Loading Conditions The final load calculation of the PLMIII system is not PLMIII records and stores data in its on-board flash sensitive to loading conditions. The final load is memory.
  • Page 171 OM6009 2/10 Payload Meter III - Section 60 Page 60-13 Haul Cycle Data The following information is recorded for each haul cycle: Table 1: HAUL CYCLE DATA Data Unit Remark Truck # alpha- Up to 22 characters can be stored in this field to identify the truck. Typically this field will be just numeric the truck number.
  • Page 172 Payload Meter III - Section 60 OM6009 2/10 Page 60-14 Haul Cycle Warning Flags F: Final Zone to Dumping Transition The payload meter expects haul cycles to progress in This message is generated when the payload meter a particular way. When something unexpected takes senses a body-up while it is calculating the final place, the system records a warning flag.
  • Page 173 OM6009 2/10 Payload Meter III - Section 60 Page 60-15 M: Haul Cycle Too Long Sprung Weight Data The haul_cycle_too_long flag indicates that the haul The payload meter is constantly monitoring the live cycle took longer than 18.2 hours to complete. The payload calculation.
  • Page 174 Payload Meter III - Section 60 OM6009 2/10 Page 60-16 Fault Code Data Table 2: Fault Code Name Description Left front pressure high Input current > 22 ma Left front pressure low Input current < 2 ma Right front pressure high Input current >...
  • Page 175 OM6009 2/10 Payload Meter III - Section 60 Page 60-17 PC SOFTWARE OVERVIEW Installing the PLMIII Software CD-ROM containing Payload Data PC Overview Management (PDM) software will automatically begin The PC software has several basic functions: installation when it is inserted into the drive on the PC.
  • Page 176 Payload Meter III - Section 60 OM6009 2/10 Page 60-18 DOWNLOADING DATA To download the payload meter: 1. Connect to the payload meter and start the PC PLMIII records many types of data. The PLMIII PC software. software is designed to download the data from a whole truck fleet.
  • Page 177 OM6009 2/10 Payload Meter III - Section 60 Page 60-19 PLM III SYSTEM CONFIGURATION Short Tons: Payload is displayed in short tons, distances and speeds will be displayed in Miles Starting Communications Metric Tons: Payload is displayed in metric tons, The PDM software allows users to download and distances and speeds are displayed in Kilometers configure the system.
  • Page 178 Payload Meter III - Section 60 OM6009 2/10 Page 60-20 There are also many configuration and download Setting the Date and Time options available from this screen. The Connection Menu is updated only when the connection is first made. It does not update automatically. To view changes made while connected, the user must close the window and reconnect to the payload meter.
  • Page 179 This field in the haul cycle record can hold the name changed from metric to short tons or long tons using of the Komatsu distributor that helped install the the Truck Configuration screen. This selection also system. Komatsu also assigns a distributor number...
  • Page 180 Payload Meter III - Section 60 OM6009 2/10 Page 60-22 Clean Truck Tare Inclinometer Calibration The inclinometer calibration procedure is designed to The payload meter uses the clean truck tare value to compensate for variations in the mounting attitude of calculate carry-back load for each haul cycle.
  • Page 181 The truck type is the size of the truck from the family to view and for what dates and times. of Komatsu trucks. This allows the user to quickly The query items are added in the "AND" condition. If view results from different types of trucks on the the user selects a truck # and date range, the query property.
  • Page 182 Payload Meter III - Section 60 OM6009 2/10 Page 60-24 Sorting on Date Range The default query starts in 1995 and runs through the current date on the PC. To narrow the range to a specific date, change the “From” and “To” dates. For example, to view the haul cycle reports from truck 374 for the month of July, 2000: 1.
  • Page 183 OM6009 2/10 Payload Meter III - Section 60 Page 60-25 The shift times selected can extend the query past Payload Detail Screen the original date. If the dates set for the query are The Payload Detail screen gives the details for any January 5 to January 8 and the times were changed individual haul cycle.
  • Page 184 Payload Meter III - Section 60 OM6009 2/10 Page 60-26 NOTE: Some haul cycles may contain the Sensor Input warning flag. This indicates that one of the four pressure sensors or inclinometer was not functioning properly during the haul cycle. Haul cycles with this warning are displayed in red on the Payload Summary window and are not included in the summary statistics for reports or display.
  • Page 185 OM6009 2/10 Payload Meter III - Section 60 Page 60-27 Creating Graphs Exporting Data The PLMIII software can generate graphs that quickly summarize payload data. These graphs can be customized for printing. Just like the reports, the graphs are generated from the query displayed on the “Payload Summary”...
  • Page 186 Payload Meter III - Section 60 OM6009 2/10 Page 60-28 • Reserved 1-5, 7-10: These values are internal calculations used in the continued development of PLMIII and should be ignored. • Reserved 6: This value is the payload estimate at the shovel just before the truck begins to move.
  • Page 187 OM6009 2/10 Payload Meter III - Section 60 Page 60-29 To export data in ZIP format: Deleting Haul Cycle Records 1. Confirm that the data displayed is the query To delete haul cycle records from the main database, data that needs to be exported. press the "Delete"...
  • Page 188 Payload Meter III - Section 60 OM6009 2/10 Page 60-30 Viewing Alarms From the Payload Summary screen, click the “Alarms” button to display the alarm screen. The alarms are sorted by the query settings from the Deleting Alarm Records Payload Summary screen. Alarms can be displayed To delete alarm records from the main database, as Active or Inactive.

  • Page 189: Am/Fm Radio / Cd Player

    OM7006 03/10 Radio / CD Player - Section 70 Page 70-1 AM/FM RADIO / CD PLAYER FIGURE 70-1. AM/FM RADIO / CD PLAYER 1. Ejects CD 7. Push Buttons 1-6 Pre-set stations/CD/MP3 func- tions 2. BAND Switches between AM, FM1, FM2, FM3, WX (Weatherband) and Auxiliary Mode 8.

  • Page 190: Display

    Radio / CD Player - Section 70 03/10 OM7006 Page 70-2 Display Auxiliary Mode The receiver will display the time of day when it is off. When in Auxiliary mode, the radio can play an audio Momentarily pressing the TMSET/DSPL (3) button source from an iPOD or an MP3 player that is con- when the receiver is on allows to toggle between dis- nected via the auxiliary radio lines.

  • Page 191: Using The Clock

    OM7006 03/10 Radio / CD Player - Section 70 Page 70-3 USING THE ALARM SEEK SENSITIVITY: To adjust seek sensitivity, press the AUDIO knob until SEEK and the sensitivity Momentarily pressing the ALARM (10) button will dis- level appear. Rotate the AUDIO knob to the desired play the alarm set time.

  • Page 192: Using The Radio

    Radio / CD Player - Section 70 03/10 OM7006 Page 70-4 After 5 seconds of inactivity, the receiver will return to the default display and the volume level at which the SCAN: Press SCAN/DIM (9) to scan all stations on receiver was previously playing.

  • Page 193: Using The Weatherband

    OM7006 03/10 Radio / CD Player - Section 70 Page 70-5 USING THE WEATHERBAND USING THE COMPACT DISC PLAYER NOAA Weather Radio is a service of the National The integral CD player plays full size CDs and MP3 Weather Service. It provides continuous broadcasts discs.

  • Page 194: Playing An Mp3 Disc

    Radio / CD Player - Section 70 03/10 OM7006 Page 70-6 5/FF: Press and hold FF to fast-forward. Upon Root Directory release, the CD will play at normal speed. The dis- The root directory is treated as a folder. If the root play will show the track number and elapsed time.
  • Page 195 OM7006 03/10 Radio / CD Player - Section 70 Page 70-7 Pre-Programmed Playlists Button Functions Pre-programmed play list function like folders con- 1/FLD (NEXT FOLDER): Press this button to go to taining compressed audio song files. This radio plays the first track in the next folder or playlist. Pressing pls, m3u, and rmp playlist formats.

  • Page 196: Troubleshooting

    Radio / CD Player - Section 70 03/10 OM7006 Page 70-8 TROUBLESHOOTING DSPL/TM SET: Pressing this button toggles between the ID3 tag (song title, artist and album title) and time The following error messages may appear while of day. There are 3 display types that can be set as playing a CD or MP3 disc: default: track, folder/playlist, and time of day.
  • Page 198 ® www.komatsuamerica.com Copyright 2011 Komatsu Printed in U.S.A. Komatsu America Corp.

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