Unsafe use of this machine may cause serious injury or death. Operators and maintenance per- sonnel must read and understand this manual before operating or maintaining this machine. This manual should be kept in or near the machine for reference, and periodically reviewed by all personnel who will come into contact with it. This material is proprietary to Komatsu America Corp (KAC), and is not to be reproduced, used, or dis- closed except in accordance with written authorization from KAC. It is the policy of the Company to improve products whenever it is possible and practical to do so. The Company reserves the right to make changes or add improvements at any time without incurring any obli- gation to install such changes on products sold previously. Because of continuous research and development, periodic revisions may be made to this publication. Customers should contact their local Komatsu distributor for information on the latest revision. CALIFORNIA Proposition 65 Warning Diesel engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. CALIFORNIA Proposition 65 Warning Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.
NON-OEM PARTS IN CRITICAL SYSTEMS For safety reasons, Komatsu America Corp. strongly recommends against the use of non-OEM replacement parts in critical systems of all Komatsu equipment. Critical systems include but are not limited to steering, braking and operator safety sys- tems. Replacement parts manufactured and supplied by unauthorized sources may not be designed, manufactured or assembled to Komatsu's design specifications; accord- ingly, use of such parts may compromise the safe operation of Komatsu products and place the operator and others in danger should the part fail. 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. Use of non-OEM parts places full responsibility for the safe performance of the Komatsu product on the supplier and user. Komatsu will not in any case accept responsibility for the failure or performance of non-OEM parts in its products, including any damages or personal injury resulting from such use.
EMISSION CONTROL WARRANTY
EMISSION CONTROL WARRANTY STATEMENT (APPLIES TO CANADA ONLY)
1. Products Warranted
Komatsu America International Company, Komatsu Mining Systems Inc. and Komatsu Utility Corporation (collectively “Komatsu”) produce and/or market products under brand names of Komatsu, Dresser, Dressta, Haulpak and Galion. This emissions warranty applies to new engines bearing the Komatsu name installed in these products and used in Canada in machines designed for industrial off-highway use. This warranty applies only to these engines produced on or after January 1, 2000. This warranty will be administered by Komatsu distribution in Canada.
Komatsu warrants to the ultimate purchaser and each subsequent purchaser that the engine is designed, built and equipped so as to conform, at the time of sale by Komatsu, with all U.S. Federal emission regulations applicable at the time of manufacture and that it is free from defects in workmanship or material which would cause it not to meet these regulations within five years or 3,000 hours of operation, whichever occurs first, as measured from the date of delivery of the engine to the ultimate purchaser.
Failures, other than those resulting from defects in materials or workmanship, are not covered by this warranty. Komatsu is not responsible for failures or damage resulting from what Komatsu determines to be abuse or neglect, including, but not limited to: operation without adequate coolant or lubricants; over fueling; over speeding; lack of maintenance of lubricating, cooling or intake systems; improper storage, starting, warm-up, run-in or shutdown practices; unauthorized modifications of the engine. Komatsu is also not responsible for failures caused by incorrect fuel or by water, dirt or other contaminants in the fuel. Komatsu is not responsible for non-engine repairs, “downtime” expense, related damage, fines, all business costs or other losses resulting from a warrantable failure.
KOMATSU IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
This warranty, together with the express commercial warranties, are the sole warranties of Komatsu. THERE ARE NO OTHER WARRANTIES, EXPRESS OR IMPLIED, OR OF MERCHANTABILITY OR FITNESS FOR A PARTICUALR PURPOSE.
GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS
ÉNONCÉ DE GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS (APPLICABLE AU CANADA SEULEMENT):
1. Produits garantis: Komatsu America International Company, Komatsu Mining Systems Inc. et Komatsu Utility Corporation (collectivement Komatsu) produisent et/ou font la mise en marché de produits portant les noms de marque Komatsu, Dresser, Dressta, Haulpak et Galion. Cette garantie sur les émissions s’applique à tous les nouveaux moteurs portant le nom Komatsu, installés dans ces produits et utilisés au Canada dans des machines conçues pour utilisation industrielle non- routière. Cette garantie s’applique seulement sur les moteurs produits à partir du 1er Janvier 2000. Cette garantie sera administrée par la distribution de Komatsu au Canada .
2. Couverture: Komatsu garantit à l’acheteur ultime et chaque acheteur subséquent que le moteur est conçu, construit et équipé en toute conformité, au moment de la vente par Komatsu, avec toutes les Réglementations fédérales américaines sur les émissions applicables au moment de la fabrication et qu’il est exempt de défauts de construction ou de matériaux qui auraient pour effet de contrevenir à ces réglementations en dedans de 5 ans ou 3000 heures d’opération, mesuré à partir de la date de livraison du moteur au client ultime.
3. Limitations: Les bris, autres que ceux résultant de défauts de matériaux ou de construction, ne sont pas couverts par cette Garantie. Komatsu n’est pas responsable pour bris ou dommages résultant de ce que Komatsu détermine comme étant de l’abus ou négligence, incluant mais ne se limitant pas à: l’opération sans lubrifiants ou agent refroidissants adéquats; la suralimentation d’essence; la survitesse; le manque d’entretien des systèmes de lubrification, de refroidissement ou d’entrée; de pratiques non-propices d’entreposage, de mise en marche, de réchauffement, de conditionnement ou d’arrêt; les modifications non-autorisées du moteur. De plus, Komatsu n’est pas responsable de bris causés par de l’essence inadéquate ou de l’eau, des saletés ou autres contaminants dans l’essence. Komatsu n’est pas responsable des réparations non-reliées au moteur, des dépenses encourues suite aux temps d’arrêts, des dommages relatifs, amendes, et de tout autre coût d’affaires ou autres pertes résultant d’un bris couvert par la garantie.
KOMATSU N’EST PAS RESPONSABLE DES INCIDENTS OU DOMMAGES CONSÉQUENTS.
Cette garantie, ainsi que les garanties expresses commerciales, sont les seules garanties de Komatsu. IL N’Y A AUCUNE AUTRE GARANTIE, EXPRESSE OU SOUS -ENTENDUE, MARCHANDABLE OU PROPICE A UNE UTILISATION PARTICULIÈRE.
CEHQ000700 - Komatsu America International Company 12/99
INFORMATION IMPORTANTE SUR LE MOTEUR AVERTISSEMENT CE MOTEUR EST CONFORME AUX NORMES AMÉRICAINES DE L’EPA (ANNÉE DU DES BLESSURES PEUVENT RÉSULTER ET LA GARANTIE MODÈLE) ET DE LA CALIFORNIE POUR LES MOTEURS LARGES NON-ROUTIERS A IGNI- S’ANNULER SI LES RPM DU TAUX D’ESSENCE OU L’ALTITUDE TION PAR COMPRESSION. CE MOTEUR EST CERTIFIÉ POUR OPERATION À ESSENCE EXCÈDENT LES VALEURS MAXIMALES PUBLIÉES POUR CE DIÉSEL. MODÈLE ET SON APPLICATION. IMPORTANT ENGINE INFORMATION THIS ENGINE CONFORMS TO YYYY MODEL YEAR U.S. EPA REGULATION AND THE CALIFORNIA REGULATIONS LARGE NON ROAD COMPRESSION IGNITION ENGINES. THIS ENGINE IS CERTI- FIED TO OPERATE ON DIESEL FUEL. MODÈLE DU MOTEUR WARNING NO. SÉRIE INJURY MAY RESULT AND WARRANTY IS VOIDED IF FUEL RATE RPM OR ALTITUDES EXCEED PUBLISHED MAXIMUM VALUES FOR THIS MODEL AND APPLICATION. FAMILLE DU MOTEUR ENGINE MODEL SERIAL NO. DÉPLACEMENT SYSTÈME DE ENGINE FAMILY DISPLACEMENT LITERS CONTROLE DES ÉMISSIONS D’ÉCHAPPEMENT EXHAUST EMISSION FIRING ORDER 1 - 5 - 3 - 6 - 2 - 4 LITRES CONTROL SYSTEM ADV. LOAD OUTPUT Kw ( HP) RPM CHARGE DE SORTIE ADV.
SÉQUENCE DE MISE À FEU VALVE LASH IN. EX. FUEL RATE mm3/STROKE mm3/BATTEMENT PORTÉE DE VALVE À FROID COLD (mm) AT ADV. (mm) TAUX D’ESSENCE À ADV. VITESSE STATIQUE IDLE SPEED RPM FAMILY EMISSION LIMIT INITIAL INJECTION DEG. BTDC DATE OF MANUFACTURE LIMITE D’ÉMISSION DE TIMING LA FAMILLE RÉGLAGE DE L’ALLUMAGE - _____________________________________________ KOMATSU LTD. INJECTION INITIALE MADE IN JAPAN DATE DE FABRICATION DEG. BTDC KOMATSU LTÉE FABRIQUÉ AU JAPON ENGINE DATAPLATE - ENGLISH / FRENCH
OM1053 4/08 Introduction - Section 10 Page 10-1 FOREWORD This manual is written for use by the operator and/or the service technician and 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 cau- tions are to be understood and followed when operating or accomplishing repairs on the truck. The first section is an introduction to the manual and contains a table of contents to locate specific areas of inter- est. Other sections include Safety, Operation, Maintenance, Specifications, and Optional Equipment. The illustrations used in this manual are TYPICAL of the component shown and may not be an exact reproduction of what is found on 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. 830E). The three numbers represent the basic truck model. The letter “M”, when present, designates a Mechanical drive system; 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 manu- facturing bill of material for this unit. This complete number wil 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 GVW. GVW is TOTAL WEIGHT: the Empty Vehicle Weight + the fuel & lubricants + the payload. To determine allowable payload: Service all lubricants for proper level and fill fuel tank of empty truck (which includes all accessories, body liners, tailgates, etc.) and then weigh truck. Record this value and subtract from the GVW rating. The result is the allowable payload. NOTE: Accumulations of mud, frozen material, etc. become a part of the GVW and reduces allowable payload. To maximize payload and to keep from exceeding the GVW rating, these accumulations should be removed as often as practical. Exceeding the allowable payload will reduce expected life of truck components.
Introduction - Section 10 4/08 OM1053 Page 10-2 ALERTS PAGE This “ALERT” symbol is used with the signal words, “CAUTION”, “DANGER”, and “WARNING” in this manual to alert the reader to hazards arising from improper oper- ating and maintenance practices. “DANGER” identifies a specific potential hazard WHICH WILL RESULT in either INJURY OR DEATH if proper precautions are not taken. “WARNING” identifies a specific potential hazard WHICH COULD RESULT in either INJURY OR DEATH if proper precautions are not taken. “CAUTION” is used for general reminders of proper safety practices OR to direct the reader’s attention to avoid unsafe or improper practices which may result in damage to the equipment.
Introduction - Section 10 4/08 OM1053 Page 10-10 TRUCK MODEL ILLUSTRATION KOMATSU MODEL 830E-AC DUMP TRUCK
OM1053 4/08 Introduction - Section 10 Page 10-11 ABOUT THIS MANUAL This manual is written for use by the operator and/or the service technician. It is designed to help these persons learn how to operate the truck and 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 per- forming maintenance and/or operational checks on the truck. All safety notices, warnings, and cautions should be understood and followed when operating or performing repairs on the truck. 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 Peoria, IL 61650-0240 United States of America Fax (309) 672-7072 This first section is an introduction to the manual and contains the table of contents to locate specific areas of inter- est. Other sections include Safety, Operating Instructions, Lubrication and Service, etc. When searching for a specific area of interest, go first to the table of contents to locate the section in which the sub- ject might generally be included. Then, go to that section of the table of contents to find a subject description that most closely describes the specific area of interest to find a page number and go to that page. Section numbers and page numbers are located at the top, outside corner of the page. At the top, inside corner of the page is a document (module) number. If there is ever a question regarding the infor- mation in a particular section, refer to the document (module) number, the manual form number, and use the address shown above to correspond. If there is a date (month/year) behind the document (module) number, that indicates the latest revision date of that page. The illustrations used in this manual are TYPICAL of the component shown and may not be an exact reproduction of what is found on the truck. This manual shows dimensioning of U.S. standard and metric (SI) units throughout. All references to “right”, “left”, “front”, or “rear” are made with respect to the operator's normal seated position, unless specifically stated other- wise. When assembly instructions are provided without references to torque values, standard torque values should be assumed. Standard torque requirements are shown in torque charts on the following pages of this section, and in the General Information section of the truck service manual. Individual torques when provided in the text are in bold face type, such as 135 N.m (100 ft lbs). All torque specifications have ±10% tolerance unless otherwise specified.
OM1200 3/05 Standard Charts and Tables - Section 12 Page 12-1 STANDARD CHARTS AND TABLES This manual provides dual dimensioning for most EFFECT OF SPECIAL LUBRICANTS specifications. U.S. standard units are specified first, On Fasteners and Standard Torque Values with metric (SI) units in parentheses. The Komatsu engineering department does not References throughout the manual to standard torques recommend the use of special friction-reducing or other standard values will be to one of the following lubricants, such as Copper Coat, Never-Seez®, and charts or tables. For values not shown in these charts other similar products, on the threads of standard or tables, standard conversion factors for most fasteners where standard torque values are applied. commonly used measurements are provided in TABLE The use of special friction-reducing lubricants will XIII, page 12-6. significantly alter the clamping force being applied to Standard torque values are not to be used when “turn- fasteners during the tightening process. of-the-nut” tightening procedures are recommended. If special friction-reducing lubricants are used with the standard torque values listed below in Table I (and in INDEX OF TABLES Komatsu shop manuals), excessive stress and TABLE I . . . . . . .Standard Torque Chart (SAE) . . 12-1 possible breakage of the fasteners may result. TABLE II .Standard Torque, 12-Point, Grade 9 . . 12-2 TABLE III . . Standard Metric Assembly Torque . . 12-2 Where the torque tables specify “Lubricated Threads” TABLE IV. . . . . .JIC Swivel Nuts Torque Chart . . 12-3 for the standard torque values listed, these standard TABLE V . . . . . . . . Pipe Thread Torque Chart . . 12-3 torque values are to be used with simple lithium base TABLE VI. . . . . . . . O-Ring Boss Torque Chart . . 12-3 chassis grease (multi-purpose EP NLGI) or a rust- TABLEVII. . . . O-Ring Face Seal Torque Chart . . 12-3 preventive grease (see list, page 12-2) on the threads TABLE VIII.Torque Conversions (ft lbs to N•m) . . 12-4 and seats unless specified otherwise. TABLE IX. Torque Conversions (ft lbs to kg•m) . . 12-4 NOTE: Ensure the threads of fasteners and tapped TABLE X . . Pressure Conversions (psi to kPa) . . 12-4 holes are free of burrs and other imperfections before TABLE XI. Pressure Conversions (psi to MPa) . . 12-5 assembling. TABLE XII . . . . . . . Temperature Conversions . . 12-5 TABLE XIII. . . Common Conversion Multipliers . . 12-6 TABLE I. STANDARD TORQUE CHART SAE HEX HEAD CAP SCREW AND NUT ASSEMBLY Grade 5 (LUBRICATED THREADS) Grade 8 TOLERANCES ±10% Capscrew TORQUE - TORQUE - Capscrew TORQUE - TORQUE - Thread GRADE 5 GRADE 8 Thread GRADE 5 GRADE 8 Size Size ft lbs kg•m N•m ft lbs kg•m N•m ft lbs kg•m N•m ft lbs kg•m N•m 1/4-20 7 0.97 9.5 10 1.38 13.6 3/4-16 235 32.5 319 335 46.3 454 1/4-28 8 1.11 10.8 11 1.52 14.9 7/8-9 350 48.4 475 500 69.2 678 5/16-18 15 2.07 20.3 21 2.90 28 7/8-14 375 51.9 508 530 73.3 719 5/16-24 16 2.21 22 22 3.04 30 1.0-8 525 72.6 712 750 103.7 1017 3/8-16 25 3.46 34 35 4.84 47 1.0-12 560 77.4 759 790 109.3 1071 3/8-24 30 4.15 41 40 5.5 54 1.0-14 570 78.8 773 800 110.6 1085 7/16-14 40 5.5 54 58 8.0 79 1 1/8-7 650 89.9 881 1050 145 1424 7/16-20 45 6.2 61 62 8.57 84 1 1/8-12 700 96.8 949 1140 158 1546 1/2-13 65 9 88 90 12.4 122 1 1/4-7 910 125.9 1234 1480 205 2007 1/2-20 70 9.7 95 95 13.1 129 1 1/4-12 975 134.8 1322 1580 219 2142 9/16-12 90 12.4 122 125 17.3 169 1 3/8-6 1200 166 1627 1940 268 2630 9/16-18 95 13.1 129 135 18.7 183 1 3/8-12 1310 181 1776 2120 293 2874 5/8-11 125 17.3 169 175 24.2 237 1 1/2-6 1580 219 2142 2560 354 3471 5/8-18 135 18.7 183 190 26.2 258 1 1/2-12 1700 235 2305 2770 383 3756 3/4-10 220 30.4 298 310 42.8 420 1 ft. lbs. = 0.138 kg•m = 1.356 N•m
Standard Charts and Tables - Section 12 OM1200 3/05 Page 12-2 STANDARD ASSEMBLY TORQUES STANDARD ASSEMBLY TORQUES For 12-Point, Grade 9 Cap screws (SAE) For Class 10.9 Cap screws & Class 10 Nuts The following specifications apply to required assembly The following specifications apply to required assembly torques for all 12-point, grade 9 (170,000 psi minimum torques for all metric Class 10.9 finished hexagon head tensile) cap screws. cap screws and Class 10 nuts. • Cap screw threads and seats shall be lubricated
• Cap screw threads and seats shall not be when assembled. lubricated when assembled. These specifications are based on all cap screws, nuts, and hardened NOTE: Unless the instructions specifically recommend washers being phosphate and oil coated. otherwise, these standard torque values are to be used with simple lithium base chassis grease (multi-purpose NOTE: If zinc-plated hardware is used, each piece EP NLGI) or a rust preventive grease (see list, this must be lubricated with simple lithium base chassis page) on the threads. grease (multi-purpose EP NLGI) or a rust preventive grease (see list, this page) to achieve the same • Torques are calculated to give a clamping force of clamping forces provided below. approximately 75% of proof load. • Torques are calculated to give a clamping force of • The maximum torque tolerance shall be ±10% of approximately 75% of proof load. the torque value shown. • The maximum torque tolerance shall be within ±10% of the torque value shown. TABLE II. STANDARD ASSEMBLY TORQUE for 12-Point, Grade 9 Cap screws TABLE III. STANDARD ASSEMBLY TORQUE CAPSCREW TORQUE TORQUE TORQUE for Metric Class 10.9 Cap screws & Class 10 Nuts SIZE* ft lbs N•m kg•m CAPSCREW TORQUE TORQUE TORQUE 0.250 - 20 12 16 1.7 SIZE* N•m ft lbs kg•m 0.312 - 18 24 33 3.3 M6 x1 12 9 1.22 0.375 - 16 42 57 5.8 M8 x 1.25 30 22 3.06 0.438 -14 70 95 9.7 M10 x 1.5 55 40 5.61 0.500 -13 105 142 14.5 M12 x 1.75 95 70 9.69 0.562 - 12 150 203 20.7 M14 x 2 155 114 15.81 0.625 - 11 205 278 28.3 M16 x 2 240 177 24.48 0.750 - 10 360 488 49.7 M20 x 2.25 465 343 47.43 0.875 - 9 575 780 79.4 M24 x 3 800 590 81.6 1.000 - 8 860 1166 119 M30 x 3.5 1600 1180 163.2 1.000 - 12 915 1240 126 M36 x 4 2750 2028 280.5 1.125 - 7 1230 1670 170 * Shank Diameter (mm) - Threads per millimeter 1.125 - 12 1330 1800 184 This table represents standard values only. Do not use these 1.250 - 7 1715 2325 237 values to replace torque values which are specified in assembly 1.250 - 12 1840 2495 254 instructions. 1.375 - 6 2270 3080 313 Suggested* Sources for Rust Preventive Grease: 1.375 - 12 2475 3355 342 1.500 - 6 2980 4040 411
• AMERICAN ANTI-RUST GREASE #3-X from 1.500 - 12 3225 4375 445 Standard Oil Company (also American Oil Co.) * Shank Diameter (in.) - Threads per inch • GULF NORUST #3 from Gulf Oil Company. This table represents standard values only. Do not use these values to replace torque values which are specified in assembly • MOBILARMA 355, Product No. 66705 from Mobil instructions. Oil Corporation. • RUST BAN 326 from Humble Oil Company. • RUSTOLENE B GREASE from Sinclair Oil Co. • RUST PREVENTIVE GREASE - CODE 312 from the Southwest Grease and Oil Company. NOTE: This list represents the current engineering approved sources for use in Komatsu manufacture. It is not exclusive. Other products may meet the same specifications of this list.
OM1200 3/05 Standard Charts and Tables - Section 12 Page 12-5 TABLE XI. PRESSURE CONVERSIONS Pounds per square inch (psi) to Megapascals (MPa) Formula: psi x 0.0069 = MPa psi 0 10 20 30 40 50 60 70 80 90 0 (MPa) 0.069 0.14 0.21 0.28 0.34 0.41 0.48 0.55 0.62 100 0.69 0.76 0.83 0.90 0.97 1.03 1.10 1.17 1.24 1.31 200 1.38 1.45 1.52 1.59 1.65 1.72 1.79 1.86 1.93 2.00 300 2.07 2.14 2.21 2.28 2.34 2.41 2.48 2.55 2.62 2.69 400 2.76 2.83 2.90 2.96 3.03 3.10 3.17 3.24 3.31 3.38 500 3.45 3.52 3.59 3.65 3.72 3.79 3.86 3.93 4.00 4.07 600 4.14 4.21 4.27 4.34 4.41 4.48 4.55 4.62 4.69 4.76 700 4.83 4.90 4.96 5.03 5.10 5.17 5.24 5.31 5.38 5.45 800 5.52 5.58 5.65 5.72 5.79 5.86 5.93 6.00 6.07 6.14 900 6.21 6.27 6.34 6.41 6.48 6.55 6.62 6.69 6.76 6.83 See NOTE below regarding Table usage. NOTE: Tables such as Table VIII, IX, X, and XI may be used as in the following example: Example: Convert 975 psi to kilopascals (kPa). 3. Multiply by 10: 1. Select Table X. 970 psi = 6688 kPa. 2. Go to psi row 90, column 7; read 668.8 4. Go to psi row 0, column 5; read 34.475 97 psi = 668.8 kPa. psi = 34.47 kPa. Add to step 3. 5. 970 + 5 psi = 6688 + 34 = 6722 kPa. TABLE XII. TEMPERATURE CONVERSIONS Formula: F° - 32 ³ 1.8 = C° or C° x 1.8 + 32 = F° CELSIUS FAHRENHEIT CELSIUS FAHRENHEIT CELSIUS FAHRENHEIT C° F° C° F° C° F° 121 250 482 63 145 293 4 40 104 118 245 473 60 140 284 2 35 95 116 240 464 57 135 275 – 1 30 86 113 235 455 54 130 266 – 4 25 77 110 230 446 52 125 257 – 7 20 68 107 225 437 49 120 248 – 9 15 59 104 220 428 46 115 239 – 12 10 50 102 215 419 43 110 230 – 15 5 41 99 210 410 41 105 221 – 18 0 32 96 205 401 38 100 212 – 21 – 5 23 93 200 392 35 95 293 – 23 – 10 14 91 195 383 32 90 194 – 26 – 15 5 88 190 374 29 85 185 – 29 – 20 – 4 85 185 365 27 80 176 – 32 – 25 – 13 82 180 356 24 75 167 – 34 – 30 – 22 79 175 347 21 70 158 – 37 – 35 – 31 77 170 338 18 65 149 – 40 – 40 – 40 74 165 329 15 60 140 – 43 – 45 – 49 71 160 320 13 55 131 – 46 – 50 – 58 68 155 311 10 50 122 – 48 – 55 – 67 66 150 302 7 45 113 – 51 – 60 – 76 Note: The numbers in the unmarked columns refer to temperature in either degrees Celsius (C°) or Fahrenheit (F°). Select a number in this unmarked column and read to the left to convert to degrees Celsius (C°) or read to the right to convert to degrees Fahrenheit (F°). If starting with a known temperature (either C° or F°), find that temperature in the marked column and read the converted temperature in the center, unmarked column.
Standard Charts and Tables - Section 12 OM1200 3/05 Page 12-6 Table XIII. TABLE XIII COMMON CONVERSION MULTIPLIERS COMMON CONVERSION MULTIPLIERS COMMON CONVERSION MULTIPLIERS ENGLISH TO METRIC METRIC TO ENGLISH To Convert Multiply Multiply From TO By To Convert From TO By inch – in. millimeter (mm) 25.40 millimeter (mm) inch – in. 0.0394 inch – in. centimeter (cm) 2.54 centimeter (cm) inch – in. 0.3937 foot – ft. meter (m) 0.3048 meter (m) foot – ft. 3.2808 yard – yd. meter (m) 0.914 meter (m) yard – yd. 1.0936 mile – mi. kilometer (km) 1.61 kilometer (km) mile – mi. 0.6210 sq. in. – in.2 sq. centimeters (cm2) 6.45 sq. centimeters (cm2) sq. in. – in.2 0.1550 sq. ft. – ft.2 sq. centimeters (cm2) 929 sq. centimeters (cm2) sq. ft. – ft.2 0.001 cu. in. – in.3 cu. centimeters (cm3) 16.39 cu. centimeters (cm3) cu in – in.3 0.061 cu. in. – in.3 liters (l) 0.016 liters (l) cu in – in.3 61.02 cu. ft. – ft.3 cu. meters (m3) 0.028 cu. meters (m3) cu ft – ft.3 35.314 cu. ft. – ft.3 liters (l) 28.3 liters (l) cu ft – ft.3 0.0353 ounce – oz. kilogram (kg) 0.028 grams (g) ounce – oz. 0.0353 fluid ounce – fl. oz. milliliter (ml) 29.573 milliliter (ml) fluid ounce – fl. oz. 0.0338 pound (mass) kilogram (kg) 0.454 kilogram (kg) pound (mass) 2.2046 pound (force) – lbs. Newton (N) 4.448 Newton (N) pound (force) – lbs. 0.2248 in. lbs. (force) Newton-meters (N•m) 0.113 Newton-meters (N•m) kilogram-meters (kg•m) 0.102 ft. lbs. (force) Newton-meters (N•m) 1.356 Newton-meters (N.m) ft lbs 0.7376 ft. lbs. (force) kilogram-meters (kg•m) 0.138 kilogram-meters (kg•m) ft lbs 7.2329 psi (pressure) kilopascals (kPa) 6.895 kilogram-meters (kg•m) Newton-meters (N•m) 9.807 psi (pressure) megapascals (MPa) 0.007 kilopascals (kPa) psi 0.1450 psi (pressure) kilograms/cm2 (kg/cm2) 0.0704 megapascals (MPa) psi 145.038 ton (short) kilogram (kg) 907.2 kilograms/cm2 (kg/cm2) psi 14.2231 ton (short) metric ton 0.0907 kilograms/cm2 (kg/cm2) kilopascals (kPa) 98.068 quart – qt. liters (l) 0.946 kilogram (kg) ton 0.0011 gallon – gal. liters (l) 3.785 metric ton ton 1.1023 HP (horsepower) Watts 745.7 liters (l) quart – qt. 1.0567 HP (horsepower) kilowatts (kw) 0.745 liters (l) gallon – gal. 0.2642 Watts Horsepower HP 0.00134 kilowatts (kw) Horsepower HP 1.3410
OM2038 8/07 Safety - Section 20 Page 20-1 GENERAL SAFETY Safety records of most organizations will show that Clothing And Personal Items the greatest percentage of accidents are caused by • Avoid wearing loose unsafe acts of persons. The remainder are caused clothing, jewelry, by unsafe mechanical or physical conditions. Report and loose long hair. all unsafe conditions to the proper authority. They can catch on The following safety rules are provided as a guide for controls or in moving the operator. However, local conditions and regula- parts and cause serious injury or tions may add many more to this list. death. Additionally, never wear oily clothes as they are flammable. • Wear a hard hat, safety glasses, safety shoes, a Read and follow all safety precautions. Failure to mask and gloves when operating or maintaining do so may result in serious injury or death. a machine. Always wear safety goggles, a hard hat and heavy gloves if your job involves Safety Rules scattering metal chips or minute materials. This • Only trained and authorized personnel can is particularly important when driving pins with a operate and maintain the machine. hammer or when cleaning air cleaner elements with compressed air. Also, ensure that the work • Follow all safety rules, precautions and area is free of other personnel during such tasks. instructions when operating or performing maintenance on the machine. Unauthorized Modification • When working with another operator or a person • Any modification made to this vehicle without on work site traffic duty, ensure all personnel authorization from Komatsu America Corp. can understand all hand signals that are to be used. possibly create hazards. Truck Safety Features • Before making any modification, consult your authorized regional Komatsu America Corp. • Ensure all guards and covers are in their proper distributor. Komatsu will not be responsible for position. Repair any damaged guards and any injury or damage caused by any covers. (See Walk-Around Inspection, later in unauthorized modification. this section.) Leaving The Operator’s Seat • Learn the proper use of safety features such as safety locks, safety pins, and seat belts. Always While leaving the operator's seat, DO NOT touch any use these safety features, properly. controls. To prevent accidental operations from • Never remove any safety features. Always keep occurring, always perform the following: safety features in good operating condition. • Move the directional control lever to the PARK • Improper use of safety features may result in position (this will apply the parking brake). Do not serious bodily injury or death. apply the wheel brake lock. • Lower the dump body, and move the hoist control lever to the FLOAT position. • Turn the key switch to the OFF position to stop the engine. • Stop the engine. When exiting the machine, always lock compartments, and take the keys with you to prevent entry from unauthorized persons. • Wait 90 seconds before exiting the cab. If any warning lights are illuminated or warning horns are sounding, do not leave the cab and notify maintenance personnel immediately. When exiting the machine, always lock compartments, and take the keys with you to prevent entry from unauthorized persons.
Safety - Section 20 8/07 OM2038 Page 20-2 Mounting And Dismounting Precautions For High Temperature Fluids • Never jump on or off the machine. Never climb • Immediately after machine on or off a machine while it is moving. operation, engine coolant, engine oil, and hydraulic oil are • When climbing on or off a machine, face the at high temperatures and are machine and use the hand-hold and steps. pressurized. If the cap is • Never hold any control levers when getting on or removed, the fluids drained, the off a machine. filters are replaced, etc., there is danger of serious burns. Allow heat and • Always maintain three-point contact with the pressure to dissipate before performing such hand-holds and steps to ensure that you support tasks and follow proper procedures as outlined in yourself. the service manual. • When bringing tools up to the operating deck, • To prevent hot coolant from spraying: always pass them by hand or pull them up by rope. 1. Stop the engine, and wait for the coolant tem- perature to decrease. • If there is any oil, grease, or mud on the hand- holds or steps, wipe them clean immediately. 2. Depress the pressure relief button on the radia- Always keep these components clean. Repair tor cap. any damage and tighten any loose bolts. 3. Turn the radiator cap slowly to allow pressure to dissipate. • Use the handrails and steps marked by arrows in • To prevent hot engine oil spray: the diagram below when getting on or off the 1. Stop the engine. machine. 2. Wait for the oil temperature to cool down. 3. Turn the cap slowly to allow pressure to dissi- pate. Asbestos Dust Hazard Prevention Asbestos dust is hazardous to your health when inhaled. If you handle materials containing asbestos fibers, follow the guidelines below: • Never use compressed air for cleaning. Fire Extinguishers And First Aid Kits • Use water for cleaning and to control dust. • Ensure fire extinguishers are accessible and • Operate the machine or perform tasks with the proper usage techniques wind to your back, whenever possible. are known. • Use an approved respirator, when necessary. • Provide a first aid kit at the storage point. • Know what to do in the event of a fire. • Keep the phone numbers of persons you should contact in case of an emergency on hand.
OM2038 8/07 Safety - Section 20 Page 20-3 Fire Prevention For Fuel And Oil • When modifying or repairing the ROPS, always consult your nearest Komatsu distributor. • Fuel, oil, and antifreeze can be ignited by a flame. These fluids are extremely flammable and • Even with the ROPS installed, the operator must hazardous. always use the seat belt when operating the machine. • Keep flames away from flammable fluids. • Stop the engine while refueling. • Never smoke while refueling Preventing Injury From Work Equipment • Tighten all fuel and oil tank caps securely. • Never position any part of your body between movable parts such as the dump body, chassis • Refuel and maintain oil in well ventilated areas. or cylinders. If the work equipment is operated, • Keep oil and fuel in a designated location. DO clearances will change and may cause serious NOT allow unauthorized persons to enter. bodily injury or death. Precautions For Optional Attachments • When installing and using optional equipment, read the instruction manual for the attachment and the information related to attachments in this manual. • DO NOT use attachments that are not authorized by Komatsu, or the authorized regional Komatsu distributor. Use of unauthorized attachments could create a safety problem and adversely affect the proper operation and useful life of the machine. • Any injuries, accidents, and product failures resulting from the use of unauthorized attachments will not be the responsibility of Komatsu America Corp., or the authorized regional Komatsu distributor. ROPS Precautions • The Rollover Protection Structure (ROPS) must be properly installed for machine operation. Precautions When Starting The Machine • The ROPS is intended to protect the operator if • Start the engine from the the machine should roll over. It is designed not operator’s seat, only. only to support the load of the machine, but also to absorb the energy of the impact. • Never attempt to start the engine by shorting across the • ROPS structures installed on equipment starter terminals. This may manufactured and designed by Komatsu fulfills cause fire, or serious injury or all of the regulations and standards for all death to anyone in the countries. If it is modified or repaired without machine’s path. authorization from Komatsu, or is damaged when the machine rolls over, the strength of the structure will be compromised and will not be able to fulfill its intended purpose. Optimum strength of the structure can only be achieved if it is repaired or modified as specified by Komatsu.
Safety - Section 20 8/07 OM2038 Page 20-4 PRECAUTIONS FOR TRUCK Fire Prevention OPERATION • Remove all wood chips, leaves, paper and other Safety Is Thinking Ahead flammable items Prevention is the best safety program. Prevent a accumulated in the engine potential accident by knowing the employer's safety compartment, as they could requirements and all necessary job site regulations. cause a fire. In addition, know the proper use and care of all the • Check fuel, lubrication, and hydraulic systems for safety equipment on the truck. Only qualified opera- leaks. Repair any leaks. Clean any excess oil, tors or technicians may attempt to operate or main- fuel or other flammable fluids, and dispose of tain a Komatsu machine. properly. Safe practices start before the operator gets to the • Ensure a fire extinguisher is present and in equipment! proper working condition. • DO NOT operate the machine near open flames. Safety At The Worksite Preparing For Operation • When walking to and from a truck, maintain a safe distance from all machines even when the • Always mount and dismount while facing the operator is visible. truck. Never attempt to mount or dismount the truck while it is in motion. Always use handrails • Before starting the engine, thoroughly check the and ladders when mounting or dismounting the area for any unusual conditions that could be truck. dangerous. • Check the deck areas for debris, loose hardware, • Examine the road surface at the job site and and tools. Check for people and objects that determine the best and safest method of remain on or around the truck. operation. • Become familiar with and use all protective • Choose an area where the ground is as equipment devices on the truck and ensure that horizontal and firm as possible before performing these items (anti-skid material, grab bars, seat the operation. belts, etc.) are securely in place. • If you need to operate on or near a public road, protect pedestrians and cars by designating a person for work site traffic duty or by installing Ventilation For Enclosed Areas fences around the work site. • The operator must personally check the work • If it is necessary to start the position, the roads to be used, and existence of engine in an enclosed area, obstacles before starting operations. provide adequate ventilation. Exhaust fumes from the • Always determine the travel roads to be used at engine can kill. the work site. Travel roads must be maintained in order to ensure safe machine travel. • If travel through wet areas is necessary, check the depth and flow of water before crossing the shallow parts. Never drive through water which exceeds the permissible water depth.
OM2038 8/07 Safety - Section 20 Page 20-5 Mirrors, Windows, And Lights OPERATING THE MACHINE • Remove any dirt from the surface of the Starting The Engine windshield, cab windows, mirrors and lights. Good visibility may prevent an accident. • NEVER ATTEMPT TO START THE MACHINE • Adjust the mirrors to a position where the BY SHORTING ACROSS THE STARTER operator can see best from the operator's seat. TERMINALS. This may cause fire, or serious injury or death to anyone in machine’s path. • Ensure headlights, work lights and taillights are in proper working order. Ensure that the machine is • NEVER start the engine if a warning tag has equipped with the proper work lamps needed for been attached to the controls. the operating conditions. • When starting the engine, sound the horn as an • Replace any broken mirrors, windows or lights. alert. • Start and operate the machine only while seated in the operator’s seat. In The Operator’s Cab - Before Starting The • DO NOT allow any unauthorized persons in the Engine operator's compartment or any other place on the machine. • DO NOT leave tools or spare parts lying around or allow trash to accumulate in the cab of the truck. Keep all unauthorized reading material out of the truck cab. Truck Operation - General • Keep the cab floor, controls, steps, and handrails • WEAR SEAT BELTS AT ALL TIMES. free of oil, grease, snow, and excess dirt. • Only authorized persons are allowed to ride in • Check the seat belt, buckle and hardware for the truck. Passengers must be in the cab and damage or wear. Replace any worn or damaged belted in the passenger seat. parts. Always use the seat belts when operating a machine. • DO NOT allow anyone to ride on the decks or on the steps of the truck. • Read and understand the contents of the Operation & Maintenance manual. Read safety • DO NOT allow anyone to get on or off the truck and operating instructions with special attention. while it is in motion. Become thoroughly acquainted with all gauges, • DO NOT move the truck in or out of a building instruments and controls before attempting without a signal person present. operation of the truck. • Know and obey hand signal communications • Read and understand the WARNING and between the operator and spotter. When other CAUTION decals in the operator's cab. machines and personnel are present, the • Ensure the steering wheel, horn, controls and operator should move in and out of buildings, pedals are free of any oil, grease or mud. loading areas and through traffic, under the direction of a signal person. Courtesy at all • Check operation of the windshield wiper, times is a safety precaution! condition of wiper blades, and check the washer fluid reservoir level. • Immediately report any adverse conditions on haul road, pit or dump area that may cause an • Be familiar with all steering and brake system operating hazard. controls, warning devices, road speeds and loading capabilities, before operating the truck.
Safety - Section 20 8/07 OM2038 Page 20-6 • Check for flat tires periodically during a shift. If Traveling In The Truck the truck has been operating on a “flat”, the truck must not be parked indoors until the tire cools. If • When traveling on rough ground, travel at low the tire must be changed, DO NOT stand in front speeds. When changing direction, avoid turning of the rim and locking ring when inflating a tire suddenly. mounted on the machine. Observers should not • Lower the dump body and move the dump lever be permitted in the area and should be kept to the FLOAT position before traveling. away from the side of such tires. • If the engine should stop when the machine is in motion, the emergency steering system will be activated. Apply the brakes immediately and stop the machine as quickly and safely as possible (off of the haul road, if possible). Apply the parking brake. A tire and rim assembly may explode if subjected to excessive heat. Personnel must move to a Precautions When Traveling In Reverse remote or protected location if there is a fire near the tire and wheel area or if the smell of burning Before operating the rubber or excessively hot brakes is evident. machine or work equip- ment, do as follows: If the truck must be approached, such as to fight a fire, those personnel must do so only while fac- ing the tread area of the tire (front or back), unless protected by use of large heavy equip- • Ensure the backup alarm works properly. ment as a shield. Stay at least 50 ft. (15 m) from • Sound the horn to warn people in the area. the tread of the tire. • Check for personnel near the machine. Do a thorough check behind the machine. In the event of fire in the tire and wheel area (including brake fires), stay away from the truck • When necessary, designate a person to watch for at least 8 hours or until the tire and wheel are the area for the truck operator. This is particularly cool. necessary when traveling in reverse. • Keep serviceable fire fighting equipment on • When operating in hazardous areas and areas hand. Report used extinguishers for replacement with poor visibility, designate a person to direct or refilling. work site traffic. • Always move the directional control lever to • DO NOT allow any one to enter the line of travel PARK (this will apply the parking brake) when of the machine. This rule must be strictly obeyed the truck is parked and unattended. DO NOT even with machines equipped with a back-up leave the truck unattended while the engine is alarm or rear view mirror. running. • Park the truck a safe distance away from other vehicles as determined by the supervisor. NOTE: Do not use wheel brake lock when parking the truck. • Stay alert at all times! In the event of an emergency, be prepared to react quickly and avoid accidents. If an emergency arises, know where to get prompt assistance.
OM2038 8/07 Safety - Section 20 Page 20-7 Traveling On Slopes Avoid Damage To The Dump Body • Traveling on slopes could result in the machine • When working in tunnels, on bridges, under tipping over or slipping. electric cables, or when entering an enclosed area where there are height limits, always use • DO NOT change direction on slopes. To ensure extreme caution. The dump body must be safety, drive to level ground before turning. completely lowered before driving. • DO NOT travel up and down on grass, fallen leaves, or wet steel plates. These materials may make the machine slip on even the slightest slope. Avoid traveling sideways, and always keep travel speed low. Driving with a raised dump body or raising the dump body in an enclosed area, may result in • When traveling downhill, use the retarder to reduce speed. DO NOT turn the steering wheel serious damage and bodily injury or death. suddenly. DO NOT use the foot brake except in Always drive with the dump body resting on the an emergency. frame. • If the engine should stop on a slope, apply the service brakes to fully and stop the machine. Apply the parking brake after the machine has Driving Near High Voltage Cables stopped. • Driving near high-voltage cables can cause Ensuring Good Visibility electric shock. Always maintain the safe distances between the machine and the electric • When working in dark places, install work lamps cable as listed below. and head lamps. Voltage Minimum Safe Distance • Discontinue operations if visibility is poor, such as in mist, snow, or rain. Wait for the weather to 6.6 kV 3 m 10 ft. improve to allow the operation to be performed 33.0 kV 4 m 14 ft. safely. 66.0 kV 5 m 17 ft. Operating On Snow 154.0 kV 8 m 27 ft. • When working on snowy or icy roads, there is 275.0 kV 10 m 33 ft. danger that the machine may slip to the side on The following actions are effective in preventing acci- even the slightest slope. Always travel slowly and avoid sudden starting, turning, or stopping in dents while working near high voltages: these conditions. • Wear shoes with rubber or leather soles. • Be extremely careful when clearing snow. The • Use a signalman to give warning if the machine road shoulder and other objects are buried in the approaches an electric cable. snow and cannot be seen. When traveling on snow-covered roads, always install tire chains. • If the work equipment should touch an electric cable, the operator should not leave the cab. • When performing operations near high voltage cables, DO NOT allow anyone to approach the machine. • Check with the electrical maintenance department about the voltage of the cables before starting operations.
Safety - Section 20 8/07 OM2038 Page 20-8 When Loading The Truck • Turn the key switch to the OFF position. Wait 90 seconds before exiting the cab. If any warning • Ensure the surrounding area is safe. If so, stop lights are illuminated or warning horns are the machine in the correct loading position and sounding, do not leave the cab and notify evenly load the body. maintenance personnel immediately. When • DO NOT leave the operator's seat during the exiting the machine, always lock compartments, loading operation. and take the keys with you to prevent entry from unauthorized persons. When Dumping • When parking on public roads, provide fences, • Before dumping, check that there is no person or flags or lights, on the machine to warn objects behind the machine. pedestrians and other vehicles. Ensure that the machine, flags, or lights DO NOT obstruct the • Stop the machine in the desired location. Check traffic. again for persons or objects behind the machine. Give the determined signal, then slowly operate the dump body. If necessary, use blocks for the wheels or position a flagman. • When dumping on slopes, machine stability is poor and there is danger of tip over. Always perform such operations using extreme care. TOWING • Never travel with the dump body raised. Improper towing methods may lead to serious per- sonal injury and/or damage. Working On Loose Ground • Tow with a solid tow bar. Do not tow with a cable. • Avoid operating the machine near cliffs, overhangs, and deep ditches. If these areas • Use a towing device with ample strength for the collapse, the machine could fall or tip over and weight of this machine. result in serious injury or death. Remember that • Never tow a machine on a slope. ground surfaces in these areas may be weakened after heavy rain or blasting. • When connecting a machine to be towed, DO NOT allow anyone to go between the tow • Freshly laid soil and the soil near ditches is loose. machine and the disabled machine. It can collapse under the weight or vibration of the machine. Avoid these areas whenever • Set the coupling of the disabled machine in a possible. straight line with the towing portion of the tow machine, and secure it in position. • DO NOT stand next to the towing device while Parking The Machine the truck is moving. • Ensure the truck body is empty. Completely (For towing method, see the Operation and Mainte- lower the dump body by placing the hoist control nance Manual, Section 30, Operating Instructions - lever in the FLOAT position. Towing.) • Choose a horizontal road surface to park the machine. If the machine must be parked on a slope, follow local regulations to secure the truck to prevent the machine from moving. • Move the directional control lever to PARK (this will apply the parking brake). NOTE: Do not apply the wheel brake lock.
OM2038 8/07 Safety - Section 20 Page 20-9 WORKING NEAR BATTERIES Jump Starting With Booster Cables Battery Hazard Prevention • Always wear safety glasses or goggles when starting the machine with booster cables. • Battery electrolyte contains sulfuric acid and can • While jump starting with another machine, DO quickly burn the skin and eat holes in clothing. If NOT allow the two machines to touch. electrolyte comes in contact with skin, immediately flush the area with water. • Be sure to connect the positive (+) cable first • Battery acid can cause blindness if splashed into when installing booster the eyes. If acid gets into the eyes, flush them cables. Disconnect the immediately with large quantities of water and ground or negative (-) see a doctor immediately. cable first during removal. • If acid is accidentally ingested, drink a large • If any tool touches quantity of water, milk, beaten eggs or vegetable between the positive (+) terminal and the oil. Call a doctor or poison prevention center chassis, it will cause sparks. Always use caution immediately. when using tools near the battery. • Always wear safety glasses or goggles when • Connect the batteries in parallel: positive to working with batteries. positive and negative to negative. • Batteries generate hydrogen gas. Hydrogen gas • When connecting the ground cable to the frame is very explosive and is easily ignited with a small of the disabled machine, connect the ground as spark of flame. far as possible from the battery. • Batteries generate hydrogen gas. Hydrogen gas is very EXPLOSIVE, and is easily ignited with a small spark or flame. • Before working with batteries, stop the engine and turn the key switch to the OFF position. • Avoid short-circuiting the battery terminals through accidental contact with metallic objects, such as tools, across the terminals. • When removing or installing a battery, positively identify the positive (+) terminal and negative (-) terminal and use precautions not to short circuit the terminals. • Tighten battery caps securely. • Tighten battery terminals securely. Loose terminals can generate sparks and lead to an explosion.
Safety - Section 20 8/07 OM2038 Page 20-10 PRECAUTIONS FOR MAINTENANCE BEFORE PERFORMING MAINTENANCE Securing The Dump Body Stopping The Engine Before Service • Before performing inspections or maintenance, stop the machine on firm, flat ground. Lower the dump body, place the directional control lever to the PARK position (this will apply the parking Any time personnel are required to perform main- brake), and turn the key switch to the OFF tenance on the vehicle with the dump body in the position to stop the engine. Put blocks under the raised position, the body-up retention cable wheels. MUST be installed. • If the engine must be operated during service, always move the directional control lever to the PARK position (this will apply the parking brake). Always perform this work with two people. One person must sit in the operator's seat to stop the engine if necessary. Never move any controls not related to the task at hand during these situations. • When servicing the machine, use care not to touch any moving parts. Never wear loose clothing. • When performing service with the dump body raised, always place the dump lever in the HOLD position, and apply the lock (if equipped). Install the body-up safety pins or cable securely. Warning Tag • Never start the engine or operate the controls while a person is performing maintenance. Serious injury or death may result. 1. To hold the dump body in the up position, raise • Always attach a warning tag to the control lever the body to it's maximum height. in the operator's cab to alert others that you are working on the machine. Attach additional 2. Remove cable (3) from its stored position on the warning tags around the machine, if necessary. body, and install between rear body ear (1) and axle housing ear (4). • These tags are available from your Komatsu distributor. 3. Secure the cable clevis pins with cotter pins. • Part No. 09963-03000 4. Return the cable to stored position (2) after maintenance is complete. Proper Tools • Use only tools suited to the task. Using damaged, low quality, faulty, or makeshift tools can cause personal injury. • Extra precaution should be used when grinding, welding, and using a sledge-hammer.
OM2038 8/07 Safety - Section 20 Page 20-11 DURING MAINTENANCE Rules To Follow When Adding Fuel Or Oil Personnel • Spilled fuel and oil may cause slipping. Always clean up spills, immediately. • Only authorized personnel can service and repair • Always tighten the cap of the fuel and oil fillers the machine. securely. Attachments • Never use fuel for washing any parts. • Place attachments that have • Always stop the engine before adding fuel or oil. been removed from the machine in a safe place and • Always add fuel and oil in a well-ventilated area. manner to prevent them from falling. Working Under The Machine • Always lower all movable work equipment to the ground or to their lowest position before performing service or repairs under the machine. • Always block the tires of the machine securely. • Never work under the machine if the machine is poorly supported. Keeping The Machine Clean Radiator Coolant Level • Spilled oil, grease, scattered tools, etc. • If it is necessary to add can cause you to coolant to the radiator, stop slip or trip. Always the engine. Allow the keep your machine engine and radiator to cool clean and tidy. down before adding the coolant. • If water gets into the electrical • Depress the pressure relief button on the radiator system, there is danger that the machine may cap to relieve any pressure. move unexpectedly and/or damage to • Slowly loosen the cap to relieve pressure during components may occur. DO NOT use water or removal. steam to clean any sensors, connectors, or the inside of the operator's compartment. • Use extreme care when washing the electrical Use Of Lighting control cabinet. DO NOT allow water to enter the control cabinet around the doors or vents. DO • When checking fuel, oil, coolant, or battery NOT allow any water to enter the cooling air inlet electrolyte, always use lighting with anti- duct above the electrical control cabinet. If water explosion specifications. If lighting without this enters the control cabinet (through any opening protection is used, there is a danger of explosion. or crevice) major damage to the electrical components may occur. • Never spray water into the rear wheel electric motor covers. Damage to the wheel motor armatures may occur. • DO NOT spray water into the retarding grids. Excess water in the retarding grids can cause a ground fault, which will prevent propulsion.
Safety - Section 20 8/07 OM2038 Page 20-12 Precautions With The Battery Maintenance Near High Temperatures And High Pressures • When repairing the electrical system or • Immediately after stopping the when performing truck, the engine coolant and welding, remove the operating oils are at high negative (-) terminal of temperature and under high the battery to stop the pressure. In these conditions, flow of current. opening the system or replacing filters may result in burns or other injury. Wait for the temperature to cool and Handling High Pressure Hoses pressure to subside before performing the inspection and/or maintenance as outlined in the • DO NOT bend high-pressure hoses or hit them service manual. with hard objects. DO NOT use any bent or cracked piping, tubes or hoses. They may burst during use. Rotating Fan And Belts • Always repair any loose or broken hoses. Fuel and/or oil leaks may result in a fire. • Keep a safe distance from rotating parts such as the radiator fan and fan belts. Precautions With High Pressure Oil • Serious bodily injury may result from direct or indirect • Always remember that work equipment circuits contact with rotating parts and flying objects. are always under pressure. • DO NOT add oil, drain oil, or perform maintenance or inspections before completely Waste Materials releasing the internal pressure. • Never dump oil or other harmful fluids into a sewer system, rivers, etc. • Obey appropriate laws and regulations when disposing of harmful objects such as oil, fuel, coolant, solvent, filters, batteries, and others. • Always put fluids drained from your machine in • Small, high pressure pin-hole leaks are extremely appropriate containers. Never drain fluids directly dangerous. The jet stream of high-pressure oil onto the ground. can pierce the skin and eyes. Always wear safety glasses and thick gloves. Use a piece of cardboard or a sheet of wood to check for oil leakage. • If you are hit by a jet of high-pressure oil, consult a doctor immediately for medical attention.
OM2038 8/07 Safety - Section 20 Page 20-13 TIRES Tire Maintenance Handling Tires If the proper procedure for performing maintenance or replacement of the wheel or tire is not used, the Rim and tire maintenance can be hazardous unless the wheel or tire may burst, causing damage, serious correct procedures are followed by trained personnel. injury, or even death. When performing such mainte- Improperly maintained or inflated tires can overheat nance, consult your authorized regional Komatsu dis- and burst due to excessive pressure. Improper infla- tributor, or the tire manufacturer. tion can also result in cuts in the tire caused by sharp Refer to the Society of Automotive Engineers (SAE), stones. Both of these conditions can lead to tire dam- SAE J1337, Off-Road Rim Maintenance Procedures age, serious personal injury, or even death. and Service Precautions, Section 4.2 for additional To safely maintain a tire, adhere to the following con- information on demounting the tires and rim assem- ditions: blies. Also, refer to Section 4.4 of SAE J1337 for assembly and inflation recommendations. • Before a tire is removed from a vehicle for tire repair, the valve core must be partially removed The U.S. Department of Labor Mine Safety and Health to allow deflation, and then the tire/rim assembly Administration (MSHA) addresses tire repairs in its Title can be removed. During deflation, persons must 30 Code of Federal Regulations, 30 CFR 57.14104. stand outside of the potential trajectory of the locking ring of a multi-piece wheel rim. • After the tire/rim assembly is installed on the vehicle, inflate the tires to their specified DO NOT stand in front of a rim and locking ring pressure. Abnormal heat is generated, when inflating a tire mounted on the machine. particularly when the inflation pressure is too low. Observers must not be permitted in the area. NOTE: To prevent injury from the wheel rims during DO NOT weld or heat the rim assembly with the tire tire inflation, use one of the following: mounted on the rim. Resulting gases inside the tire may ignite, causing explosion of the tire and rim. 1. A wheel cage or other restraining device that will constrain all wheel rim components during Storing Tires After Removal an explosive separation of a multi-piece wheel rim, or during the sudden release of air. • As a basic rule, store the tires in a warehouse in which unauthorized persons cannot enter. If the 2. A stand-off inflation device which permits a per- tires are stored outside, always erect a fence son to stand outside of the potential trajectory of around the tires and put up “No Entry” and other the wheel components. warning signs that even young children can understand. • Use the specified tires. • Stand the tire on level ground, and block it The tire inflation pressure and permissible speeds, securely so that it cannot roll or fall over. given in this manual, are general values. The actual values may differ, depending on the type of tire and • If the tire should fall, flee the area as quickly as the specific operating conditions. For details, please possible. The tires for off-road equipment are consult the tire manufacturer. extremely heavy. Never attempt to hold a tire upright when the tire is falling. This may lead to When the tires become overheated, a flammable gas serious injury or death. is produced inside the tire which can ignite. It is par- ticularly dangerous if the tires become overheated while the tires are pressurized. If the gas generated inside the tire ignites, the internal pressure will sud- denly rise, and the tire will explode, resulting in dan- ger and/or death to personnel in the area. Explosions differ from punctures or tire bursts because the destructive force of the explosion is extremely large. Therefore, the following operations are strictly pro- hibited when the tire is pressurized: Mounted tires stored as spares must be inflated to • Welding the rim the minimum inflation pressure necessary to keep the tire beads properly seated. Maximum inflation • Welding near the wheel or tire. pressure of the stored tire must, in no instance, • Smoking or creating open exceed 15% of the tire’s cold inflation pressure. flames
Safety - Section 20 8/07 OM2038 Page 20-14 ADDITIONAL JOB SITE RULES • Use this space to add any additional job site rules not covered in any of the previous discussions. • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________
OM2038 8/07 Safety - Section 20 Page 20-15 WHEN REPAIRS ARE NECESSARY 1. Only qualified maintenance personnel who 9. If a truck is to be towed for any reason, use a understand the systems being repaired should rigid tow bar. Check the truck cab for decals for attempt repairs. special towing precautions. (Also refer to the 2. Many components on the Komatsu truck are Operation and Maintenance Manual, Operating large and heavy. Ensure that lifting equipment - Instructions - Towing.) hoists, slings, chains, lifting eyes - are of ade- 10. Drain, clean and ventilate fuel tanks and/or quate capacity to handle the lift. hydraulic tanks before making any welding 3. DO NOT stand under a suspended load. DO repairs. NOT work under raised body unless body safety cables, props, or pins are in place to hold the body in up position. 4. DO NOT repair or service the truck while the engine is running, except when adjustments Any operating fluid, such as hydraulic oil or can only be made under such conditions. Keep brake fluid escaping under pressure, can have a safe distance from moving parts. sufficient force to enter a person's body by pene- trating the skin. Serious injury and possibly 5. When servicing any air conditioning system with death may result if proper medical treatment by a refrigerant, wear a face shield and cold resistant physician familiar with this injury is not received gloves for protection against freezing. Be cer- immediately. tain to follow all current regulations for handling and recycling refrigerants. 6. Follow package directions carefully when using 11. Relieve pressure in lines or hoses before mak- cleaning solvents. ing any disconnects. 7. If an auxiliary battery assist is needed, first use 12. After adjustments or repairs, replace all shields, one cable to connect the 24V positive (+) post screens and clamps. of the disabled truck batteries to the 24V posi- 13. Working near tires can be dangerous. Use tive (+) post of the auxiliary assist. Use second extreme caution when working around tires. cable to connect the 24V negative (-) post of the auxiliary assist battery to a frame ground (-) on the disabled truck away from the battery. 8. Always disconnect the positive and negative battery cables of the vehicle before doing any DO NOT stand in front of a rim and locking ring welding on the unit. Failure to do so may seri- when inflating a tire mounted on the machine. ously damage the battery and electrical equip- Observers must not be permitted in the area. ment. Disconnect the battery charging alternator lead wire and isolate electronic con- DO NOT weld or apply heat to the rim assembly trol components before making welding repairs. with the tire mounted on the rim. Resulting gases (It is not necessary to disconnect or remove any inside the tire may ignite, causing explosion of control circuit cards on electric drive dump the tire and rim. trucks or any of the Alarm Indicating Device (AID) circuit control cards.) 14. Only a qualified operator or experienced main- Always fasten the welding machine ground (-) tenance personnel who are also qualified in lead to the piece being welded; the grounding operation can move the truck under its own clamp must be attached as near as possible to power in the repair facility or during road testing the weld area. Never allow welding current to after repairs are complete. pass through ball bearings, roller bearings, sus- pensions, or hydraulic cylinders. Always avoid laying welding cables over or near the vehicle electrical harnesses. Welding voltage could be induced into the electrical harness and cause damage to components.
Safety - Section 20 8/07 OM2038 Page 20-16 SPECIAL PRECAUTIONS FOR WORKING ON A 830E-AC TRUCK Preliminary Procedures before Welding or Per- Engine Shutdown Procedure before Welding or forming Maintenance Performing Maintenance Prior to welding and/or repairing a 830E-AC dump Normal operation of the drive system at shutdown truck, maintenance personnel should attempt to should leave the system safe to maintain. However, notify a Komatsu service representative. Only quali- in the event of a system failure, performing the fol- fied personnel, specifically trained for servicing the lowing procedure prior to any maintenance activities AC drive system, should perform this service. will ensure that no hazardous voltages are present in the AC drive system. If it is necessary to perform welding or repair to the truck without the field engineer present, the following 1. Before shutting down the engine, verify the sta- procedures should be followed to ensure that the tus of all the drive system warning lights on the truck is safe for maintenance personnel to work on overhead display panel. Use the lamp test and to reduce the chance for damage to equipment. switch to verify that all lamps are functioning properly. If any of the red drive system warning lights remain on, DO NOT attempt to open any cabi- nets, disconnect any cables, or reach inside the Anytime the engine is operating: retarder grid cabinet without a trained drive sys- • DO NOT open any of the cabinet doors or tem technician present - even if engine is off. remove any covers. Only qualified personnel, specifically trained for • DO NOT use any of the power cables for hand servicing the A-C drive system, should perform holds or foot steps. this service. • DO NOT touch the retarding grid elements. 2. If all red drive system warning lights are off, fol- low the “Normal Engine Shutdown Procedure”. 3. After the engine has been off for at least five minutes, inspect the link voltage lights on the exterior of the main control cabinet and rear of Before opening any cabinets or touching a grid the center console. If all lights are off, the retard element or a power cable, the engine must be grids, wheel motors, alternator, and related shutdown and the red drive system warning power cables are safe to work on. lights must not be illuminated. 4. Locate the GF cut-out switch in the access panel on the left side of the main control cabi- net. Place the switch in the CUTOUT position. This will prevent the alternator from re-energiz- ing and creating system voltage until the switch is returned to the previous position. 5. Before welding on the truck, disconnect all elec- trical harnesses from the Engine Control Sys- tem (ECS) inside the electrical cabinet behind the operator's cab. Also, disconnect the ground strap from the ECS.
OM2038 8/07 Safety - Section 20 Page 20-17 6. DO NOT weld on the rear of the control cabinet! 10. If the red lights on the exterior of the control The metal panels on the back of the cabinet are cabinet and/or the back wall of the center con- part of capacitors and cannot be heated. sole continue to be illuminated after following 7. DO NOT weld on the retard grid exhaust lou- the above procedure, a fault has occurred. vers - they are made of stainless steel. Some Leave all cabinet doors in place; DO NOT touch power cable panels throughout the truck are the retard grid elements; DO NOT disconnect also made of aluminum or stainless steel. They any power cables, or use them as hand or foot must be repaired with the same material or the holds. power cables may be damaged. 8. Power cables must be cleated in wood or other non-ferrous materials. DO NOT repair cable cleats by encircling the power cables with metal clamps or hardware. Always inspect power cable insulation prior to servicing the cables and Notify your Komatsu service representative, prior to returning the truck to service. Discard immediately. Only qualified personnel, specifi- cables with broken insulation. cally trained for servicing the A-C drive system, should perform this service. 9. Power cables and wiring harnesses should be protected from weld spatter and heat. 11. Replace all covers and doors and place the GF cutout switch and battery disconnect switches Always fasten the welding machine ground (-) in their original positions. Reconnect all har- lead to the piece being welded; the grounding nesses prior to starting the truck. clamp must be attached as near as possible to the weld area. Leave the drive system in the rest mode until the truck is to be moved. Always avoid laying welding cables over or near the vehicle electrical harnesses. Welding voltage could be induced into the electrical har- ness and cause damage to components. Before doing any welding on the truck, always disconnect the battery charging alternator lead wire and isolate electronic control components. In addition, always disconnect the positive and negative battery cables of the vehicle. Failure to do so may seriously damage the battery and electrical equipment. Never allow welding current to pass through ball bearings, roller bearings, suspensions, or hydraulic cylinders.
Safety - Section 20 8/07 OM2038 Page 20-18
OM2212 Warnings And Cautions - Section 22 Page 22-1 WARNINGS AND CAUTIONS The following pages give an explanation of the warn- ing, caution, and service instruction plates and decals attached to the truck. The plates and decals listed here are typical of this Komatsu model, but because of customer options, individual trucks may have plates and decals that are different from those shown here. The plates and decals must be kept clean and legi- ble. If any decal or plate becomes illegible or dam- aged, it must be replaced with a new one. A warning decal surrounds the key switch located to the right of the steering column on the instrument panel. The warning stresses the importance of read- ing the operator's manual before operation. A grade/speed retard chart is located on the left front post of the operator's cab and provides the recom- mended MAXIMUM speeds to be used when descending various grades with a loaded truck. Always refer to the decal in operator's cab. This decal may change with optional truck equipment such as: wheel motor drive train ratios, retarder grids, tire sizes, etc. A plate attached to the right rear corner of the cab states the Rollover Protective Structure (ROPS) and Falling Object Protective Structure (FOPS) meets various SAE performance requirements. ! WARNING! Do not make modifications to this structure, or attempt to repair damage without written approval from Komatsu. Unauthorized repairs will void certification.
Warnings And Cautions - Section 22 OM2212 Page 22-2 Attached to the exterior of both battery compartments is a danger plate. This plate stresses the need to keep from making any sparks near the battery. When another battery or 24VDC power source is used for auxiliary power, all switches must be OFF prior to making any connections. When connecting auxiliary power cables, positively maintain correct polarity. Connect the positive (+) posts together and then con- nect the negative (-) lead of the auxiliary power cable to a good frame ground. Do not connect to the neg- ative posts of the truck battery or a ground near the battery box. This hookup completes the circuit but minimizes danger of sparks near the batteries. Sulfuric acid is corrosive and toxic. Use proper safety gear, goggles, rubber gloves and rubber apron when handling and servicing batteries. Get proper medical help immediately, if required. This plate is placed on both battery boxes and near the battery disconnect switches to indicate that the battery system (24VDC) is a negative (-) ground sys- tem. These decals are placed above the battery discon- nect switches on the right side of the front bumper to indicate OFF and ON positions of the switches.
OM2212 Warnings And Cautions - Section 22 Page 22-3 A warning plate is mounted on top of the radiator surge tank cover near the radiator cap. The engine cooling system is pressurized. Always turn the key switch OFF and allow the engine to cool before removing the radiator cap. Unless the pressure is first released, removing the radiator cap after the engine has been operating for a time will result in the hot coolant being expelled from the radiator. Serious scalding and burning may result. Warning plates are mounted on the frame in front of, and to the rear, of both front tires. All personnel are warned that the clearances change when the truck is steered and could cause serious injury. Warning plates are attached to both the hydraulic tank and fuel tank to alert technicians not to work on the truck with the body in the raised position unless the body-up retention device (pins or cable) is in position.
Warnings And Cautions - Section 22 OM2212 Page 22-4 These danger plates are mounted on the outside of each frame rail to alert technicians to read the warn- ing labels attached to the side of each of the accumu- lators (see below) prior to releasing internal nitrogen pressure or disconnecting any hydraulic lines or hardware. There are similar decals mounted on top of each of the accumulators (both steering and brake) with the same danger message. This danger plate is attached to all four suspensions. The plate contains instructions for releasing internal pressure before disconnecting any hardware. Serious injury can occur if these directions are not followed. A plate on the side of the hydraulic tank furnishes instructions for filling the hydraulic tank. Keep the system open to the atmosphere only as long as absolutely necessary to lessen the chances of system contamination. Service the tank with clean Type C-4 hydraulic oil. All oil being put into the hydraulic tank must be filtered using filters rated at three microns. A caution decal is attached below the hydraulic tank oil level sight gauge. Check level with body down, engine stopped, and key switch OFF. Add oil per fill- ing instructions, if oil level is below top of sight glass.
OM2212 Warnings And Cautions - Section 22 Page 22-5 A warning plate is attached to the hydraulic tank to inform technicians that high pressure hydraulic oil is present during operation. When it is necessary to open the hydraulic system, Ensure the engine is stopped and key switch is OFF to bleed down hydraulic pressure. There is always a chance of residual pressure being present. Open fittings slowly to allow all pressure to bleed off before removing any connections. Any operating fluid, such as hydraulic oil, escap- ing under pressure can have sufficient force to enter a person's body by penetrating the skin. Serious injury and possibly death may result if proper medical treatment by a physician familiar with this injury is not received immediately. A wheel motor oil level decal is attached to the gear cover on both electric wheel motors. This decal stresses the fact that the truck must be on a level surface and parked for 20 minutes prior to checking the oil level. This is necessary in order to get an accurate reading. A decal plate located on the frame near the left hoist cylinder provides the operator or technician with the hook-up procedure for dumping a loaded, disabled truck. The use of a functional truck for hydraulic power is required. Refer to the Section L for additional instructions for using this procedure. Warning decals are applied to both brake accumula- tors located inside the brake system cabinet behind the operator cab. These decals remind servicing technicians to close the accumulator drain valves after they have been opened to bleed brake pres- sure. It further warns not to over-tighten the drain valves to prevent damage to the valve seat(s).
Warnings And Cautions - Section 22 OM2212 Page 22-6 A decal plate is located on the frame near the left hoist cylinder. It provides the operator or technician with the hydraulic hook-up procedure before towing a disabled truck, by using a functional truck for hydrau- lic power. This warning decal is located below the battery dis- connect switches to warn personnel not to discon- nect the batteries during the first 90 seconds after turning the key switch off. This decal is located on the automatic lubrication res- ervoir informing the technician that the cover should never be removed for filling purposes as there is potential for dirt or debris entering the system. Always fill the grease reservoir through the coupling provided where the grease passes through a filter before entering the reservoir.
OM2212 Warnings And Cautions - Section 22 Page 22-7 This caution decal is placed near the battery discon- nect switches on the right side of the front bumper to alert servicing technicians that before doing any welding on the truck, always disconnect the battery charging alternator lead wire and isolate electronic control components before making welding repairs. In addition, always disconnect the positive and nega- tive battery cables of the vehicle. Failure to do so may seriously damage the battery and electrical equipment. Always fasten the welding machine ground (-) lead to the piece being welded; grounding clamp must be attached as near as possible to the weld area. Never allow welding current to pass through ball bearings, roller bearings, suspensions, or hydraulic cylinders. Always avoid laying welding cables over or near the vehicle electrical harnesses. Welding volt- age could be induced into the electrical harness and possibly cause damage to components. A high voltage danger plate is attached to the door of the rear hatch cover. High voltage may be present! Only authorized personnel can access this rear housing. A caution decal is also attached to the door of the rear hatch cover to alert personnel that hot exhaust air is present and may cause injury. This caution decal is also placed around the retard- ing grid cabinet. These warning plates are mounted on all of the AC drive control housings and cabinets. High voltage may be present, with or without, the engine running! Only authorized personnel can access these cabi- nets.
Warnings And Cautions - Section 22 OM2212 Page 22-8 This caution decal is placed on the back of the con- trol cabinet to alert service technicians that this area contains capacitors and must not be disturbed in any manner. This information decal is placed on the outside of the door panel on the control cabinet wall that faces the right side of the operator cab. This decal is placed near three different indicator lights: • In the operator cab, on the rear of the center console. • On the front of the control box which is mounted on the right side of the main control cabinet. • On the outside of the left control cabinet wall that faces the right side of the operator cab. (See also Information decal above.) When any of these indicator lights are on, high voltage is present throughout the propulsion and retarding system. Extreme care should be exer- cised!
OM2212 Warnings And Cautions - Section 22 Page 22-9 This decal is placed on the ground level engine shut- down switch which is mounted on the right side of the front bumper structure. It specifies that this switch is for emergency shutdown only. This page illustrates a variety of decals which are mounted on deck mounted cabinets, housings, and structures which must be lifted in a specific manner, and from specific points, in order to safely move or lift any of these structures. If any of these decals are damaged or defaced, so that it is no longer legible, it should be replaced immediately. Maintenance personnel must follow these lifting instructions.
Warnings And Cautions - Section 22 OM2212 Page 22-10 A product identification plate is located on the frame in front of the right side front wheel and shows the truck model number, maximum GVW and Product Identification Number (PIN). The PIN consists of 19 total characters. The first and last characters are tamper preventative symbols (*). The remaining 17 alpha/numeric characters are used to identify 5 characteristics of the machine. The 5 characteristics are detailed below. WMC - Character positions 1, 2 and 3 identify the Worldwide Manufacturer Code (WMC). The WMC designates the manufacturer of the product. Komatsu brand products are identified with the letters KMT. MDS - Character positions 4, 5, 6, 7 and 8 identify the Machine Descriptor Section (MDS). The MDS code identifies general information regarding machine specifications. The MDS is a code for the machine type and model. CL - Character position 9 identify the Check Letter (CL). The CL is used to verify the accuracy of the individual PIN. FC - Character positions 10 and 11 identify the Fac- tory Code (FC). The FC identifies the Komatsu fac- tory in charge of claims for the product. The FC for electric drive trucks is 61. SN - Character positions 12, 13, 14, 15, 16, and 17 identify the Serial Number (SN). The SN is a unique sequential number.
OM2212 Warnings And Cautions - Section 22 Page 22-11 The lubrication chart is mounted on the right hand side of the radiator grille structure. Refer to Section P, Lubrica- tion and Service, in this manual for more complete lubrication instructions.
Warnings And Cautions - Section 22 OM2212 Page 22-12 NOTES:
OM3047 4/08 Operating Instructions - Section 30 Page 30-1 TRUCK OPERATION PREPARING FOR OPERATION Local work practices may prevent an operator from performing all tasks suggested here. To the extent The safest trucks are those which have been prop- permitted, the operator should follow this or a similar erly prepared for operation. At the beginning of each routine. shift, a careful check of the truck must be made by the operator before starting the engine. Safety Is Thinking Ahead Prevention is the best safety program. Prevent a High voltage may be present on this truck! DO potential accident by knowing the employer's safety NOT open any electrical cabinet doors on the requirements, all necessary job site regulations, as truck while the engine is operating! Never climb well as use and care of the safety equipment on the on any power cables or use power cables for truck. Only qualified operators or technicians can handholds or footholds, unless the engine has operate or maintain a Komatsu truck. been shut off and the system has been verified Safe practices start before the operator gets to the as at rest! equipment! • Wear the proper clothing. Loose fitting clothing, 1. Start at left front of the truck. While performing unbuttoned sleeves and jackets, jewelry, etc., the walk around inspection, visually inspect al can catch on a protrusion and cause a potential lights and safety equipment for external dam- hazard. age from rocks or misuse. Ensure lenses are • Always use the personal safety equipment clean and unbroken. provided for the operator such as hard hats, safety shoes, safety glasses or goggles. There Empty the dust pans on the left side of the air are some conditions when protective hearing cleaners. Ensure the battery box covers are in devices must also be worn for operator safety. place and secure. • When walking to and from the truck, maintain a 2. Move behind the front of the left front tire. safe distance from all machines, even if the Inspect the hub and brake assemblies for leaks operator is visible. and any abnormal conditions. 3. Check that all suspension attaching hardware is secure and inspect the mounting key area for WALK AROUND INSPECTION evidence of wear. Check that the suspension At the beginning of each shift, a careful walk around rod extension is correct, and that there are no inspection of the truck must be performed before the leaks. Ensure the suspension protective boot is operator attempts engine start-up. A walk around in good condition. inspection is a systematic ground level inspection of 4. Inspect the anchor end of the steering cylinder the truck and its components to ensure that the truck for proper greasing and all parts are secure. is safe to operate before entering the operator's cab. 5. With the engine stopped, check the engine oil Start at the left front corner of the truck (see illustra- level. Use the service light if necessary. tion, next page), and move in a counter-clockwise 6. Inspect air conditioner belts for correct tension, direction. Move front-to-rear, across the rear, and obvious wear, and tracking. Inspect fan guard continuing forward up the opposite side of the truck security and condition. When leaving this point, to the original starting point. be sure to turn off the service light, if used. If these steps are performed in sequence, and are 7. Move outboard of the front wheel. Inspect repeated from the same point and in the same direc- attaching lugs/wedges to be sure all are tight tion before every shift, many potential problems may and complete. Inspect the tires for cuts, dam- be avoided, or scheduled for maintenance. Unsched- age or bubbles. Check tire inflation pressure. uled downtime and loss of production can be Check sight glass for front wheel oil level. reduced as a result.
Operating Instructions - Section 30 4/08 OM3047 Page 30-2 START HERE Walk Around Inspection
OM3047 4/08 Operating Instructions - Section 30 Page 30-3 8. Move behind the front wheel and inspect the 15. Open the rear hatch cover, turn on work light, if steering cylinder. Check for proper greasing necessary. Inspect for leaks around wheel and inspect the mounting hardware to ensure it motor mounting to rear housing, and also brake is all in place. Inspect the suspension mounting hoses and fittings. ensure that covers on wheel hardware to ensure it is all in place. Ensure the motor sump are in place, and that there are no suspension protective boot is in good condition. rags or tools left behind. Inspect condition of Inspect the hub and brakes for any unusual hatch cover gasket, report any bad gasket to conditions. Check the entire area for leaks. maintenance. Turn off work light if used, close 9. Inspect the sight glass on the hydraulic tank. and latch hatch. With the engine stopped and body down, 16. While standing in front of the rear hatch, look up hydraulic fluid must be visible in the upper sight to see that rear lights are in good condition, glass. along with the back-up horns. Look up at the 10. Verify all hydraulic tank shut off valves are panhard rod to see that it is getting proper locked in their fully open positions. greasing. Also look at both body hinge pins for greasing and any abnormal condition. Check 11. Move around the hydraulic tank and in front of hoist limit switch and clear any mud/debris from the rear dual tires. Inspect the hoist cylinder for contacts. any damage and leaks. Inspect both upper and lower hoist cylinder pins for integrity and for 17. Perform the same inspection on the right rear proper greasing. suspension as done on the left. 12. Before leaving this position, look under the 18. Move around the right dual tires. Inspect lower edge of the chassis to ensure the flexible between the tires for rocks, and check the con- duct that carries the air from the blower to the dition of the rock ejector. Inspect the tires for final drive housing is in good condition with no cuts or damage, and for correct inflation. holes or breakage. Also, look up at the main 19. Perform the same inspection for wheel lugs/ hydraulic pumps to see that there is no leakage wedges, wheel cover latches, and wheel leaks or any other unusual condition with the pumps that was done on the left hand dual wheels. or the pump drive shafts. 20. Move in front of the right dual tires and inspect 13. Move around the dual tires, and check to see the hoist cylinder in the same manner as the left that all lugs/wedges are in place and tight. side. Check integrity and condition of the body- Inspect latches on the wheel cover to be sure up limit switch. Remove any mud/dirt accumula- they are properly latched. Inspect the wheel for tion from the switch. any oil that would indicate brake leakage or wheel motor leakage. 21. Move around the fuel tank. Inspect the fuel sight gauge, (this should agree with what will show Check the dual tires for cuts, damage or bub- on the gauge in the cab). Inspect the attaching bles. Verify that inflation appears to be correct. hardware for the fuel tank at the upper saddles, If the truck has operating on a flat tire, the tire and then at the lower back of the tank for the must be cool before moving the truck inside a security and condition of the mounts. Check the building. Check for any rocks that might be hoist filters for leaks. lodged between the dual tires. Inspect the rock 22. Move behind the right front wheel, and inspect ejector condition and straightness so that it can the steering cylinder. Check for proper greasing not damage a tire. and inspect the mounting hardware. Check the 14. Inspect the left rear suspension for damage and suspension mounting hardware and suspension for correct rod extension. Check for leaks. extension. Ensure the suspension protective Ensure that the covers over the chrome piston boot is in good condition. Inspect the hub and rod are in good condition. Inspect for proper brakes for any unusual conditions. Check the greasing. entire area for leaks.
Operating Instructions - Section 30 4/08 OM3047 Page 30-4 23. Move around the right front wheel; check that all 30. When checking the coolant level in the radiator, lugs/wedges are in place and tight. use the coolant level sight gauge. If it is neces- 24. Move in behind the front of the right front wheel, sary to remove the radiator cap, relieve coolant check the hub and brakes for leaks and any pressure by depressing the pressure relief but- unusual condition. Check the hoist filters for ton, and then slowly removing the radiator cap. leaks. Inspect the steering cylinder for secure- ness and for proper greasing. Inspect the engine compartment for any leaks and unusual conditions. Inspect the fan guard and belts. If the engine has been running, allow the coolant Check for any rags or debris behind the radia- to cool before removing the fill cap or draining tor. the radiator. Serious burns may result if skin 25. Inspect the auto lube system. See Automatic comes in contact with hot coolant. Lubrication System in Section P, for specific 31. Inspect the covers over the retarding grids and details concerning the auto lube system. ensure they are secure. Inspect the main air 26. Move around to the right front of the truck, drop inlet to ensure it is clear. Ensure all cabinet door the air cleaner pans and empty. Inspect the bat- latches are secure. tery box cover for damage and ensure it is in 32. Move to the back of the cab. Open the doors to place and secure. the brake cabinet and inspect for leaks. 27. While in front of the radiator, inspect for any 33. Clean the cab windows and mirrors. Clean out debris in the radiator and remove. Check for the cab floor as necessary. Ensure steering any coolant leaks. Inspect headlights and fog wheel, controls and pedals are free of any oil, lights. grease or mud. 28. Ensure the ground level engine shutdown 34. Stow personal gear in the cab in a manner that switch is ON. Inspect the fire control actuator to does not interfere with truck operation. Dirt or ensure the safety pin is in place and the plastic trash buildup, specifically in the operator's cab, tie that prevents accidental actuation is in place must be cleaned. DO NOT carry tools or sup- and in good condition. Ensure the battery dis- plies in the cab of the truck or on the decks. connect switches are ON. Always use grab rails and the ladder when mounting or dismounting 35. Adjust the seat and the steering wheel for use. the truck. Clean the ladder and hand rails of any 36. Read and understand the description of all foreign material, such as ice, snow, oil or mud. operator controls. Become familiar with all con- 29. Use the stairs and handrails while climbing from trol locations and functions before operating the the first level to the cab deck. truck. Always mount and dismount ladders facing the truck. Never attempt to mount or dismount while the truck is in motion.
OM3047 4/08 Operating Instructions - Section 30 Page 30-5 ENGINE START-UP SAFETY PRACTICES 4. The key switch is a three position (OFF, RUN, START) switch. When the switch is rotated one position clockwise, it is in the RUN position and all electrical circuits (except START) are acti- vated. a. Turn key switch to the RUN (not START) Never attempt to start the engine by shorting position. across the cranking motor terminals. This may cause a fire, or serious injury or death to anyone b. With the directional control lever in PARK, in the machine’s path. rotate the key switch fully clockwise to the START position, and hold this position until Start the engine from the operator’s seat only. the engine starts (see NOTE below). The START position is spring-loaded and will return to RUN when the key is released. 1. Ensure all personnel are clear of the truck before starting the engine. Always sound the c. After the engine has started, place the rest horn as a warning before actuating any opera- switch in the OFF position to enable the drive tional controls. If the truck is in an enclosure, system. Refer to the discussion on the rest ensure there is adequate ventilation before switch, in 32, Operator Cab Controls. start-up. Exhaust fumes are dangerous! NOTE: This truck is equipped with an engine prelube 2. The directional control lever must be in the system. With this feature, a noticeable time delay PARK position before starting. may occur (while engine lube oil passages are being filled and pressurized) before engine cranking will NOTE: The park brake will always be applied begin. whenever the directional control lever is in the park position and the truck is moving slower than 0.5 mph. Move the rest switch to the ON position to put the drive system in rest mode of operation. Refer to discussion of the rest switch in Section 32, Operator Cab Controls. Starting fluid is extremely volatile and flammable! 3. If the truck is equipped with auxiliary cold Use with extreme care. weather heater system(s), DO NOT attempt to If truck is equipped with optional engine starting aid start the engine while the heaters are in opera- and ambient temperature is below 10°C (50°F), turn tion. Damage to coolant heaters will result! the key switch to the START position, and while cranking the engine, move the engine starting aid switch to the ON position for three seconds MAXI- MUM, then release engine starting aid. If the engine does not start, wait at least 15 seconds before repeating the procedure. DO NOT crank electric cranking motors for more than 30 seconds. Allow two minutes for cooling before attempting to start the engine again. Severe damage to the cranking motors may result from overheating.
Operating Instructions - Section 30 4/08 OM3047 Page 30-6 AFTER ENGINE HAS STARTED EMERGENCY STEERING SYSTEM 1. Become thoroughly familiar with steering and Operation emergency controls. After the engine has been started, do not accelerate engine speed or This truck is equipped with an emergency steering drive truck until low pressure and warning sys- system. This system is a backup in the event of loss tems are normal, and the coolant temperature of oil supply to the main steering system. The is at least 71°C (160°F). emergency steering system was designed to meet or 2. Test the truck steering in extreme right and left exceed SAE J1511 and ISO 5010 standards. directions. If the steering system is not operat- If the low steering system pressure indicator light and ing properly, shut the engine off immediately. alarm are activated, a failure in the hydraulic oil Determine the steering system problem and supply to the steering and brake system exists. When have it repaired before resuming operation. the alarm is activated, typically there is enough 3. Operate each of the truck's brake circuits at hydraulic pressure stored in the brake and steering least twice prior to operating and moving the accumulators to allow brief operation of the steering truck. These circuits include individual activa- and brake functions. However, this oil supply is tion from the operator's cab of the service limited. Therefore, it is important to stop the truck as brake, parking brake, and wheel brake lock. quickly and safely as possible after the alarm is first With the engine running and with the hydraulic activated. circuit fully charged, activate each circuit indi- If the oil supply pressure drops to a predetermined vidually. level, the low brake pressure warning light will also a. Park the truck on level ground. illuminate. If the oil pressure continues to decrease, the brake auto-apply feature will activate the service b. To operate the park brake, place the direc- brakes to stop the trucK. tional control lever in the PARK position. c. To operate the wheel brake lock, apply the service brake and move directional control Pre-Operation Testing lever to neutral. Release service brakes, and apply wheel brake lock. Turn the wheel NOTE: Komatsu recommends that operators perform brake lock OFF, then back ON again. this test to verify that the steering accumulator precharge pressure is adequate at the beginning of d. Release wheel brake lock and apply service each shift before operating the truck. brakes several times. e. With service brakes applied, move direc- tional control lever to PARK. 4. If any application or release of any brake circuit appears sluggish or improper, or if warning alarms are activated on application or release, Ensure no one is near the front tires during this shut the engine off and notify maintenance per- test. All personnel are warned that the clearances sonnel. DO NOT operate the truck until the change when the truck is steered and this could brake circuit in question is fully operational. cause serious injury. 5. Check the gauges, warning lights and instru- ments before moving the truck to ensure proper This test can only be performed with an empty truck. system operation and proper instrument func- 1. Park the empty truck on flat, level ground. tioning. Pay special attention to braking and Lower the dump body onto the frame and stop steering circuit hydraulic warning lights. If warn- the engine. Make sure that the key switch is in ing lights come on, shut off the engine immedi- the OFF position. ately and determine the cause. 6. Ensure the headlights, work lights and taillights are in proper working order. Good visibility may prevent an accident. Check operation of the windshield wipers.
OM3047 4/08 Operating Instructions - Section 30 Page 30-7 2. Wait at least 90 seconds to verify that all 7. Stop the engine by using the engine stop button hydraulic pressure has been relieved from the located on the center console. Leave the key steering accumulators. Turn the steering wheel switch in the ON position. This allows the from stop to stop. If the front wheels do not steering accumulators to retain their hydraulic move, there is no hydraulic pressure. charge. 3. Check the hydraulic tank oil level. The oil level If the warning light and buzzer do activate, must be visible in the center of the upper sight turn the key switch OFF and notify glass and must not cover the entire upper sight maintenance personnel. Do not operate the glass. Add oil if necessary. Do not overfill. truck until the problem is corrected. 4. Turn the key switch to the ON position, but do If the steering accumulators are adequately not start the engine. charged, the low steering pressure warning light and the low accumulator precharge a. Steering system pressure: Verify that the low warning light will not illuminate. Continue to steering pressure warning light is the next step. illuminated. If it is not illuminated, 8. Turn the steering wheel from stop to stop. The immediately notify maintenance personnel. front wheels should turn fully to the left and to Do not operate the truck until the problem is the right. Eventually, the low steering pressure corrected. warning light should illuminate and the warning b. Steering accumulator precharge: Verify that buzzer should sound. This is normal. the low accumulator precharge warning light If the front wheels cannot be turned fully to the is not illuminated and the warning buzzer is left and right, or if the warning light and buzzer not sounding. If the warning light is do not activate, immediately notify maintenance illuminated and the buzzer is sounding, personnel. Do not operate the truck until the immediately notify maintenance personnel. problem is corrected. Do not operate the truck until the problem is corrected. If the truck passes this test, the emergency steering system is functioning properly. 5. Start the engine and allow the steering accumulators to fully charge. Turn the steering wheel so that the front wheels are straight. 6. Check the hydraulic tank oil level while the engine is on. Additional Guidelines a. If the oil level is visible in center of the lower 1. When the truck body is raised, DO NOT allow sight glass and does not cover the entire anyone beneath it unless the body-up retaining lower sight glass, the steering accumulators cable is in place. are adequately charged. Proceed to Step 7. 2. DO NOT use the fire extinguisher for any pur- pose other than putting out a fire! If an extin- b. If the oil level is below the lower sight glass, guisher is discharged, report the occurrence so the steering accumulators are not ade- the used unit can be refilled or replaced. quately charged. Stop the engine and turn the key switch to the OFF position. Immedi- 3. DO NOT allow unauthorized personnel to ride ately notify maintenance personnel. Do not in the truck. DO NOT allow anyone to ride on operate the truck until the problem is cor- the ladder or outside of the truck cab. Passen- rected. gers must be belted into the passenger seat during travel. 4. DO NOT leave the truck unattended while the engine is running. Move the directional control lever to PARK, then shut the engine off before getting out of the cab.
Operating Instructions - Section 30 4/08 OM3047 Page 30-8 MACHINE OPERATION SAFETY 6. DO NOT allow the engine to run at idle for PRECAUTIONS extended periods of time. After the truck engine is started and all systems are 7. Check the brake lock performance periodically functioning properly, the operator must follow all local to ensure safe loading and dumping. safety rules to ensure safe machine operation. DO NOT use the brake lock for parking. When the If any of the red warning lights illuminate or if any engine is turned off, hydraulic pressure will bleed gauge reads in the red area during truck opera- down, allowing the brakes to release! tion, a malfunction is indicated. Stop the truck as soon as safety permits, and stop the engine. Have the problem corrected before resuming 8. Proceed slowly on rough terrain to avoid deep truck operation. ruts or large obstacles. Avoid traveling close to soft edges and near the edges of a fill area. 9. Truck operation requires a concentrated effort by the driver. Avoid distractions of any kind while operating the truck. The truck is equipped with "slip/slide" control. If this function should become inoperative, operat- ing the truck with stalled or free spinning wheel MACHINE OPERATION ON THE HAUL motors may cause serious damage to wheel motors! If the truck does not begin to move ROAD within ten seconds after depressing the throttle 1. Always stay alert! If unfamiliar with the haul pedal (directional control lever in a drive posi- road, drive with extreme caution. Cab doors tion), release the throttle pedal and allow wheels must remain closed at all times if the truck is in to regain traction before accelerating again. motion or unattended. 1. Always look to the rear before reversing the 2. Obey all road signs. Keep the truck under con- truck. Watch for and obey the ground spotter's trol at all times. Govern truck speed by the road hand signals before traveling in reverse. Sound conditions, weather and visibility. Report poor the horn (three blasts). The spotter will have a haul road conditions immediately. Muddy or icy clear view of the total area at the rear of the roads, pot holes or other obstructions can truck. present hazards. 2. Operate the truck only while properly seated 3. Initial propulsion with a loaded truck should with seat belt fastened. Keep hands and feet begin from a level surface whenever possible. inside the cab compartment while the truck is in At times, starting on a hill or grade cannot be operation. avoided. Refer to Starting On A Grade With A 3. Check gauges and instruments frequently dur- Loaded Truck later in this chapter. ing operation for proper readings. 4. Before traveling in reverse, give a back-up sig- 4. Observe all regulations pertaining to the job nal of three blasts on the horn. Before starting site's traffic patterns. Be alert to any unusual forward, signal with two blasts on the horn. traffic patterns. Obey the spotter's signals. These signals must be given each time the truck is moved forward or backward. 5. Match the truck speed to haul road conditions and slow the truck in congested areas. Keep a 5. Use extreme caution when approaching a haul firm grip on the steering wheel at all times. road intersection. Maintain a safe distance from oncoming vehicles.
OM3047 4/08 Operating Instructions - Section 30 Page 30-9 6. Maintain a safe distance when following STARTING ON A GRADE WITH A another vehicle. Never approach another vehi- LOADED TRUCK cle from the rear, in the same lane, closer than 15 m (50 ft). When driving on a down grade, this Initial propulsion with a loaded truck should begin distance should not be less than 30 m (100 ft). from a level surface whenever possible. There are circumstances when starting on a hill or grade cannot 7. DO NOT stop or park on a haul road unless be avoided. In these instances use the following pro- unavoidable. If the truck must be stopped on a cedure: haul road, park in a safe place, move the direc- tional control lever to PARK, and shut the 1. Fully depress the service brake pedal (DO NOT engine off before leaving the cab. Block the use retarder lever) to hold the truck on the wheels securely and notify maintenance per- grade. With the service brakes fully applied, sonnel for assistance. move the directional control lever to a drive 8. While driving on a slope, maintain a speed that position (FORWARD/REVERSE) and increase will ensure safe driving and provide effective engine rpm with the throttle pedal. retarding under all conditions (Refer to Dynamic 2. As engine rpm approaches maximum, and Retarding, in Section 32 Operator Cab Con- when propulsion effort is felt working against trols.) The grade/speed retard chart in the oper- the brakes, release the brakes and allow truck ator's cab should always be referenced to movement. Be sure to completely release the determine maximum safe truck speeds for service brake pedal. As truck speed increases descending various grades with a loaded truck. above 5-8 kph (3-5 mph) the PSC will drop pro- 9. When operating the truck in darkness, or when pulsion if the retarder is still applied. visibility is poor, DO NOT move the truck unless NOTE: Releasing and reapplying dynamic retarding all headlights, clearance lights, and tail lights during a hill start will result in loss of propulsion. are on. DO NOT back the truck if the back-up horn or lights are inoperative. Always dim the headlights when approaching oncoming vehi- cles. PASSING 10. If the emergency steering light and/or low brake 1. DO NOT pass another truck on a hill or on a pressure warning light illuminate during opera- blind curve! tion, immediately steer the truck to a safe stop- 2. Before passing, ensure the road ahead is clear. ping area, away from other traffic if possible. If a disabled truck is blocking your lane, slow Refer to item 7 above. down and pass with extreme caution. 11. Check the tires for proper inflation during each 3. Use only the areas designated for passing. shift. If the truck has been operating on a flat or under-inflated tire, the truck must remain out- side of any buildings until the tire cools.
Operating Instructions - Section 30 4/08 OM3047 Page 30-10 LOADING 4. When the truck is stopped and in dump posi- tion, apply the brake lock and move the direc- 1. Approach the loading area with caution. tional control lever to the NEUTRAL position. Remain at a safe distance while the truck ahead is being loaded. 2. DO NOT drive over unprotected power cables. 3. When approaching or leaving a loading area, watch for other vehicles and for personnel work- The dumping of very large rocks (10% of payload, ing in the area. or greater) or sticky material (loads that do not 4. When pulling in under a loader or shovel, follow flow freely from the body) may allow the material the spotter’s or the shovel operator’s signals. to move too fast and cause the body to move The truck operator may speed up loading by RAPIDLY and SUDDENLY. This sudden move- observing the location and loading cycle of the ment may jolt the truck violently and cause pos- truck being loaded ahead, and then following a sible injury to the operator, and/or damage to the similar pattern. hoist cylinders, frame, and/or body hinge pins. If 5. During loading, the operator must stay in the it is necessary to dump this kind of material, truck cab with the engine running. Place the slowly accelerate engine rpm while raising the directional control lever in NEUTRAL and apply body. When the material starts to move, release the brake lock. the hoist lever to the HOLD position. If the mate- rial does not continue moving and clear the body, 6. When loaded, pull away from the shovel as repeat this procedure until the material has been quickly as possible with extreme caution. dumped. 5. Pull the lever to the rear (to HOIST position) to DUMPING actuate the hoist circuit. (Releasing the lever anywhere during the raise cycle will hold the Raising The Dump Body body at that position.) 1. Approach the dump area with extreme caution. Ensure the area is clear of persons and obstructions, including overhead utility lines. Obey signals as directed by the spotter, if present. 2. Avoid unstable areas. Keep a safe distance from the edge of the dump area. Position the truck on a solid, level surface before dumping. As the body raises, the truck center of gravity will move. The truck must be on level surface to pre- vent tipping/rolling! 6. Raise engine rpm to accelerate hoist speed. 7. Reduce the engine rpm as the last stage of the 3. Carefully maneuver the truck into the dump hoist cylinder begins to extend. Keep engine position. When backing the truck into the dump speed at low idle as the last stage reaches half- position, use only the brake pedal to stop and extension. hold the truck; DO NOT rely on the brake lock to 8. Release the hoist lever as the last stage of the stop the truck; this control is not modulated and hoist cylinder reaches full extension. applies the rear service brakes only.
OM3047 4/08 Operating Instructions - Section 30 Page 30-11 Lowering The Dump Body Lowering The Dump Body (When dumping on flat ground): (When dumping over a berm or into a crusher): It is very likely when dumping on flat ground that the 1. Move the hoist lever to the DOWN position and dumped material will build up enough to prevent the release. Releasing the lever places the hoist body from lowering. In this case, the truck will have to control valve in the FLOAT position allowing the be driven forward a short distance (just enough to body to return to the frame. clear the material) before the body can be lowered. NOTE: If dumped material builds 1. Shift the directional control lever to FORWARD, up at the rear of the body and the release brake lock, depress Override button body cannot be lowered, perform and drive just far enough forward for the body Steps a & b below: to clear the material. Stop, shift the directional control lever to NEUTRAL apply the brake lock. 2. Move the hoist lever forward to the DOWN posi- a. Move the hoist lever back tion and release. Releasing the lever places the to the HOIST position to hoist control valve in the FLOAT position allow- fully raise the dump body. Release the hoist ing the body to return to the frame. lever to return it to the HOLD position. NOTE: If dumped material builds NOTE: DO NOT drive forward if the tail of the body up at the rear of the body and the will not clear the crusher wall in the fully raised body cannot be lowered, then position. perform Steps "a" and "b" below: b. Move the directional control lever to FOR- WARD, release the brake lock. Depress the override button and drive forward to clear the material. Stop, shift the directional control a. Move the hoist lever back to the RAISE posi- lever to NEUTRAL, apply the brake lock and tion to fully raise the dump body. Then, lower the body again. release the hoist lever so it returns to the NOTE: When an attempt to lower the body is HOLD position. unsuccessful because of material obstruction, raise b. Move the directional control lever to FOR- the body back up. This will help to prevent the body WARD, release the brake lock, depress the from suddenly dropping when pulling away from the override button and drive forward to clear the obstruction. material. Stop, move the directional control lever to NEUTRAL, apply the brake lock and lower the body, again. NOTE: When an attempt to lower the body is CAUTION! DO NOT move the truck with the dump unsuccessful because of material obstruction, raise body raised except for emergency purposes the body back up. This will help to prevent the body only. Failure to lower the body before moving the from suddenly dropping when pulling away from the truck may cause damage to the hoist cylinders, obstruction. frame and/or body hinge pins. 2. With the body returned to the frame, move the directional control lever to FORWARD, release The truck is not to be moved with the dump body the brake lock, and carefully leave the dump raised except for emergency purposes only. Fail- area. ure to lower the body before moving the truck may cause damage to the hoist cylinders, frame and/or body hinge pins. 3. With the body returned to the frame, move the directional control lever to FORWARD, release the brake lock, and carefully leave the dump area.
Operating Instructions - Section 30 4/08 OM3047 Page 30-12 SUDDEN LOSS OF ENGINE POWER FUEL DEPLETION If the engine suddenly stops, there is enough hydrau- The high pressure injection (HPI) fuel system uses lic pressure stored in the brake and steering accumu- fuel to adjust fuel delivery timing by creating a lators to allow the operation of the steering and brake hydraulic link between the upper plunger and the tim- functions. However, this oil supply is limited so it is ing plunger. Metered fuel is also used for lubricating important to stop the truck as quickly and safely as the injector plunger and barrel. The maximum possible after the loss of engine power. demand for metered fuel is required during high speed / low load conditions. If the brake supply pressure drops to a pre-deter- mined level, the low brake pressure warning light will illuminate and a buzzer will sound. If the brake pres- sure continues to decrease, the auto-apply feature will activate and the service brakes will apply auto- matically to stop the truck. 1. Bring the truck to a safe stop as quickly as pos- Operating the truck to fuel depletion forces the sible by using the foot pedal to apply the ser- injector train into a no-follow* condition. No fuel vice brakes. If possible, safely steer the truck to flow between the plungers may cause damage to the side of the road while braking. the injectors and the overhead due to adhesive wear, resulting in costly repairs and unnecessary downtime. Dynamic retarding will not be available! DO NOT use the service brakes for continuous retarding purposes. 2. As soon as the truck has stopped moving, shift Allowing the Komatsu truck to operate until fuel the directional control lever to PARK. This will depletion can lead to unsafe operating condi- apply the parking brake. tions possibly resulting in an uncontrollable 3. Slowly release the service brakes to check the vehicle and/or personal injury. capacity of the parking brake. If the parking brake can not hold the truck stationary, apply the service brakes and hold them ON. DO NOT turn the key switch OFF, and do not release the service brakes. 4. Notify maintenance personnel immediately. 5. If the truck is on level ground, or if the parking brake can hold the truck stationary and the truck is in a stable condition, it is then OK to turn the key switch OFF. 6. If safe to do so, have maintenance personnel place wheel chocks or other mechanisms in front or behind the wheels to reduce the risk of the truck rolling. 7. If traffic is heavy near the disabled machine, mark the truck with warning flags during day- light hours or use flares at night. Adhere to local regulations.
OM3047 4/08 Operating Instructions - Section 30 Page 30-13 SAFE PARKING PROCEDURES c. Be sure the parking brake applied indicator light in the overhead display panel is illumi- The operator must continue to use safety precau- nated. tions when preparing for parking and stopping the engine. d. Allow the engine to cool gradually by operat- ing at low idle for three to five minutes, or if In the event that the equipment is being used in con- preferred, activate the five minute shutdown secutive shifts, any questionable truck performance delay timer as described on the following the operator may have noticed must be checked by page. maintenance personnel before the truck is released to another operator. 2. Place the rest switch in the ON position to put the AC drive system in rest mode. Be sure the 1. Park the truck on level ground, if possible. If it is rest indicator light in the overhead panel is illu- necessary to park on a grade, the truck must be minated. positioned at right angles to the grade. 3. With the engine cooled down, turn the key 2. Stop the truck using the service brakes. Place switch counterclockwise to the OFF position to the directional control lever in the PARK posi- stop the engine. tion. This will apply the parking brake. Slowly release the service brakes. If the truck starts to If the engine does not turn off with the key roll, apply the service brakes and notify mainte- switch, use the engine stop switch on operator nance personnel immediately. cab center console. Pull the switch up to stop the engine. Push the switch back down to 3. If the truck is stationary with only the parking enable engine operation. brake applied, then place chocks fore/aft of the wheels to reduce the risk of the truck rolling. NOTE: There is also an engine stop switch located at Each truck should be parked at a reasonable at ground level at the right front corner of the truck. distance from other trucks/equipment. 4. Haul roads are not safe parking areas. In an 4. With the key switch OFF and engine stopped, emergency, pick the safest spot most visible to wait at least 90 seconds. Ensure the steering other machines in the area. If the truck circuit is completely bled down by turning the becomes disabled where traffic is heavy, mark steering wheel back and forth several times. No the truck with warning flags in daylight, or flares front wheel movement will occur when hydraulic at night. pressure is relieved. If the front tires continue to steer after the engine is stopped, notify mainte- nance personnel. 5. Verify all link voltage lights are off (one on the NORMAL ENGINE SHUTDOWN back side of the center console inside the oper- PROCEDURE ator cab, two on the electrical cabinet), and notify maintenance personnel if the lights The following procedure should be followed to stop remain illuminated longer than five minutes the engine. after the engine has been stopped. 1. Stop the truck out of the way of other traffic. 6. Close and lock all windows. Remove the key Park on a level surface, free of overhead power from the key switch and lock the cab to prevent lines or other objects that could prevent raising possible unauthorized truck operation. Properly the dump body. dismount the truck. Put wheel chocks in place. a. Reduce engine speed to idle. b. Place the directional control lever in PARK. This will apply the parking brake. Do not apply the wheel brake lock. NOTE: If the truck starts to roll, apply the service brakes and notify maintenance personnel immediately.
Operating Instructions - Section 30 4/08 OM3047 Page 30-14 DELAYED ENGINE SHUTDOWN 5. Turn the key switch counterclockwise to the PROCEDURE OFF position to cause the engine to stop when the timing sequence is complete. When the 1. Stop the truck out of the way of other traffic. engine stops, the hydraulic bleed-down timer Park on a level surface, free of overhead power will activate and the 24 VDC electric circuits will lines or other objects that could prevent raising turn off. the dump body. 6. With the key switch OFF and engine stopped, a. Reduce engine speed to low idle. wait at least 90 seconds. Ensure the steering b. Place the directional control lever in PARK. circuit is completely bled down by turning the This will apply the parking brake. steering wheel back and forth several times. No front wheel movement will occur when hydraulic c. Be sure the parking brake applied indicator pressure is relieved. If the front tires continue to light in the overhead display panel is illumi- steer after the engine has stopped, notify main- nated. tenance personnel. 2. Place the rest switch in the ON position to put 7. Verify all link voltage lights are off (one on the the AC drive system in the rest mode. Be sure back side of the center console inside the oper- the rest indicator light in the overhead panel is ator cab, two on the electrical cabinet), and illuminated. notify maintenance personnel if the lights 3. Refer to Instrument Panel and Indicator Lights remain illuminated longer than five minutes in Section 32 for location of the engine stop after the engine is shut down. switch with five minute idle timer delay. This is a 8. Close and lock all windows. Remove the key 3-position rocker-type switch (OFF-ON- from the key switch and lock the cab to prevent MOMENTARY). possible unauthorized truck operation. Properly 4. Press the top of the engine dismount the truck. Put wheel chocks in place. shutdown switch to select the ON (center) position. Press the top of the switch again to NOTE: To cancel the five minute idle timer activate the timer delay sequence, press the timer delay shutdown switch to (MOMENTARY position). the OFF (lower) position. Release the switch and allow it to return to the ON position. • If the key switch is in the OFF position, the engine will stop. When the engine shutdown timer has been activated, the • If the key switch is in the ON position, the engine timer delay indicator light in will continue to operate. the overhead status panel will If engine does not stop with the key switch, use illuminate to indicate that the engine stop switch on operator cab center console. shutdown timing sequence Pull the switch up to stop the engine. Push the switch has started. The engine will back down to enable engine operation. continue to idle for approximately five minutes to allow for proper engine cool-down before The ground level shutdown switch will also stop the stopping. engine during this time.
OM3047 4/08 Operating Instructions - Section 30 Page 30-15 DISABLED TRUCK DUMPING b. Remove the cap from the hoist pilot valve PROCEDURE relief valve located in the hydraulics compo- nents cabinet behind the cab. While counting Sometimes it is necessary to dump a load from the the number of turns, slowly screw relief valve body of a truck when the hoist system is inoperable. adjustment screw clockwise until it bottoms. The following instructions describe the use of a "good" truck to provide the hydraulic power required 5. Repeat Step 4 to dump the disabled truck. to raise the body of the "disabled" truck to dump the Lowering the Body load. 6. Place the hoist lever of the good truck in FLOAT In the example below, Figure 30-1 illustrates a typical to lower the body. If necessary, momentarily hookup from the good truck. The disabled truck may place the hoist control in POWER UP until the be another Model 830E or a different Komatsu body is able to descend in FLOAT. Do not model. accelerate the engine. Hookup 7. After the body is lowered, stop the engine. Bleed the hydraulic system of pressure and dis- Ensure there is an adequate, clear area to dump the connect the hoses. loaded body. When the good truck is in position, stop 8. Reduce power down relief valve pressure to the engine and allow the hydraulic system to bleed normal on the good truck by turning the adjust- down. Ensure pressure has bled off before connect- ment counterclockwise the same number of ing hoses. turns as required in Step 4 b. 1. With the good truck parked as close as possible 9. Check power down relief pressure per instruc- to the disabled truck, attach a hose from the tions in the shop manual, Section L, Hydraulic power up quick disconnect (3, Figure 30-1) to Check-Out Procedure. the power down circuit of the disabled truck. The hose must be rated to withstand 17 237 10. Check the hydraulic tank oil level. kPa (2500 psi) or greater pressure. NOTE: The power down circuit will use a smaller diameter hose (tube) than the power up circuit. 2. Connect another hose from power down quick disconnect (4) to the power up circuit of the dis- abled truck. NOTE: If both trucks are a model 830E, the hoses will be installed at the quick disconnects shown in Figure 30-1 and will be crossed when connected. Raising the Body 3. On the disabled truck, move the hoist control lever to POWER UP and then release it to place the hoist pilot valve in the HOLD position. Leave in this position during entire procedure. 4. Start the engine on the good truck. Place the FIGURE 30-1. PUMP MODULE, HOSE HOOKUP hoist control in the POWER DOWN position and increase engine rpm to high idle to dump the 1. Hoist Valve disabled truck. If the body of the disabled truck 2. Overcenter Manifold fails to raise, increase the good truck power 3. Power Up Quick Disconnect (Connect to power down relief pressure as follows: down circuit of disabled truck.) a. Stop the engine and allow the hydraulic sys- 4. Power Down Quick Disconnect (Connect to tem to bleed down. power up circuit of disabled truck.)
Operating Instructions - Section 30 4/08 OM3047 Page 30-16 TOWING 4. Inspect the tow bar for adequacy. The bar must be approximately 1.5 times the gross vehicle Prior to towing a truck, many factors must be care- weight of the truck being towed. fully considered. Serious personal injury and/or sig- nificant property damage may result if important 5. Ensure whether the tow vehicle has adequate safety practices, procedures and preparation for capacity to both move and stop the disabled moving heavy equipment are not observed. DO NOT truck under all conditions. tow the truck any faster than 8 kph (5 mph). 6. Block the disabled truck to prevent movement while attaching tow bar. Attachments for towing the 830E are available from Komatsu distributors as follows: 7. Release the disabled truck brakes and remove the blocking. Front Bumper Modification Kit - XK0309: This kit con- 8. Sudden movement may cause tow bar failure. tains the parts necessary to modify the front bumper Smooth, gradual truck movement is preferred. for installation of towing bosses. One XK0309 kit is required for each truck in the fleet. 9. Minimize tow angle at all times - never exceed 30°. The disabled truck must be steered in the Tow Adaptor Structure - MK3945: This structure direction of the tow bar. must be ordered (or designed) to mate with the intended towing vehicle and is intended for towing an unloaded vehicle only. A disabled machine may be towed after the following minimum precautions have been taken. 1. Shut the engine off. 2. If equipped, install hydraulic connections for steering and dumping between the tow vehicle the and disabled vehicle. Check the disabled vehicle braking and steering systems for normal operation. 3. If the disabled truck is loaded, dump the entire load. Never pull or tow a loaded truck.
OM3047 4/08 Operating Instructions - Section 30 Page 30-17 RESERVE ENGINE OIL SYSTEM NOTE: Do not use the oil in the reserve tank to fill the (Optional) engine sump. Both must be at proper level before starting the engine. The reserve oil tank for the engine is designed to add more oil capacity to the engine and to make less fre- 4. The engine oil level must be checked with the quent servicing of the engine oil. The circulation of oil engine dipstick at every shift change. If the oil between the engine sump and reserve tank level in the engine is incorrect, check for proper increases the total volume of working oil. This dilutes operation of the reserve engine oil system. the effects of contamination and loss of additives and The oil level in the reserve tank must also be maintains the oil quality over longer periods. A filter checked at every shift change using the fill cap in the supply circuit protects the pumping unit and dipstick. If necessary, add oil to the reserve prevents transfer of contaminants to the engine tank by using the quick fill system utilizing tank sump which might enter the tank during servicing. It fill valve (3). For filling instructions, refer to Sec- also gives an added level of oil cleanup. tion 40, Lubrication and Service. Operation NOTE: Oil should always be visible in the lower sight gauge. If the tank is equipped with three sight Engine oil is circulated between the engine sump and gauges, oil should always be visible in the middle the reserve tank by two electrically driven pumps sight gauge. within a single pumping unit (11, Figure 30-2). The pump unit is mounted on the side of the reserve tank, and is equipped with an LED monitor light on one side. Pump 1 (in the pump unit) draws oil from the engine sump at a preset control point determined by the height of the suction tube. Oil above this point is with- drawn and transferred to reserve tank (9). This low- ers the level in the engine sump until air is drawn. Air reaching the pumping unit activates pump 2 (in the pump unit) which returns oil from the reserve tank and raises the engine sump level until air is no longer drawn by pump 1. Pump 2 then turns off. The running level is continuously adjusted at the control point by alternation between withdrawal and return of oil at the sump. LED Monitor Light • Steady - Pump 1 is withdrawing oil from the engine sump and bringing down the oil level. • Regular Pulsing - Pump 2 is returning oil to the engine sump and raising the oil level. • Irregular Pulsing - Oil is on the correct operat- ing level. FIGURE 30-2. RESERVE ENGINE OIL SYSTEM 1. Oil Suction 7. Tank Fill Line Changing Oil 2. Oil Tank Fill 8. Fill Cap 1. Drain both the engine sump and the reserve 3. Fill Valve 9. Reserve Oil Tank tank. Refill both the engine and reserve tank 4. Engine Fill Line 10. Engine Fill Line with new oil to proper levels. 5. Oil Level Sensor 11. Pump Unit 2. Change engine and reserve tank filters as 6. Air Valve 12. Sight Gauge required. 13. Tank Return Line 3. Start the engine and check for proper operation.
Operator Cab And Controls - Section 32 4/08 OM3228 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. Horn Button Multi-function turn signal switch (4, Figure 32-2) is Horn (2, Figure 32-2) is actuated by pushing the but- used to activate the turn signal lights, the windshield ton in the center of the steering wheel. Ensure that wipers, and to select either high or low beam head- the horn operates before moving the truck. Observe lights. all local safety rules regarding the use of the horn as a warning signal device before starting the engine Turn Signal Operation and moving the vehicle. Move the lever upward to signal a right turn. An indicator in the top, center of the instrument Tilt / Telescope Lever panel will illuminate to indicate turn direction The steering column can be telescoped or the wheel selected. Refer to Instrument Panel and Indicator tilted with lever (3, Figure 32-2). Lights in this section. Adjust the tilt of the steering wheel by pulling the le- ver toward the steering wheel and moving the wheel Move the lever downward to signal a left to the desired angle. Releasing the lever will lock the turn. wheel in the desired location. NOTE: The turn signal does not automatically Adjust the telescope function by pushing the lever cancel after the turn has been completed. forward to unlock. After positioning as desired, release the lever to the lock position. High Beam Headlight Operation Pulling the lever inward (toward the rear of the cab) changes the headlights to high beam. When the high beams are selected, the indicator in the top center of the instrument panel will illuminate. Moving the switch back to the original position will return the headlights to low beam. Windshield Wiper Operation Windshield Wipers OFF Intermittent - Long Delay Intermittent -Medium Delay Intermittent -Short Delay Low Speed High Speed FIGURE 32-2. STEERING WHEEL & CONTROLS Depressing the button at the end of the 1. Steering Wheel 3. Tilt/Telescope Lever lever will activate the windshield washer. 2. Horn Button 4. Multi-Function Turn Signal Switch
OM3228 4/08 Operator Cab And Controls - Section 32 Page 32-3 PEDALS Dynamic Retard Pedal Service Brake Pedal Dynamic retard pedal (3, Figure 32-1) is a foot oper- ated pedal which allows the operator to slow the The service brake pedal (2, Figure 32-1) is a foot truck and maintain a safe productive speed without operated pedal which applies the service brakes. the use of the service brakes. For normal truck oper- Service brakes should only be applied when dynamic ation, only dynamic retarding should be used to slow retarding requires additional braking force to slow the and control the speed of the truck. The Grade/Speed truck speed quickly. They should also be used to Chart (8, Figure 32-1) should always be followed to bring the truck to a complete stop once the speed is determine MAXIMUM safe truck speeds for descend- less than 4.8 kph (3 mph). ing various grades with a loaded truck. Service brakes should be applied only when dynamic retard- Dynamic Retarding ing requires additional braking force to slow the truck Dynamic retarding is a braking torque (not a brake) speed quickly or to bring the truck to a complete stop. produced through electrical generation by the wheel- When dynamic retarding is in operation, the engine motors when the truck motion (momentum) is the rpm will automatically go to an advance rpm retard propelling force. speed setting (usually 1250 rpm)*. Dynamic retarding For normal truck operation, dynamic retarding will be applied automatically, if the speed of the truck should be used to slow and control truck speed. reaches the predetermined overspeed retard setting. Dynamic Retarding is available in FORWARD/ Dynamic retarding is available in FORWARD/ REVERSE at all truck speeds above 0 kph/mph, but REVERSE at all truck speeds above 0 kph/mph; is available in NEUTRAL only when truck speed is however, as the truck speed slows below 4.8 kph (3 above 4.8 kph (3 mph). mph), the available retarding force may not be effec- tive. Use the service brakes to bring the truck to a complete stop. Dynamic retarding will not hold a stationary truck on an incline.Use the parking brake or wheel brake lock for this purpose. Dynamic retarding is available in NEUTRAL only when truck speed is above 4.8 kph (3 mph). When dynamic retarding is in operation, engine rpm will automatically go to an advance retard speed set- ting. This rpm will vary depending on temperature of several electrical system components. Dynamic retarding will be applied automatically if the speed of the truck obtains the maximum speed set- ting programmed in the control system software. When dynamic retarding is activated, an indicator light in the overhead display will illuminate. The grade/speed retard chart should always be used to determine safe downhill speeds. Refer to Grade/ Speed Retard Chart in this chapter.
Operator Cab And Controls - Section 32 4/08 OM3228 Page 32-4 Throttle/Accelerator Pedal GRADE/SPEED RETARD CHART Throttle/accelerator pedal (4, Figure 32-1), and Grade/speed retard chart (8, Figure 32-1), and shown below, is a foot-operated pedal which allows shown below, provides the recommended MAXI- the operator to control engine rpm depending on MUM retarding limits at various truck speeds and pedal depression. grades with a fully loaded truck. It is used by the operator to request torque from the This decal in the truck may differ from the decal motors when in forward or reverse. In this mode, the below due to optional truck equipment such as: propulsion system controller commands the correct wheel motor drive train ratios, retarder grids, tire engine speed for the power required. In NEUTRAL, sizes, etc. Always refer to this decal in the operator's this pedal controls engine speed directly. cab and follow these recommendations for truck operation. The operator must reference this chart before descending any grade with a loaded truck. Proper use of dynamic retarding will maintain a safe speed. Two speed lists are provided, one for continuous retarding, and the second for short term (approxi- mately three-minute) retarding. Both lists are matched to the truck at maximum Gross Vehicle Weight (GVW). The two ratings are guidelines for proper usage of the retard function on downhill grades.
OM3228 4/08 Operator Cab And Controls - Section 32 Page 32-5 The "short term" numbers listed on the chart indicate The "short term" rating will successfully accommo- the combination of speeds and grades which the date most downhill loaded hauls. It is necessary to vehicle can safely negotiate for a short duration divide haul road grade segment length by allowable before system components reach the maximum speed to determine actual time on grade. If actual allowable temperature during retarding. These time on the grade exceeds the allowable limits, the speeds are faster than the "continuous" values, grade will need to be negotiated at the "continuous" reflecting the thermal capacity of various system speed. components. System components can accept heat- The "continuous" numbers on the chart indicate the ing at a higher-than-continuous rate for a short period combination of speeds and grades which the vehicle of time. Beyond this short duration of time, the sys- can safely negotiate for unlimited time or distance tem would become overheated. during retarding. If the vehicle is operated at "short term" grade and DO NOT exceed these recommended MAXIMUM speed limits for a period of time exceeding thermal speeds when descending grades with a loaded truck. capacity, the Propulsion System Controller (PSC) gradually reduces retarding effort from "short term" to "continuous". The "retard @ continuous" indicator light will illuminate alerting the operator of the retard- ing reduction and the need for a reduction in speed. The operator must use the service brakes to quickly slow the truck to maximum "continuous" retarding limits or less. Do not LIGHTLY apply the service brakes when attempting to slow the truck on a downhill grade. Overheating of the brakes will result. FULLY apply the brakes (within safe limits for road con- ditions) in order to quickly slow the truck to max- imum "continuous" retarding limits or less. NOTE: The "three minute" curve is a MINIMUM; the actual time limit could be greater. Ambient temperature, barometric pressure and recent motor power levels can affect this number.
Operator Cab And Controls - Section 32 4/08 OM3228 Page 32-6 OVERHEAD PANEL AND DISPLAYS Status/Warning Indicator Light Panel The items listed below are located on the overhead Panel (13, Figure 32-1) contains an array of indicator panel. Refer to Figure 32-1 for the location of each lights to provide the operator with important status item. A brief description of each component is docu- messages concerning selected truck functions. Refer mented below. to Instrument Panel and Indicator Lights in this sec- tion for a detailed description of these indicators. Radio Speakers Radio speakers (9, Figure 32-1) for the AM/FM Ste- reo cassette are located at the far left and right of the Air Cleaner Vacuum Gauges overhead panel. Air cleaner vacuum gauges (14, Figure 32-1) provide a continuous reading of the Warning Alarm Buzzer maximum air cleaner restric- Warning alarm buzzer (10, Figure 32-1) will sound tion reached during operation. when activated by any one of several truck functions. The air cleaner(s) should be Refer to Instrument Panel and Indicator Lights in this serviced when the gauge(s) section for a detailed description of functions and shows the maximum recommended restriction of indicators that will activate this alarm. 635 mm (25 in.) of H2O vacuum. NOTE: After service, push the reset button on face of gauge to allow the gauge to return to zero. Cab Radio This panel will normally contain AM/FM Stereo Cas- sette (11, Figure 32-1). Refer to Section 70 for a Windshield Wipers more complete description of the radio and its func- Windshield wipers (15, Figure 32-1) are powered by tions. Individual customers may use this area for an electric motor. Refer to Steering Wheel And Con- other purposes, such as a two-way communications trols in this section for a location and description of radio. the windshield wiper and washer controls. Warning Light Dimmer Control Warning light dimmer control (12, Figure 32-1) per- mits the operator to adjust the brightness of warning indicator lights (13).
OM3228 4/08 Operator Cab And Controls - Section 32 Page 32-7 CENTER CONSOLE Directional Control Lever Directional Control Lever (2, Figure 32-3) is mounted on a console to the right of the operator's seat. It is a four position lever that controls the park, reverse, neutral, and forward motion of the truck. Before mov- ing the directional control lever, apply the service brakes to completely stop the truck. Depress the but- ton on the side to release the detent lock, then move the control lever to the desired position. When the control lever is in the center N position, it is in NEU- TRAL. When the control lever is in the P position, it is in PARK, and the parking brake will be applied. The parking brake is spring applied and hydraulically released. It is designed to hold the truck stationary when the engine is off and the key switch is turned OFF. The truck must be completely stopped before moving the control lever to PARK, or damage may occur to the park brake. When the key switch is ON, and the control lever is in PARK, the parking brake indicator light (A3, overhead panel, Figure 32-8) will be illuminated. FIGURE 32-3. CENTER CONSOLE 1. Center Console 2. Directional Control Lever The directional control lever must be in PARK to 3. Override/Fault Reset Switch start the engine. 4. Engine Stop Switch NOTE: Do not move the directional control lever to 5. L.H. Window Control Switch the PARK position at the shovel or dump. With key 6. R.H. Window Control Switch switch ON and engine on, a sudden shock caused by 7. Hoist Control Lever loading or dumping could cause the system's motion 8. Retarder Speed Control Dial sensor to release the parking brake. 9. RSC Switch 10. Data Store Button The operator can select FORWARD drive by moving 11. VHMS Snapshot In Progress Light the control lever to the F position. 12. Link Energized Light (Red) The operator can select REVERSE drive by moving 13. Service Engine Light (Blue) the control lever to the R position. Do not allow the 14. 12V Auxiliary Power Outlets control lever to travel too far and go into the PARK position when REVERSE is desired. NOTE: The truck must be completely stopped before the control lever is moved to a drive position or into PARK. A GE fault will be recorded if the control lever is placed into the PARK position while the truck is still moving.
Operator Cab And Controls - Section 32 4/08 OM3228 Page 32-8 Override/Fault Reset Switch R.H. Window Control Switch Switch (3, Figure Switch (6, Figure 32-3) is spring-loaded to the OFF 32-3) is spring- position. loaded to the OFF • Pushing the front of the switch raises the right position. When side cab window. pushed in and held, this switch may be • Pushing the rear of the switch lowers the window. used for several functions. 1. This switch permits the operator to override the body-up limit switch and move the truck forward Hoist Control Lever when the directional control lever is in FOR- Hoist control (7, Figure 32-3) is a four position hand- WARD, the dump body is raised, and the operated lever located between the operator seat brakes are released. and the center console (see illustration below). Use of the override switch for this purpose is intended for emergency situations only! 2. The push button deactivates the retard pedal function when speed of truck is below 4.8 kph (3 mph). 3. The override switch is also used to reset an electric system fault when indicated by a red warning light. Refer to Overhead Status/Warn- ing Indicators in this section. Engine Stop Switch Switch (4, Figure 32-3) is used to stop the engine. Pull the switch up to stop the engine. Push the switch back down to Raising The Dump Body enable engine operation. 1. Pull the lever to the rear to actuate hoist circuit. Use this switch to stop the engine if the key switch (Releasing the lever anywhere during "hoist up" should fail to operate, or to stop the engine without will place the body in HOLD at that position.) turning off the 24 VDC electrical circuits. 2. Raise engine rpm to increase hoist speed. A ground level engine stop switch is also located at 3. Reduce engine rpm as the last stage of the the right front corner of the truck. hoist cylinders begin to extend and then let the engine go to low idle as the last stage reaches half-extension. 4. Release hoist lever as the last stage reaches L.H. Window Control Switch full extension. 5. After material being dumped clears the body, Switch (5, Figure 32-3) is spring-loaded to the OFF lower the body to frame. position. Refer to Operating Instructions - Dumping, for more • Pushing the front of the switch raises the left side complete details concerning this control cab window. • Pushing the rear of the switch lowers the window. Lowering The Dump Body Move hoist lever forward to DOWN position and release. Releasing the lever places hoist control valve in the FLOAT position allowing the body to return to frame.
OM3228 4/08 Operator Cab And Controls - Section 32 Page 32-9 Retard Speed Control (RSC) Adjust Dial With RSC switch on and dial adjusted, the system will function as follows: As truck speed increases to Dial (8, Figure 32-3) allows the operator to vary the the "set" speed and throttle pedal released, dynamic downhill truck speed that the retard speed control retarding will apply. As truck speed tries to increase, system will maintain when descending a grade. This the amount of retarding effort will automatically function can be overridden by either the accelerator, adjust to keep the selected speed. When truck speed retard lever, or retard pedal. decreases, the retarding effort is reduced to maintain When the dial is rotated counterclockwise the selected speed. If truck speed continues to toward this symbol, the truck will descend decrease to approximately 4.8 kph (3 mph) below a grade at lower speeds. "set" speed, dynamic retarding will turn off automati- cally. If truck speed must be reduced further, the When the dial is rotated clockwise toward operator can turn the adjust dial to a new setting or this symbol, the truck speed will increase. depress the foot operated retard pedal. If the operator depresses the foot operated retard Always refer to the Grade/Speed Retard Chart in the pedal and the retard effort called for is greater than operator's cab and follow the recommendations for that from the automatic system, the foot pedal retard truck operation. DO NOT exceed these recom- will override RSC. mended MAXIMUM speeds when descending grades with a loaded truck. Throttle pedal position will override RSC setting. If operator depresses throttle pedal to increase truck speed, dynamic retarding will not come on unless truck overspeed setting is reached or foot operated Retard Speed Control (RSC) Switch retard pedal is used. When throttle pedal is released Switch (9, Figure 32-3) turns the system on and off. and RSC switch is on, dynamic retarding will come Push the knob in for OFF and pull the knob out to on at, or above, the RSC dialed speed and will adjust turn the system ON. truck speed to, and maintain, the dialed speed. To adjust RSC control, pull switch (9) ON and start with dial (8) rotated toward fastest speed while driv- ing truck at desired maximum speed. Relax throttle pedal to let truck coast and turn RSC adjusting dial slowly counterclockwise until dynamic retarding is activated. Dynamic retarding will now be activated automatically anytime the "set" speed is reached, the RSC switch is on, and throttle pedal is released.
Operator Cab And Controls - Section 32 4/08 OM3228 Page 32-10 Data Store Button Truck Control Interface (TCI) Diagnostic Port Button (10, Figure 32-3) is for use by qualified main- Diagnostic port (4) is used to access diagnostic infor- tenance personnel to record in memory a “snap-shot” mation for the Truck Control Interface (TCI). of the AC drive system. It will also trigger the VHMS system to store a snap-shot of the truck operating Propulsion System Controller (PSC) system. Light (11, Figure 32-3) will stay illuminated Diagnostic Port while the VHMS system is recording the snap-shot. Diagnostic port (4) is used to access diagnostic infor- mation for the Propulsion System Controller (PSC). VHMS Snapshot In Progress Light Light (11, Figure 32-3) is an indicator that will illumi- Engine Diagnostic Port (CENSE) nate while the VHMS system is in the process of tak- Diagnostic port (6) is a three pin connector used to ing a snapshot of machine data. access diagnostic information for the engine monitor- ing system. Link Energized Light Light (12, Figure 32-3) is a red indictor that, when illu- Engine Diagnostic Port (QUANTUM) minated, indicates that the AC drive system is ener- Diagnostic port (7) is a nine pin connector used to gized. No one is permitted to work on the AC drive access diagnostic information for the engine control system while this light is illuminated. system. Service Engine Light Light (13, Figure 32-3) is a blue indicator that will illu- minate if a problem is detected by the electronic engine monitoring system. Electric propulsion and dynamic retarding will still be available. If this light is ON, notify maintenance personnel so they can diagnose and repair the problem the next time the truck is in the shop for repairs or at the next PM (Preventive Maintenance) interval. DIAGNOSTIC PORTS The diagnostic ports shown in Figure 32-4 are FIGURE 32-4. DIAGNOSTIC PORTS located on the back wall of the cab next to the D.I.D. Panel. 1. VHMS Diagnostic 5. PSC Diagnostic Port Port 6. Engine Diagnostic VHMS Diagnostic Port 2. IM Diagnostic Port Port (CENSE) 3. Payload Meter 7. Engine Diagnostic Diagnostic port (1, Figure 32-4) is used to download Diagnostic Port Port (QUANTUM) truck operation data from the VHMS controller. 4. TCI Diagnostic Port Interface Module (IM) Diagnostic Port Diagnostic port (2) is used to connect the interface module to a computer for installing software. Payload Meter Diagnostic Port Diagnostic port (3) is used to download data from the payload meter system. Refer to Section 60, Payload Meter III, for a more complete description of the pay- load meter and its functions.
OM3228 4/08 Operator Cab And Controls - Section 32 Page 32-11 OPERATOR’S SEAT The operator's seat provides a fully adjustable cush- ioned ride for driver comfort and easy operation. Adjustment The following adjustments must be made while sit- ting in the seat. 1. Headrest: (1, Figure 32-5) will move up, down, fore, or aft by moving headrest to desired posi- tion. 2. Armrests: Rotate adjusting knob until the arm- rest is in the desired position. 3. Backrest: Lift backrest adjustment handle (3) to release and select the backrest angle. Release the control handle to set. 4. Seat Belt: The operator must have seat belt (4) buckled in place and properly adjusted when- ever vehicle is in motion. 5. Seat Slope: Lift seat slope lever (5) and hold to adjust the slope of the seat. Release the lever to lock the adjustment. 6. & 7 Air Lumbar Support: Each rocker switch (6 or 7) controls an air pillow. Switch (7) controls the lower air pillow and switch (6) controls the upper air pillow. To inflate, press on top of the rocker switch and hold for desired support, then release. To deflate, press on the bottom of the rocker switch and hold for desired support, then release. Adjust each pillow for desired support. 8.Seat Suspension: Press rocker switch (8) on top to increase ride firmness. Press on lower part of rocker switch to decrease ride firmness. 9.Fore/Aft Location of Seat: Lift fore and aft lever (9) and hold. Bend knees to move seat to a comfortable position. Release the control lever to lock the adjustment. 12. Seat Height: Lift lever (12) and hold to adjust FIGURE 32-5. OPERATOR’S SEAT ADJUSTMENT the height of the seat. Release the lever to lock CONTROLS the adjustment. 1. Headrest 8. Seat Firmness 2. Armrest Adjustment 9. Fore and Aft Adjust- 3. Backrest Adjustment ment 4. Seat Belt 10. Mounting Hardware 5. Seat Slope Adjust- 11. Seat Tether ment Cap Screw 6. Upper Air Pillow 12. Seat Height Lumbar Support Adjustment 7. Lower Air Pillow Lumbar Support
Operator Cab And Controls - Section 32 4/08 OM3228 Page 32-12 HEATER / AIR CONDITIONER Heater Vents COMPARTMENT AND CONTROLS Each heater/air conditioner vent (4, Figure 32-6) is a The heater/air conditioner compartment contains flapper type which may be opened or closed or heater/air conditioner controls (6, Figure 32-1) and rotated 360° for optimum air flow. There are four some of the heater/air conditioner components, such (three not shown) across the top of the panel, one as the blower motor assembly and heater coils. Opti- each in the right and left panel modules, and four mum cab air climate can be selected by using the fol- below the panel. lowing controls in various combinations. Fan Control Knob Knob (1, Figure 32-6) controls the cab air fan motor.
The fan motor is a 3-speed motor: low (setting 1), medium (setting 2), and high (setting 3). Speeds are selected by rotating the control knob clockwise to the desired position. OFF is full counter-clockwise position (setting 0). Temperature Control Knob Knob (2, Figure 32-6) allows the operator to select a comfortable temperature. • Rotating the knob counterclockwise (blue arrow) will select cooler temperatures. Full counterclockwise position is the coldest air FIGURE 32-6. A/C & HEATER CONTROLS setting. • Rotating the knob clockwise (red arrow) will select warmer temperatures. Full clockwise position is the warmest heater setting. Directional Control Knob Knob (3, Figure 32-6) directs heated air to different areas of the cab. • The full counterclockwise position directs air to the floor vents only. • Turning the knob one position clockwise directs air to both the floor and dash vents. • Turning the knob one more position clockwise directs air to the dash vents only. • Turning the knob one more position clockwise directs air to the windshield defrost vents only. • The full clockwise position directs air to both the floor and windshield defrost vents.
OM3228 4/08 Operator Cab And Controls - Section 32 Page 32-13 INSTRUMENT PANEL This symbol when it appears on an indicator or control identifies Control Symbols that this indicator or control is The operator must understand the function and oper- NOT used. ation of each instrument and control. Many control functions are identified with international symbols that the operator should learn to recognize immedi- ately. This knowledge is essential for proper and safe operation. This symbol identifies a rotary Items that are marked optional do not apply to every control or switch. Rotate the knob truck. clockwise or counterclockwise for The following symbols are general indicators and functions. may appear in multiple locations and combinations on the instrument panel. Most switches have two LED lights inside them, one amber and one green in color. The amber is located This symbol identifies a switch in the top portion of the switch and indicates that used to test or check a function. function has been activated. The green LED is Press the switch on the side near located in the lower portion of the switch and indi- the symbol to perform the test. cates that function has not been activated. • To activate a function, push on the top portion of the switch. At this time, the amber LED will be illuminated, and the green LED will be OFF. • To de-activate a function, push on the lower portion of the switch. At this time, the green LED will be illuminated, and the amber LED will be OFF. NOTE: The green LED light in the hazard light switch, head light switch and the ladder light switch will be illuminated when battery power is connected to the truck. The LED lights in the other switches will illuminate when the key switch is turned to the ON position.
Operator Cab And Controls - Section 32 4/08 OM3228 Page 32-14 FIGURE 32-7. PANEL GAUGES, INDICATORS, AND CONTROLS 1. Key Switch 14. Left Turn Signal Indicator 2. Engine Stop Switch with Timer Delay 15. Water Temperature Gauge 3. Rotating Beacon (Optional) 16. Lamp Check Switch 4. Heated Mirrors (Optional) 17. Headlight/Panel Illumination Light Switch 5. AC Drive System Rest Switch 18. Ladder Light Switch (3-Way) 6. Wheel Brake Lock Switch 19. Backup Light Switch 7. Hazard Lights Switch 20. Fog Light Switch 8. Heater/Air Conditioner Vents 21. Payload Meter Mode Switch 9. Engine Oil Pressure Gauge 22. Panel Illumination Lights Dimmer Control 10. Right Turn Signal Indicator Light 23. Hydraulic Oil Temperature Gauge 11. Digital Tachometer 24. Engine Hourmeter 12. High Beam Headlight Indicator 25. Fuel Level Gauge 13. Speedometer/Payload Meter Display
OM3228 4/08 Operator Cab And Controls - Section 32 Page 32-15 Key Switch Operation Key switch (1, Figure 32-7) is a three-position (OFF, 1. Stop the truck, and reduce engine rpm to low RUN, START) switch. idle. Place the selector switch in PARK. Place the rest switch in the ON position to put the drive system in REST mode of operation. Refer to the discussion of the rest switch later in this chapter. 2. Press the top of the engine shutdown switch to select the ON (center) position. Press the top of the switch again to activate the timer delay (MOMENTARY position). Release the switch and allow it to return to the ON position. When the delay timer has been activated, the timer delay indicator light (C4, Figure 32-8) in the overhead status panel will illuminate to indi- cate that the shutdown timing sequence has started. The engine will continue to idle for approximately five minutes to allow for proper engine cool-down before stopping. Starting 3. Turn the key switch counterclockwise to the OFF position to cause the engine to stop when When the switch is rotated one position clockwise, it the timing sequence is complete. When the is in the RUN position and all electrical circuits engine stops, this will activate the hydraulic except START are activated. bleed-down timer and turn off the 24 VDC elec- 1. With the selector switch in PARK, rotate key tric circuits controlled by the key switch. switch fully clockwise to the START position, NOTE: To cancel the five minute idle timer and hold this position until the engine starts. sequence, press the timer delay switch to the OFF The START position is spring-loaded to return (lower) position. If the key switch is in the OFF to RUN when the key is released. If the engine position, the engine will stop. If the key switch is in is equipped with a prelube system, a noticeable the ON position, the engine will continue to run. delay will occur before engine cranking begins. 4. With key switch OFF, and engine stopped, wait 2. After engine has started, place rest switch (5, at least 90 seconds. Ensure the steering circuit Figure 32-7) in the OFF position, which will de- is completely bled down by turning the steering activate the rest mode of operation. Refer to the wheel back and forth several times. No front discussion of rest switch later in this chapter. wheel movement will occur when hydraulic pressure is relieved. 5. Verify all the link voltage lights turn off within Engine Stop Switch with Five Minute Idle Timer five minutes after the engine is shut down. One Delay is located on the rear of the center console in Switch (2, Figure 32-7) is a three- the cab, two others are located in the access position, rocker type switch with panel at the left front corner of the electrical OFF, ON and MOMENTARY posi- cabinet. If the lights remain on, refer to Section tions. When used, the engine is E in the service manual for additional instruc- allowed to idle for approximately tions and information. five minutes before it stops. The 6. Close and lock all windows. Remove key from delayed shutdown feature allows key switch and lock cab to prevent possible the engine to cool down slowly, unauthorized truck operation. Dismount the reducing internal temperatures as truck properly. coolant is circulated through the engine.
Operator Cab And Controls - Section 32 4/08 OM3228 Page 32-16 Rotating Beacon Light Switch Wheel Brake Lock Control (Optional) Switch (6, Figure 32-7) should be Switch (3, Figure 32-7) controls used when the engine is running dur- the operation of the rotating bea- ing dumping and loading operations con light. only. The brake lock switch actuates the hydraulic brake system which Heated Mirror Switch locks the rear wheel service brakes (Optional) only. When pulling into the shovel or dump area, stop the truck using the Switch (4, Figure 32-7) controls foot-operated service brake pedal. the operation of the heated mir- When the truck is completely rors. stopped and in the loading position, apply the brake lock by pressing on the top of the rocker switch. Rest Switch Move the directional control lever to NEUTRAL. DO Switch (5, Figure 32-7) is a rocker NOT place the control lever in PARK. To release, type switch with a locking device for press the lower part of the rocker switch. the OFF (lower side pressed in) position. There is no LED light to illuminate when this switch is in the OFF position. A small red tab must be pushed up to unlock the switch before the top side can be Do not use this switch to stop the truck unless depressed to the rest position. the foot-operated treadle valve is inoperative. When in the rest (ON) position, an Use of this switch applies rear service brakes at a internal amber lamp will illuminate. The switch should reduced, unmodulated pressure. Do not use the be activated to de-energize the AC drive system brake lock for parking. With the engine stopped, whenever the engine is to be shutdown or parked for hydraulic pressure will bleed down, allowing the a length of time with the engine running. brakes to release. The selector switch must be in PARK and the vehicle not moving to enable this function. This will allow the Use at shovel and dump only to hold the truck in engine to continue running while the AC drive system position is de-energized. Hazard Warning Lights Activation of the rest switch alone DOES NOT Switch (7, Figure 32-7) flashes all completely ensure that the drive system is safe the turn signal lights. Pressing the to work on. Refer to Section 20, Safety, for more top side of the rocker switch acti- information on servicing a 830E truck. Check all vates these lights. When these "link-on", or "link energized", indicator lights to lights are on, a red LED light will be verify the AC drive system is de-engergized illuminated inside the switch. Press- before performing any maintenance on the drive ing on the lower side of the rocker system. DO NOT activate the rest switch while switch turns these lights off, and a the truck is moving! The truck may unintention- green LED light will be illuminated. ally enter the “rest” mode after stopping. An amber (yellow) indicator light Cab/Air Conditioner Vents in the overhead panel (B6, Figure 32-8) will illuminate when the Vents (8, Figure 32-7) may be directed by the opera- "rest" state has been requested tor to provide the most comfortable cabin air flow. and entered.
OM3228 4/08 Operator Cab And Controls - Section 32 Page 32-17 Engine Oil Pressure Gauge Left Turn Signal Indicator Gauge (9, Figure 32-7) indicates pres- Indicator (14, Figure 32-7) illuminates to indicate that sure in the engine lubrication system the left turn signals are operating when the turn sig- in pounds per square inch (psi). nal lever on the steering column is moved downward. Moving the lever to its center position will turn the Normal operating pressure after indicator off. engine warm up should be: Idle - 138 kPa (20 psi) Minimum Rated Speed - 310 - 483 kPa (45 to 70 psi) Water Temperature Gauge Gauge (15, Figure 32-7) indicates the temperature of the coolant in the engine cooling system. The tempera- Right Turn Signal Indicator ture range after engine warm-up and truck operating under normal condi- Indicator (10, Figure 32-7) illuminates to indicate that tions should be: the right turn signals are operating when the turn sig- nal lever on the steering column is moved upward. 85°-97°C (185°-207°F) Moving the lever to its center position will turn the indicator off. Lamp Test Switch Switch (16, Figure 32-7) is pro- vided to allow the operator to test the indicator lamps prior to starting Tachometer the engine. To test the lamps and Tachometer (11, Figure 32-7) displays engine crank- the warning horn, turn key switch shaft speed in revolutions per minute (rpm). (1, Figure 32-7) to the RUN posi- tion and press the top side of the Governed rpm rocker switch for the CHECK posi- Low Idle - 750 rpm tion. All lamps should illuminate except those which are for optional High Idle - 1910 rpm equipment that may not be installed. The warning Full Load - 1900 rpm horn should also sound. Any lamp bulbs which do not illuminate should be replaced before operating the truck. Releasing the spring-loaded switch will allow the switch to return to the OFF position. A green LED will illuminate in both switch positions. High Beam Indicator NOTE: Do not use the lamp check switch while the Indicator (12, Figure 32-7) illuminates to indicate that engine is on. Pressing this switch while the engine is the truck headlights are on high beam. To switch the on will cause false electrical system faults. Warning headlights to high beam, push the turn indicator lever light (D5, Figure 32-8) will illuminate and engine away from the steering wheel. For low beam, pull the shutdown is required to turn it off. lever toward the steering wheel. Light Switch Speedometer/Payload Meter Display The instrument panel lights, clear- Speedometer/payload meter display (13, Figure 32- ance lights, and the headlights are 7) indicates the truck speed in kilometers per hour controlled by this three-position (kph) or in miles per hour (mph). The display also rocker type switch (17, Figure 32- shows payload meter information. For more informa- 7). OFF is selected by pressing the tion, see Section 60, Payload Meter III, in this man- bottom of the switch. Press the top ual. of the switch until it reaches the first detent to select the panel lights, clearance lights and tail lights only. Press the top of the switch again until it reaches the second detent to select head- lights, panel lights, clearance lights and tail lights.
Operator Cab And Controls - Section 32 4/08 OM3228 Page 32-18 Ladder Light Switch Payload Meter Switch Ladder light switch (18, Figure 32-7) Payload meter switch (21, Figure turns the ladder lights on or off. 32-7) is a two-way, momentary Pressing the top of the rocker switch rocker switch. The top position is turns the lights on. Pressing the bot- the SELECT position. The SELECT tom of the switch turns the lights off. position is used to step through the A green LED light will illuminate in different displays. The lower posi- both switch positions. Another ladder tion is the SET position. The SET light switch is mounted at the right position is used to set the operator front corner of the truck near the ID, or clear the load and total ton base of ladder. counters. Refer to Section 60, Payload Meter III, for a more complete description of the payload meter sys- tem and its functions. Manual Backup Switch Manual backup switch (19, Figure Panel Light Dimmer 32-7) allows the backup lights to be turned on for added visibility and Panel light dimmer (22, Figure 32-7) safety when the selector switch is a rheostat which allows the opera- (see Operator Controls) is not in tor to vary the brightness of the REVERSE position. When the instruments and panel lights. switch is in the ON position, the manual back up light indicator (B4, overhead panel, Figure 32-8) will be • Rotating the knob to the full clockwise position illuminated. turns the panel lights on to the brightest condition. • Rotating the knob counterclockwise continually dims the lights until OFF position is reached at full counterclockwise rotation. Fog Lights (Optional) Fog lights (20, Figure 32-7) are optional equipment that are useful in foggy conditions and heavy rain. Pressing the top of the rocker switch turns the fog lights on. Pressing the bottom of the switch turns the lights off.
OM3228 4/08 Operator Cab And Controls - Section 32 Page 32-19 Hydraulic Oil Temperature Gauge Hourmeter Hydraulic oil temperature gauge (23, Hourmeter (24, Figure 32-7) registers Figure 32-7) indicates oil tempera- the total number of hours the engine ture in the hydraulic tank. There are has been in operation. two colored bands: green and red. Green indicates normal operation. As the needle approaches the red zone, minimum engine idle speed will increase to help cool the oil. Red indicates high oil temperature in the hydraulic Fuel Level Gauge tank. Continued operation could damage compo- Fuel level gauge (25, Figure 32-7) nents in the hydraulic system. There is also a red indicates how much diesel fuel is in temperature warning light in the overhead panel (A1, the fuel tank. Figure 32-8) that will illuminate when the temperature exceeds a certain level (when the needle enters the The fuel tank capacity is 4542 liters red zone). If this condition occurs, the operator (1200 gallons). should safely stop the truck, move selector switch to PARK, and operate engine at 1200 - 1500 rpm to reduce system temperature. If temperature gauge does not move into the green range after a few minutes, and the red overhead indicator light does not go out, stop the engine and notify maintenance personnel imme- diately.
Operator Cab And Controls - Section 32 4/08 OM3228 Page 32-20 OVERHEAD STATUS / WARNING INDICATORS FIGURE 32-8. OVERHEAD STATUS / WARNING INDICATOR Row / Indicator Indicator Color Row / Indicator Indicator Color Column Description Wire Index Column Description Wire Index A1* Hydraulic Oil Temp. High Red-24VIM/34TL A5 No Propel/ No Retard Red-12M/75-6P1 B1* Low Steering Pressure Red-12F/33A B5 Propulsion System Amber-12F/79WI C1 Low Accumulator Press. Red-12F/33K Warning D1 Not Used C5 Propulsion System Amber -12F/34TW1 Temperature E1 Low Brake Pressure Red-12F/33L D5 System/Component Red-24VIM/311MLI A2* Low Hydraulic Oil Level Red-12F4/34LL Failure B2* Low Automatic Amber-12MD8/ E5 Battery Charge System Red-24VIM/11BCF1 Lubrication Pressure 68LLP Failure C2* Circuit Breaker Tripped Amber-12MD3/31CB A6 NO PROPEL Red-12M/75NPI D2* Hydraulic Oil Filter Amber-12MD/39 B6 Propulsion System @ Amber-12M/72PR1 E2* Low Fuel Amber-24VIM/38 Rest A3* Park Brake Applied Amber-24VIM/52AL C6* Propulsion System Not Amber-12MD/72NR1 B3* Service Brake Applied Amber-12MD/44L Ready C3* Body Up Amber-12MD6/63L D6* Reduced Propulsion Amber-12MD/72LP1 System D3* Dynamic Retarding Amber-12MD/44DL E6* Retard @ Reduced Level Amber-12MD/76LR1 E3 Stop Engine Red-12M/31MT * Brightness for these indicator lamps can be A4* Starter Failure Amber-21SL/24VIM adjusted by using dimmer control (12, Figure 32-1). B4* Manual Back-Up Lights Amber-12MD/47L C4* 5 Min. Shutdown Timer Amber-12MD/23L1 D4* Retard Speed Control Amber-12MD/31R E4* Check Engine Amber-12MD7/419
OM3228 4/08 Operator Cab And Controls - Section 32 Page 32-21 Status / Warning Indicator Light Symbols B1. Low Steering Pressure Amber indicator lights alert the operator that the indi- When the key switch is turned cated truck function requires some precaution when ON, the low steering pressure lighted. warning light will illuminate until the steering system hydraulic Red indicator lights alert the operator that the indi- pressure reaches 15 858 kPa cated truck function requires immediate action by (2300 psi). The warning alarm the operator. Safely stop the truck and turn the will also turn on, and both will remain on, until the engine off. accumulator has been filled with hydraulic oil. DO NOT OPERATE THE TRUCK WITH A RED During truck operation, the low steering pressure WARNING LIGHT ILLUMINATED! warning light and warning horn will turn on if the Refer to Figure 32-8 and the descriptions below it for steering system hydraulic pressure drops below explanations of the symbols. Location of the symbols 15 858 kPa (2300 psi). are described by rows (A - E) and columns (1 - 6). • If the light illuminates momentarily (flickers) while turning the steering wheel while at low truck speed and low engine rpm, truck operation may A1. High Hydraulic Oil Temperature continue. This may be considered normal. • If the indicator light illuminates at higher truck This red warning light indicates speed and high engine rpm, DO NOT OPERATE high oil temperature in the THE TRUCK. hydraulic tank. Continued opera- tion could damage components in the hydraulic system. The light illuminates at 107°C (225°F) If the low steering warning light continues to illu- If this condition occurs, the operator should safely minate and the alarm continues to sound, low stop the truck, move selector switch to PARK, and steering pressure is indicated. The remaining operate engine at 1200 - 1500 rpm to reduce system pressure in the accumulators allows the operator temperature. to control the truck to a stop. If the oil pressure continues to decrease, the brake auto-apply fea- ture will activate and the service brakes will apply automatically to stop the truck. Do not attempt further operation until the malfunction is located and corrected. If temperature gauge does not move into the green range after a few minutes, and the red overhead indicator light does not go out, stop the 1. Stop the truck as quickly as possible by using engine and notify maintenance personnel imme- the foot pedal to apply the service brakes. If diately. possible, steer the truck to the side of the road while braking. 2. When stopped, shift the directional control lever to PARK. This will apply the parking brake. 3. Turn the key switch OFF and notify mainte- nance personnel. 4. If safe to do so, place wheel chocks in front or behind the wheels so that truck can not roll. 5. If traffic is excessive near the disabled machine, mark the truck with warning flags during day- light hours or use flares at night. Adhere to local regulations.
Operator Cab And Controls - Section 32 4/08 OM3228 Page 32-22 C1. Low Accumulator Pre- A2. Low Hydraulic Tank Level charge Pressure This warning light indicates the The low accumulator precharge oil level in the hydraulic tank is warning light, if illuminated, indi- below recommended level. Dam- cates low nitrogen precharge for age to hydraulic pumps may the steering accumulator(s). To occur if operation continues. check for proper accumulator Stop the truck and turn the nitrogen precharge, the engine must be stopped and engine off. Notify maintenance personnel immedi- the hydraulic system completely bled down. Turn the ately. key switch to the RUN position. The warning light will not illuminate if the accumulators are properly charged. The warning light will flash if the nitrogen precharge within the accumulator(s) is below 7585 ± 310 kPa (1100 ± 45 psi). B2. Automatic Lubrication Sys- tem Pressure This amber light will illuminate if the automatic lubrication system fails to reach 13 790 kPa (2,000 If the low accumulator precharge warning light psi) at the junction block located flashes, notify maintenance personnel immedi- on the rear axle housing within a ately. Do not attempt further operation until the specified time after the lube timer initiates a cycle of accumulators have been recharged with nitro- grease. To turn the light off, turn key switch OFF, gen. Refer to the shop manual for proper charg- then back to ON again. Notify maintenance person- ing instructions. If nitrogen precharge pressure nel at earliest opportunity after light comes on. is low, sufficient oil for emergency steering may not be available. D1. Not Used C2. Circuit Breaker Tripped This light is reserved for future use. This amber light will illuminate if any of the circuit breakers in the relay circuit control boards are tripped. The relay circuit boards are located in the electrical con- trol cabinet. E1. Low Brake Pressure This red indicator light indicates a malfunction within the hydraulic brake circuit. If this light illumi- D2. Hydraulic Oil Filter Monitor nates and the buzzer sounds, This amber light indicates a stop the truck, shift to PARK, restriction in the high pressure fil- and turn the engine off. Notify ter assembly for either the steer- maintenance personnel. ing or hoist circuit. This light will NOTE: Adequate hydraulic fluid is stored to allow the illuminate before filters start to operator to safely stop the truck. bypass. Notify maintenance per- sonnel at earliest opportunity after the light illumi- nates. NOTE: The filter monitor warning light may also illuminate after the engine is initially started if the oil is cold. If the light turns off after the oil is warmed, filter maintenance is not required.
OM3228 4/08 Operator Cab And Controls - Section 32 Page 32-23 E2. Low Fuel E3. Stop Engine This amber low fuel indicator This red engine monitor warning light wil illuminate when the light will illuminate if a serious usable fuel remaining in the tank engine malfunction is detected is approximately 95 liters (25 gal- in the electronic engine control lons). A warning buzzer will also system. sound. • Electric propulsion to the wheelmotors will be discontinued. • Dynamic retarding will still be available if needed to slow or stop the truck. A3. Parking Brake This amber parking brake indi- cator will illuminate when the parking brake is applied. Do not Stop the truck as quickly as possible in a safe attempt to drive the truck with area and shift to PARK. TURN THE ENGINE OFF the parking brake applied. IMMEDIATELY. Additional engine damage is likely to occur if operation is continued. B3. Service Brake Listed below are a few conditions that could cause the stop engine light to illuminate: This amber service brake indi- cator light will illuminate when
• Low Oil Pressure - red warning light will illuminate, but the engine does not stop. the service brake pedal is applied or when wheel brake • Low Coolant Level - red warning light will lock is applied. Do not attempt illuminate, but the engine does not stop. to drive the truck from stopped • Low Coolant Pressure - red warning light will position with the service brakes applied, except as illuminate, but the engine does not stop. noted in Section 30, Operating Instructions - Starting On A Grade With A Loaded Truck. • High Coolant Temperature - red warning light will illuminate, but the engine does not stop. C3. Body Up A4. Cranking Motor Failure This amber body up indicator, This amber indicator will illumi- when illuminated, indicates that nate when either starter motor the body is not completely down (of two) fails to crank the engine, on the frame. The truck should leaving just one cranking motor not be driven until body is down to start the engine. With only one and the light is off. cranking motor doing the work of two, the motor life will be shortened. If this indicator illuminates, truck operation may continue, but main- D3. Dynamic Retarding tenance personnel should be alerted as soon as pos- This amber dynamic retarding sible. indicator light illuminates when- ever the retarder pedal is oper- ated, RSC is activated, or the automatic overspeed retarding circuit is energized. It indicates that the dynamic retarding function of the truck is being used.
Operator Cab And Controls - Section 32 4/08 OM3228 Page 32-24 B4. Manual Backup Lights A5. No Power This amber indicator will illumi- This red “no retard/no propel” nate when the manually oper- indicator light indicates a fault ated manual backup light switch has occurred which has elimi- (19, Figure 32-7) is turned ON. nated the retarding and propul- sion capability. A warning buzzer will also sound. If this condition occurs, the operator should safely C4. Engine Shutdown Timer - 5 stop the truck, move selector switch to PARK, shut- Minute Idle down the engine, and notify maintenance personnel immediately. When the engine shutdown timer switch has been activated (2, Figure 32-7), this indicator light will illuminate to indicate that the shutdown timing sequence has B5. Propulsion System Warn- started. Information detailing the operation of this ing switch is outlined earlier in this section. When this amber indicator is illuminated, the light indicates a “no propel” or “no retard” event may be about to occur. It is D4. Retard Speed Control intended to provide advance (RSC) Indicator notice of these events when possible. It does not require the operator to stop the This amber light is illuminated truck, but may suggest that truck operation be appro- when the RSC switch mounted priately modified, in case a red alarm does occur. on the console is pulled out to the ON position. The light indi- cates the retarder is active. It is for feedback only and does not signal a problem. C5. Propulsion System Tem- perature This amber AC drive system E4. Check Engine temperature warning light indi- cates the drive system tempera- This amber check engine indica- ture is above a certain level. tor will illuminate if a malfunction When this condition occurs, the is detected by the engine elec- operator should consider modifying truck operation in tronic control system. order to reduce system temperature. The operator is If this indicator illuminates, truck not required to stop the truck at this time. operation may continue, but maintenance personnel should be alerted as soon as possible. D5. System/Component Fail- ure This red warning light indicates that the interface module system detected a failure somewhere on the truck. There are many condi- tions that could trigger the light to illuminate. If this light illuminates, the operator should safely stop the truck, move selector switch to PARK, shut the engine off, and notify maintenance personnel immediately.
OM3228 4/08 Operator Cab And Controls - Section 32 Page 32-25 E5. Battery Charging System C6. Propel System Not Ready Failure The amber indicator light func- The red battery charging system tions during start-up much like light indicates a problem has the hour glass icon on a com- been detected in the charging puter screen. This light indicates system, and system voltage is at the computer is in the process or below 24.0 volts. If this light of performing the self-diagnos- illuminates, the operator should safely stop the truck, tics and set-up functions at start-up. Propulsion will move selector switch to PARK, shut the engine off, not be available at this time. and notify maintenance personnel immediately. If truck operation continues, and the battery voltage drops below 20.0 volts, the propulsion system will not operate, but retarding will still be available. D6. Reduced Propulsion The amber “reduced propulsion” light is used to indicate that the full AC drive system performance A6. No Propel in propulsion is not available. At The red “no propel” light indi- this time, the only event that cates a fault has occurred which should activate this light is the has eliminated the propulsion use of “limp home mode”. This mode of operation capability. If this condition requires a technician to enable. occurs, the operator should safely stop the truck, move selec- tor switch to PARK, shut down the engine, and notify maintenance personnel, immediately. E6. Retard At Continuous Level The amber retard at continuous level light indicates that the B6. Propel System @ Rest retarding effort is at the continu- The amber “propel system @ ous level. The operator should rest” light is used to indicate that control the speed of the truck in the AC drive system is de-ener- accordance to the "continuous" speeds on the gized and propulsion is not avail- GRADE/SPEED RETARD CHART on page 32-4. able. This light is activated when the instrument panel rest switch is turned ON and the AC drive system is de-ener- gized. The three link energized lights (one on rear of the center console inside the operator cab, and two on the deck-mounted control cabinets) should NOT be illuminated at this time.
Operator Cab And Controls - Section 32 4/08 OM3228 Page 32-26 VEHICLE HEALTH MONITORING During normal truck operation, the red LED digits on SYSTEM (VHMS) the VHMS controller will count from 00-99 continu- ously. Operation When the key switch is turned OFF, the VHMS con- This system uses VHMS controller (2, Figure 32-10) troller will remain on while it finishes processing inter- to gather data about the operation of the truck from nal data and saves the recent data into permanent sensors and other controllers installed on the truck. memory. When the data has been safely stored, the The data stored in the VHMS controller is collected two digit LED display will turn OFF. This process by a laptop personal computer (PC) or transmitted could take up to three minutes to complete. directly by communications satellite (utilizing the Orb- comm controller). This data is then compiled at the Komatsu computer server. Based on this information, the servicing Komatsu distributor will suggest If 24V power is disconnected (using the battery improvements and provide information aimed at disconnect switches) from the VHMS controller reducing machine repair costs and downtime. before it has completed it’s shut down proce- dure, the VHMS controller will lose all data gath- When the data-store button (1, Figure 32-9) is ered since the key switch was last turned ON. Do pressed on the back side of the center console, it will not disconnect battery power until the VHMS store a “snapshot” of the Statex III drive system. It controller has completed the shut down proce- will also trigger the VHMS system to store a “snap- dure and has turned the LED digits off. shot” of the truck operating system. A light (2, Figure 32-9) will stay illuminated while the VHMS system is recording the “snapshot”, which lasts for 7.5 minutes. The VHMS system is turned on by the truck key switch. Immediately after receiving 24V power from the key switch, the VHMS controller begins the power-up initialization sequence. This sequence takes about three seconds, during which time the red LED digits (4, Figure 32-10) display a circular sequence of flashing LED segments. FIGURE 32-10. VHMS COMPONENT LOCATION 1. Orbcomm Controller 4. Red LED Lights FIGURE 32-9. CENTER CONSOLE, REAR VIEW 2. VHMS Controller 5. Green LED Light 3. Interface Module 1. Data Store Button 2. VHMS Snapshot In Progress Light
OM3228 4/08 Operator Cab And Controls - Section 32 Page 32-27 The Orbcomm controller (1, Figure 32-10) transmits Basic Precautions data through antenna (1, Figure 32-11) mounted on When using this truck, there is no particular need to top of the cab. The antenna coaxial cable is routed operate the VHMS system. through the inside of the cab to protect it from dam- age. If the antenna or coaxial cable is damaged, Never disassemble, repair, or modify the VHMS sys- replace the parts. tem. This may cause failure or fire on the machine or this system. Do not touch the system when operating the machine. Do not pull on the wiring harnesses, connectors. or sensors of this system. This may cause short circuits or disconnections that lead to failure or fire on the machine or this system. Do not get water, dirt or oil on the system controllers. If there is any abnormality with the VHMS system, please consult the servicing Komatsu distributor. FIGURE 32-11. ORBCOMM 1. Orbcomm Antenna 2. Magnetic Base Interface Module Interface module (3, Figure 32-10) receives data from the sensors installed on the truck and sends this FIGURE 32-12. DIAGNOSTIC PORTS information to the VHMS controller. There is a smal (D.I.D. PANEL AT REAR OF CAB) green LED light on the face of the controller. With the 1. IM Diagnostic Port key switch ON, the light should be blinking. If the light 2. VHMS Diagnostic Port is continuously illuminated, there is a problem in the controller. When a new interface module controller is installed on the truck, new software has to be installed inside the controller. IM-Diag connector (1, Figure 32-12) is used to connect the interface module to a laptop PC for installing software.
Operator Cab And Controls - Section 32 4/08 OM3228 Page 32-28 FUSE BLOCK #1 LOCATION AMPS DEVICES(S) PROTECTED CIRCUIT 1 15 A/C, Heater Blower Motor 12H 2 15 Windshield Washer / Wiper 63 3 5 Instrument Panel Gauges 712G 4 10 Key Switch Power 712P 5 10 Hoist Limit Solenoid 712H 6 15 Turn Signal / Clearance Lights 712T 7 10 Engine Options 712E 8 10 AID and Indicator Lights 12M 9 5 Engine Start Failure 712SF 10 10 Engine Shutters 712R 11 10 Dome Light Switch 712A 13 10 Radio Memory 65 17 15 Key Switch Supplemental Power 11KS 18 15 Payload Meter Lights 39J 19 5 Payload Meter System 39G FUSE BLOCK #2 LOCATION AMPS DEVICES(S) PROTECTED CIRCUIT 1 15 Service Lights 11SL 2 15 Cab Dome, Fog, Ladder Lights 11L 3 15 Hazard Lights 46 4 10 Interface Module 11INT 5 10 VHMS & Orbcomm Controllers 85 6 20 Modular Mining System 11M 7 15 VHMS & Orbcomm Battery 11DISP 8 15 Headlights 11HDL 9 15 Oil Reserve System Pump 11ORS 10 15 Oil Reserve System Control 11RCNT 11 20 Hydraulic Bleed Down 11BD 12 10 Engine Load 11EM 13 10 Key Switch Power 11KS 17 20 Engine Battery Power 11E1 18 20 Engine Battery Power 11E2 19 20 Engine Battery Power 11E3 20 20 Engine Battery Power 11E4
Operator Cab And Controls - Section 32 4/08 OM3228 Page 32-30 CIRCUIT BREAKERS AMPS DEVICES(S) PROTECTED CIRCUIT LOCATION CBA 5 Pay Load Meter III 396 Auxiliary Control Cabinet CBB 15 Pay Load Meter III 11S Auxiliary Control Cabinet CB13 12.5 Clearance Lights 46 RB1, Auxiliary Control Cabinet CB14 12.5 Turn Signal Flasher 11Z RB1, Auxiliary Control Cabinet CB15 12.5 Tail Lights 41T RB1, Auxiliary Control Cabinet CB16 12.5 Retard Lights 44D RB3, Auxiliary Control Cabinet CB17 12.5 Manual Back-Up Lights 47B RB3, Auxiliary Control Cabinet CB18 12.5 Stop Lights 44A RB3, Auxiliary Control Cabinet CB19 12.5 Backup Lights and Horn 79A RB3, Auxiliary Control Cabinet CB11 12.5 Backup Horn and Lights 79A RB3, Auxiliary Control Cabinet CB20 12.5 Engine Control Power 23D RB4, Auxiliary Control Cabinet CB21 12.5 Service Lights, Horn, Solenoid 11A RB4, Auxiliary Control Cabinet CB22 12.5 Engine Run Relay 439E RB4, Auxiliary Control Cabinet CB23 12.5 Headlights, Left Low Beam 11DL RB5, Auxiliary Control Cabinet CB24 12.5 Headlights, Right Low Beam 11DR RB5, Auxiliary Control Cabinet CB25 12.5 Headlights, Left High Beam 11HL RB5, Auxiliary Control Cabinet CB26 12.5 Headlights Right High Beam 11HR RB5, Auxiliary Control Cabinet CB27 12.5 Headlights and Dash Lights 11D RB5, Auxiliary Control Cabinet CB60 50 12VDC Power Supply 11CB2 Battery Control Box CB61 15 Battery Monitor Relay 11C1 Battery Control Box
OM4048 1/08 Lubrication & Service - Section 40 Page 40-1 LUBRICATION AND SERVICE Recommended preventive maintenance will contrib- HYDRAULIC TANK SERVICE ute to the long life and dependability of the truck and its components. The use of proper lubricants and the There are two sight gauges on the side of the performance of checks and adjustments at the rec- hydraulic tank. With the engine stopped, key switch ommended intervals is most important. OFF, hydraulic system bled down and body down, oil should be visible in the top sight gauge. If hydraulic Lubrication requirements are referenced to the lube oil is not visible in the top sight gauge, follow Adding key found in the Lubrication Chart (page 40-3). For Oil instructions below. detailed service requirements for specific compo- nents, refer to the service manual section for that Adding Oil component (i.e. Section H for suspensions, Section L for hydraulic system, etc.). Keep the system open to the atmosphere only as long as absolutely necessary to lessen the chances Refer to the manufacturer's service manual when of system contamination. servicing any components of the General Electric system. Service the tank with clean Type C-4 hydraulic oil only. All oil being put into the hydraulic tank must be Refer to the engine manufacturer's service manual filtered through filters rated at three microns. when servicing the engine or any of its components. 1. With the engine stopped, key switch OFF, hydraulic system bled down and body down, The service intervals presented here are in hours of check to see that hydraulic oil is visible in the operation. These intervals are recommended in top sight gauge. lieu of an oil analysis program which may deter- mine different intervals. However, if the truck is 2. If hydraulic oil is not visible in the top sight being operated under extreme conditions, some or gauge, remove the tank fill cap. Add clean, fil- all, of the intervals may need to be shortened and the tered C-4 hydraulic oil (Lubrication Chart, Lube service performed more frequently. Key “B”) until oil is visible in the top sight gauge. 3. Install the fill cap. The 830E truck is equipped with an automatic lubri- 4. Start the engine. Raise and lower the dump cation system. The initial setup for this system pro- body three times. vides for nominal amounts of lubricant to be delivered to each serviced point. The lubrication 5. Repeat Steps 1 through 4 until oil is maintained injectors can be adjusted to vary the amount of lubri- in the top sight gauge with engine stopped, cant delivered. In addition, the timer for lubrication body down, and hydraulic system bled down. intervals is normally adjustable. For adjustments to these devices, refer to Automatic Lubrication System later in this manual. WHEEL MOTOR SERVICE 830E SERVICE CAPACITIES Due to differences in gear ratio and component evo- lution/design, wheel motor service intervals may be Crankcase: Liters U.S. unit number and/or mine specific. Because of the (including 4 oil filters) Gallons wide variety of factors involved, it is necessary to Komatsu SDA16V160 or consult your area Komatsu representative for al 280 74 SSDA16V160 Engines wheel motor service intervals and instructions. Gen- eral intervals for oil service and sampling are listed in Cooling System: 568 150 the interval charts. Komatsu SDA16V160 or SSDA16V160 Engine Hydraulic System: 947 250 Refer to “Hydraulic Tank Service” Wheel Motor Gear Box 38 10 (each side) Fuel Tank (Diesel Fuel Only) 4542 1200
Lubrication & Service - Section 40 1/08 OM4048 Page 40-2 COOLANT LEVEL CHECK RESERVE ENGINE OIL SYSTEM (Optional) Inspect the coolant sight gauge. If coolant cannot be seen in the sight gauge, it is necessary to add cool- The reserve oil tank for the engine is designed to add ant to the system before truck operation. Refer to the more oil capacity to the engine to reduce the frequent procedure below for the proper filling procedure. servicing of the engine oil. The engine oil level must still be checked every shift using the dipstick. If RADIATOR FILLING PROCEDURE engine oil level is not correct, check for proper opera- tion of the reserve oil system. Never add oil to the engine unless it has been drained. If the engine oil has been drained from the oil pan, the new oil must be added to the engine oil pan The cooling system is pressurized due to thermal before starting. DO NOT use the oil in the reserve expansion of coolant. DO NOT remove the radia- tank to fill an empty engine with oil. After an oil tor cap while the engine and coolant are hot. change, both the engine and reserve tank must be Severe burns may result. full of oil before starting the engine. 1. With the engine and coolant at ambient temper- ature, remove the radiator cap. Reserve Oil Tank Filling Procedure (Remote fill) NOTE: If coolant is added using the Wiggins quick fill 1. Connect the pressure supply hose from the system, the radiator cap MUST be removed prior to new oil supply to the quick coupler on the truck. adding coolant. Open valve on supply hose to apply pressure. 2. Fill the radiator with the proper coolant mixture 2. Pull out on switch (2, Figure 40-1) to turn the (as specified by the engine manufacturer) until system on. coolant is visible in the sight gauge. 3. Push start switch (3). The VALVE OPEN light 3. Install the radiator cap. (5) should illuminate and the filling process will begin. 4. Operate the engine for five minutes. Check the coolant level. 4. When tank is full, the VALVE OPEN light will turn off and FULL light (4) will illuminate. 5. If coolant is not visible in the sight gauge, repeat Steps 1 through 4. Any excess coolant 5. Close the oil supply valve in the fill hose. will be discharged through the vent hose after 6. Press and hold start switch (3) for a couple of the engine reaches normal operating tempera- seconds. ture. 7. Disconnect the new oil supply hose. Engine coolant must always be visible in the sight 8. Push switch (2) in to turn system power OFF. gauge before truck operation. COOLING SYSTEM ANTI-FREEZE RECOMMENDATIONS (Ethylene Glycol Permanent Type Anti-Freeze) Percentage of Protection Anti-Freeze To: 10 + 23° F - 5° C 20 + 16° F - 9° C 25 + 11° F - 11° C 30 + 4° F - 16° C 35 - 3° F - 19° C 40 - 12° F - 24° C 45 - 23° F - 30° C 50 - 34° F - 36° C 55 - 48° F - 44° C FIGURE 40-1. CONTROL PANEL 60 - 62° F - 52° C Use only anti-freeze that is compatible with engine as 1. Remote Control Box 4. “FULL” Light specified by engine manufacturer. 2. System Switch 5. “VALVE OPEN” 3. Start Switch Light
Lubrication & Service - Section 40 1/08 OM4048 Page 40-4 10 HOUR (DAILY) INSPECTION Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS 1. MACHINE - Inspect the entire machine for leaks, worn parts, and damage. Repair as necessary. 2. FAN DRIVE AND TURBOCHARGERS - Check for leaks, vibration or unusual noise. Check alternator and fan belt condition and alignment. 3. RADIATOR - Check the coolant level and fill with the proper mixture as shown in the Cooling System Rec- ommendation Chart in this chapter. Refer to the engine manual for proper coolant additives. 4. ENGINE - a. Check the oil level on the dipstick. Refer to the engine manual for oil recommendations. (Lube Key “A”). NOTE: If the truck is equipped with a reserve engine oil tank, check the oil level with the reserve tank dipstick. If necessary, add oil to the reserve tank. Also, with the engine running, check operation of the LED indicator light. See below for description of LED light signals. Refer to Figure 40-1. LED Light Signals: • Steady - Pump 1 is withdrawing oil from the engine sump and bringing down the oil level. • Regular pulsing - Pump 2 is returning oil to the engine sump and raising the oil level. • Irregular pulsing - Oil is at the correct operating level. b. Inspect exhaust piping for integrity. c. Check for abnormal noises and fluid leaks. d. Eliminator Filter - Check operating indicator. 5. HYDRAULIC TANK - Check the oil level in the tank. Add oil if necessary. Refer to Hydraulic Tank Service - Adding Oil. Oil should be visible in the top sight glass. - DO NOT overfill. Lube Key “B”. 6. WHEELS AND TIRES - a. Inspect tires for proper inflation and wear. b. Check for embedded debris in tread and remove. c. Inspect for damaged, loose, or missing wheel mounting nuts and studs.
OM4048 1/08 Lubrication & Service - Section 40 Page 40-5 10 HOUR (DAILY) INSPECTION (Continued) Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS 7. COOLING AIR DUCTWORK - Inspect ductwork from the blower to the rear drive case. Ensure that duct- work is secure, free of damage, and unrestricted. 8. AIR INTAKE PIPING - Check all mounting hardware, joints, and connections. Ensure no air leaks exist and all hardware is properly tightened. Figure 40-2. 9. AIR CLEANERS - Check the air cleaner vacuum gauges in the operator cab, Figure 40-3. The air cleaner(s) must be serviced if the gauge(s) shows the following maximum restriction: Komatsu SDA16V160 or SSDA16V160 Engines: . . . . . . . . . . . . . . . . . . . . . . . . 25 in. of H2O vacuum. Refer to Section C in the shop manual for servicing instructions for the air cleaner elements. Empty the air cleaner dust caps. NOTE: After service, push the reset button on face of gauge to allow the gauge to return to zero. 10. CAB AIR FILTER - Under normal operating condi- tions, clean every 250 hours. In extremely dusty con- ditions, service as frequently as required. Clean the filter element with mild soap and water. Rinse com- pletely clean and air dry with a maximum of 275 kPa (40 psi). Reinstall the filter. Refer to Figure 40-4. FIGURE 40-2. FIGURE 40-3. FIGURE 40-4. 1. Filter Cover 2. Cab Filter
Lubrication & Service - Section 40 1/08 OM4048 Page 40-6 10 HOUR (DAILY) INSPECTION (Continued) Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS 11. FUEL FILTERS (Fuel Separators) - Drain water from the bottom drain valve on each fuel separator. 12. AUTOMATIC LUBE SYSTEM - • Check the grease reservoir; fill as required. Lube Key “D”. • When filling the reservoir, check the grease filter indicator. Clean or replace the grease filter if the indicator detects a problem.
• Inspect the system and check for proper operation. Ensure the following important areas are receiving adequate amounts of grease. Lube Key “D”. Steering Linkage Final Drive Pivot Pin Rear Suspension Pin Joints - Upper & Lower Body Hinge Pins - Both Sides Hoist Cylinders Pins - Upper & Lower Anti-sway Bar - Both Ends
OM4048 1/08 Lubrication & Service - Section 40 Page 40-7 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 - Change the fuel filters, (fuel separators). Refer to engine manufacturer's maintenance manual for fuel filter replacement instructions. *2. HYDRAULIC SYSTEM FILTERS - Replace filter ele- ments only, after the initial 50, 100, and 250 hours of operation; then at each 500 hours of operation there- after. *3 FAN DRIVE ASSEMBLY - Check torque for the six fan mounting cap screws: 237 N·m (175 ft lbs). See Figure 40-5. *These checks are required only after the initial 50 hours of operation (such as: the commissioning of a new truck, or after a new or rebuilt component installation). FIGURE 40-5.
Lubrication & Service - Section 40 1/08 OM4048 Page 40-8 100 HOUR LUBRICATION AND MAINTENANCE CHECKS Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS *1. HYDRAULIC SYSTEM FILTERS - Replace filter ele- ments only, after the initial 100 and 250 hours of operation; then at each 500 hours of operation there- after. *These checks are required only after the initial 100 hours of operation (such as: the commissioning of a new truck, or after a new or rebuilt component installation), check:
OM4048 1/08 Lubrication & Service - Section 40 Page 40-9 250 HOUR LUBRICATION AND MAINTENANCE CHECKS The 10 hour lubrication and maintenance checks should also be performed at this time. NOTE: “Lube Key” references are to the lubrication chart. Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS 1. ENGINE - Refer to the engine manufacturer’s Opera- tion & Maintenance manual for complete specifica- tions regarding engine lube oil specifications. NOTE: If the engine is equipped with the *Centinel™ oil system and/or the Eliminator™ filter system, engine oil and filter change intervals are extended beyond 250 hours. Refer to engine Operation & Maintenance manual for specific oil and filter change intervals. * The Centinel™ system is a duty-cycle-dependent lubrication management system whereby oil is blended with the fuel and burned and an extension of oil change intervals can occur. a. Change engine oil. Lube Key “A”. b. Replace engine oil filters. NOTE: When installing spin-on filter elements, follow the instructions as specified by the filter manufacturer. The tightening instructions are normally printed on the outside of the filter. Do not use a wrench or strap to tighten filter elements. c. If the truck is equipped with a reserve engine oil tank, change the reserve tank oil filter. d. Check belt tension and condition of each accessory belt. Refer to engine Operation & Maintenance manual for specific adjustment instructions. e. Check the torque on the cooling fan mounting cap screws (1, Figure 40-5). Tighten cap screws (2) to 237 N·m (175 ft lbs). (CONTINUED NEXT PAGE)
Lubrication & Service - Section 40 1/08 OM4048 Page 40-10 250 HOUR LUBRICATION AND MAINTENANCE (Continued) TASK COMMENTS CHECKED INITIALS 2. COOLING SYSTEM - a. COOLANT MIXTURE - Check for proper coolant mixture. Add coolant as required. b. COOLANT FILTERS - Change coolant filters. c. COOLING SYSTEM HOSES - Check cooling system hoses for damage and signs of deteri- oration. Refer to the engine maintenance manual for coolant filter replacement instructions and proper coolant mix- ture instructions. 3. FUEL FILTERS - Change the fuel filters (fuel separa- tors). Refer to engine Operation & Maintenance man- ual for specific filter replacement instructions. 4. FUEL TANK - Drain water and sediment from the fuel tank. Refer to Shop Manual, Section B, Fuel Tank - Cleaning. 5. STEERING LINKAGE - Check the torque on pin retaining nuts (1, Figure 40-6) on the steering linkage - 712 N·m (525 ft lbs). Check the torque on tie rod retaining nuts (2) - 420 N·m (310 ft lbs). 6. HYDRAULIC PUMP DRIVESHAFT & U-JOINTS - Add one or two applications of grease to each grease fitting. Non - moly grease only. Check that each bear- ing of the cross & bearing assembly is receiving grease. Replace bearings if any wear is detected. 7. CAB AIR FILTER - Under normal operating condi- tions, clean every 250 hours. In extremely dusty con- ditions, service as frequently as required. Clean the filter element with mild soap and water. Rinse com- pletely clean and air dry with a maximum of 275 kPa (40 psi). Reinstall the filter. Refer to Figure 40-4.
OM4048 1/08 Lubrication & Service - Section 40 Page 40-11 250 HOUR LUBRICATION AND MAINTENANCE (Continued) TASK COMMENTS CHECKED INITIALS 8. MOTORIZED WHEEL GEAR CASE - Refer to the G.E. Planned Maintenance Manual and specific motorized wheel shop manual. Check for correct oil level. Lube key “C”. *9. HYDRAULIC SYSTEM FILTERS - Replace filter ele- ments only after the initial 250 hours of operation; then at each 500 hours of operation thereafter. Check oil level. Add oil as necessary. Lube Key “B”. 10. BATTERIES - Check the electrolyte level and add water if necessary. 11. BODY-UP & HOIST LIMIT SWITCHES - Check oper- ation of the switches. Clean the sensing areas of any dirt accumulation and inspect the wiring for any signs of damage. 12. WHEEL MOTOR BLOWER (If equipped) - Grease motor blower shaft bearings. Lube key “D”. 13. G.E. PREFILTER BLOWER (If equipped) - Add one to two applications of grease to the grease fitting. Lube key “D”. 14. AC DRIVE BELT - Check the belt for wear or damage. Verify the belt tension is correctly set. Ensure the pulleys are aligned with each other within 3 mm (0.13 in.). 15. AUTOMATIC LUBE SYSTEM - Perform 250 hour checks as outlined in Automatic Lubrication System, Section 42, in this manual. 16. FRONT WHEELS - Check the oil level. Position the fill plug at the 12 o’clock position. The floating ball in the sight gauge must be at its highest position. Add oil as necessary. Lube key E. *This check is required only after the first 250 hours of operation (such as: the commissioning of a new truck, or after a new or rebuilt component installation), check:
Lubrication & Service - Section 40 1/08 OM4048 Page 40-12 500 HOUR LUBRICATION AND MAINTENANCE CHECKS Maintenance requirements for every 10 & 250 hour Lubrication and Maintenance Checks should also be per- formed at this time. NOTE: “Lube Key” references are to the lubrication chart. Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS 1. FINAL DRIVE CASE BREATHERS - Remove the breather elements for the motorized wheels. Clean or replace the elements. 2. HYDRAULIC SYSTEM FILTERS - Replace the tank breathers and high pressure filter elements. Check the oil level. Add oil as necessary. Lube Key “B”. 3. HYDRAULIC TANK BREATHER - Replace breather. 4. HYDRAIR® SUSPENSION - Check for proper piston extension (front and rear). Refer to Section H4 in the service manual for more information on proper sus- pension extension and maintenance procedures. 5. THROTTLE AND BRAKE PEDAL - Lubricate the trea- dle roller and hinge pins with lubricating oil. Lift the boot from the mounting plate and apply a few drops of lubricating oil between the mounting plate and the plunger. 6. HOIST ACTUATOR LINKAGE - Check operation. Clean, lubricate, and adjust as necessary. 7. PARKING BRAKE - Refer to Section J, Parking Brake Maintenance. Perform the recommended inspections. 8. RESERVE ENGINE OIL SYSTEM (OPTION) a. Check electrical system connections for tight- ness, corrosion and physical damage. Check the battery, oil pressure switch, junction boxes, remote control fill box and the circuit breakers. b. Examine all electrical cables over their entire length for possible damage. c. Examine all hoses, including those on the reserve tank and the ones leading to and from the engine. Check for leaks, cracks or other damage. Check all fittings for tightness, leakage or damage. 9. ACCUMULATOR PRECHARGE - Check all steering and brake system accumulator pre-charge pressures. Refer to shop manual for details.
OM4048 1/08 Lubrication & Service - Section 40 Page 40-13 500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued) Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS 10. WHEEL MOTOR OIL SAMPLING - Refer to Section G5, Wheel Motor, for oil sampling information. 11. WHEEL MOTOR OIL (Initial 500 hours only) - Change or filter wheel motor gear oil only after initial 500 hours or operation. Wheel motor gear oil must be filtered or changed every 2500 hours of operation thereafter. 12. VHMS DATA DOWNLOAD - Using a laptop PC with the VHMS Technical Analysis Tool Box program, per- form a data download from the VHMS controller. Send the data to WebCARE using the FTP feature. Refer to Section D in the shop manual for more detailed instructions. 13. FRONT BRAKE DISC - Measure the thickness of the disc. If 20 to 25% of the disc wear surface is worn below 28.7 (1.13 in.), the disc must be replaced. Refer to the shop manual, Parking Brake, Section J, for additional information. 14. FRONT WHEELS - Take an oil sample of the front wheel bearing oil. Refer to Section G in this shop manual for detailed instructions.
Lubrication & Service - Section 40 1/08 OM4048 Page 40-14 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS Maintenance for every 10, 250, & 500 hour Lubrication and Maintenance Checks should also be performed at this time. NOTE: “Lube Key” references are to the lubrication chart.
Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS 1. HYDRAULIC TANK - Drain the hydraulic tank and clean the inlet strainer. Refill the tank with new oil; approximate capacity 901 l (238 gal). Use Lube Key “B”. NOTE: Oil change interval can be extended to 2,500 hours if oil is sampled at every 250 hour intervals and no abnormalities are detected. 2. RADIATOR - Clean the cooling system with a quality cleaning compound. Flush with water. Refill the sys- tem with anti-freeze and water solution. Check the Cooling System Recommendation Chart in this sec- tion for the correct mixture. Refer to the engine manu- facturer’s Operation and Maintenance Manual for the correct additive mixture. 3. FUEL TANK - Remove the breather and clean in sol- vent. Dry with pressurized air and reinstall. 4. OPERATOR'S SEAT - Apply grease to the slide rails. Lube Key “D”. 5. AUTOMATIC BRAKE APPLICATION - Ensure the brakes are automatically applied when brake pres- sure decreases below the specified limit. Refer to the appropriate Shop Manual, Section J, Brake Check- out Procedure. 6. FRONT ENGINE MOUNT TRUNION - Add one or two applications of grease at fitting. Lube key “D”. 7. AUTOMATIC LUBE SYSTEM PUMP - Check pump housing oil level. Refill to bottom of level plug with SAE 10W-30 motor oil. 8. ELIMINATOR FILTER - Clean and check centrifuge. Refer to engine manufacture’s Operation & Mainte- nance Manual. (Service interval is dependent on duty cycle, oil quality, etc.)
OM4048 1/08 Lubrication & Service - Section 40 Page 40-15 2500 HOUR MAINTENANCE CHECKS Maintenance for every 10, 250, & 500 hour Lubrication and Maintenance Checks should also be performed at this time. NOTE: “Lube Key” references are to the lubrication chart. Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS 1. WHEEL MOTOR GEAR OIL - Wheel motor gear oil must be replaced every 2500 hours of operation. Refer to G.E. Motorized Wheel Service & Mainte- nance manual. 2. FRONT WHEELS - Drain and refill with oil. Refer to Section G in this manual for detailed instructions on changing the oil. Lube key “E”. NOTE: Oil may need to be changed more frequently, depending on mine conditions and the results of the oil sample tests. 5000 HOUR MAINTENANCE CHECKS Maintenance for every 10, 250, 500 1,000 & 2,500 hour Lubrication and Maintenance Checks should also be per- formed at this time. NOTE: “Lube Key” references are to the lubrication chart. Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS 1. AIR CLEANERS - Clean the Donaclone tubes in the pre-cleaner section of the air filter. Use low pressure cold water or low pressure air to clean the tubes. Refer to Section C, Air Cleaners. NOTE: Do not use a hot pressure washer or high pressure air to clean the tubes. Hot water/high pres- sure causes the pre-cleaner tubes to distort. 2. FRONT WHEELS - If oil sampling is done every 500 hours - And the con- tamination trends are not rising, do not replace the wheel bearings. Refer to Section G of the service manual for more detailed instructions on oil sampling. If oil samples are not taken - Drain oil and completely disassemble the front wheel bearings and check all parts for wear or damage. Refer to Section G of the service manual for disassembly and assembly proce- dures. Refill with oil. Check the oil level at the oil level plug on wheel hub. Lube key “E”.
Lubrication & Service - Section 40 1/08 OM4048 Page 40-16 10,000 HOUR MAINTENANCE CHECKS Maintenance for every 10, 250, 500, 1,000, 2,500 & 5000 hour Lubrication and Maintenance Checks should also be performed at this time. NOTE: “Lube Key” references are to the lubrication chart. Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS 1. WHEEL MOTORS - Clean the area around the grease ports to prevent dirt or other contaminates from entering. Remove the six grease port plugs on each wheel motor. Grease the inboard and outboard wheel hub bearings with one 14 oz. cartridge per each grease port.
OM4209 11/07 Automatic Lubrication System - Section 42 Page 42-1 AUTOMATIC LUBRICATION SYSTEM GENERAL DESCRIPTION During the down stroke, the pump cylinder is The automatic lubrication system is a pressurized extended into the grease. Through the combination lubricant delivery system which delivers a controlled of shovel action and vacuum generated in the pump amount of lubricant to designated lube points. The cylinder chamber, the grease is forced into the pump system is controlled by an electronic timer which cylinder. Simultaneously, grease is discharged signals a solenoid valve to operate a hydraulic motor through the outlet of the pump. The volume of grease powered grease pump. Hydraulic oil for pump during intake is twice the amount of grease output operation is supplied by the truck steering circuit. during one cycle. During the upstroke, the inlet check valve closes. One half the grease taken in during the Grease output is proportional to the hydraulic motor previous stroke is transferred through the outlet input flow. A pump control manifold, mounted on top check and discharged to the outlet port. of the hydraulic motor, controls input flow and pressure. A 24VDC solenoid mounted on the manifold turns the pump on and off. The pump is driven by the rotary motion of the Over-pressurizing of the system, modifying hydraulic motor, which is then converted to parts, using incompatible chemicals and fluids, reciprocating motion through an eccentric crank or using worn or damaged parts, may result in mechanism. The reciprocating action causes the equipment damage and/or serious personal pump cylinder to move up and down. The pump is a injury. positive displacement, double-acting type as grease output occurs on both the up and the down stroke. • DO NOT exceed the stated maximum working pressure of the pump, or of the lowest rated component in the system. • Do not alter or modify any part of this system unless approved by the factory. • Do not attempt to repair or disassemble the equipment while the system is pressurized. • Make sure all fluid connections are securely tightened before using this equipment.
• Always read and follow the fluid manufacturer's recommendations regarding fluid compatibility, and the use of protective clothing and equipment. • Check all equipment regularly and repair, or replace, worn or damaged parts immediately. This equipment generates very high grease pressure. Extreme caution must be used when operating this equipment as material leaks from loose or ruptured components can inject fluid through the skin and into the body causing serious bodily injury including possible need for amputation. Adequate protection is FIGURE 42-1. PUMP & RESERVOIR recommended to prevent splashing of material 1. Hose From Filter 7. Vent Valve onto skin or into the eyes. 2. Outlet to Injectors 8. Pressure Gauge If any fluid appears to penetrate the skin, get 3. Hydraulic Motor 9. Pump Assembly emergency medical care immediately! Do not 4. Pressure Reducing 10. Flow Control Valve treat as a simple cut. Tell attending physician Valve 11. Pressure Switch exactly what fluid was injected. 5. Solenoid Valve 12. Grease Reservoir 6. Override Switch 13. Vent Hose
Automatic Lubrication System - Section 42 11/07 OM4209 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. L.H. Suspension, Bottom Bearing 13. R.H. Anti-Sway Bar Bearing 2. L.H. Hoist Cylinder, Top Bearing 14. R.H. Suspension, Top Bearing 3. L.H. Hoist Cylinder, Bottom Bearing 15. Truck Frame 4. L.H. Anti-Sway Bar Bearing 16. Vent Hose 5. L.H. Suspension, Top Bearing 17. Pipe Plug (Oil Level) 6. L.H. Body Pivot Pin 18. Pressure Switch, N.O., 17,237 kPa (2500 psi) 7. R.H. Body Pivot Pin 19. Grease Pump 8. Grease Supply From Pump 20. Vent Valve 9. R.H. Suspension, Bottom Bearing 21. Filter 10. R.H. Hoist Cylinder, Top Bearing 22. Grease Supply to Injectors 11. R.H. Hoist Cylinder, Bottom Bearing 23. Injectors 12. Rear Axle Pivot Pin 24. Pressure Switch, N.O., 13,790 kPa (2000 psi)
OM4209 11/07 Automatic Lubrication System - Section 42 Page 42-3 SYSTEM COMPONENTS Solenoid Valve Filter Solenoid valve (5, Figure 42-1), when energized, allows oil to flow to the hydraulic motor. Filter assembly (21, Figure 42-2) mounted on the grease reservoir filters the grease prior to refilling the Vent Valve reservoir from the shop supply. A bypass indicator alerts service personnel when the filter requires With vent valve (7, Figure 42-1) closed, the pump replacement. continues to operate until maximum grease pressure is achieved. As this occurs, the vent valve opens and Hydraulic Motor and Pump allows the grease pressure to drop to zero, so the injectors can recharge for their next output cycle. Rotary hydraulic pump (3 & 9, Figure 42-1) is a fully hydraulically operated grease pump. An integrated Lubrication Cycle Timer pump control manifold is incorporated with the motor to control input flow and pressure. The solid state lubrication cycle timer provides a 24 VDC timed-interval signal to energize solenoid valve NOTE: The pump crankcase oil level must be (3, Figure 42-3) providing oil flow to operate the maintained to the level of the pipe plug (17, Figure grease pump motor. This timer is mounted in the 42-2). If necessary, refill with 10W-30 motor oil. Electrical Interface Cabinet. Pump Cutoff Pressure Switch Pressure switch (18, Figure 42-2) is a normally open switch set at 17,237 kPa (2500 psi). This switch de- energizes the pump solenoid relay when the grease Hydraulic oil supply inlet pressure must not line pressure reaches the switch pressure setting, exceed 20,685 kPa (3000 psi). Exceeding the turning off the motor and pump. rated pressure may result in damage to the sys- tem components and personal injury. Grease Pressure Failure Switch Pressure switch (24, Figure 42-2) is a normally open switch set at 13,789 kPa (2000 psi). This switch Grease Reservoir monitors grease pressure in the injector bank on the rear axle housing. If the proper pressure is not Reservoir (12, Figure 42-1) has an approximate sensed within 60 seconds (switch contacts do not capacity of 41 kg (90 lbs.) of grease. When the close) a warning lamp circuit to notify the operator a grease supply is replenished by filling the system at problem exists in the lube system. the service center, the grease is passed through the filter to remove contaminants before it flows into the Pressure Gauge reservoir. Pressure gauge (8, Figure 42-1) monitors hydraulic Pressure Reducing Valve oil pressure to the inlet of the hydraulic motor. Pressure reducing valve (4, Figure 42-1), located on Injectors the manifold reduces the hydraulic supply pressure (from the truck steering circuit) to a suitable operating Each injector (23, Figure 42-2) delivers a controlled pressure of 2241 - 2413 kPa (325 - 350 psi) for the amount of pressurized lubricant to a designated lube hydraulic motor used to drive the lubricant pump. point. Refer to Figure 42-2 for locations. Flow Control Valve Flow control valve (10, Figure 42-1) mounted on the manifold, controls the amount of oil flow to the hydraulic motor. The flow control valve has been factory adjusted and the setting should not be disturbed.
Automatic Lubrication System - Section 42 11/07 OM4209 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, 1. During truck operation, the lubrication cycle removing power from the hydraulic motor/pump timer will energize the system at a preset time solenoid and the pump will stop. The relay will interval. remain energized until grease pressure drops 2. The timer provides 24 VDC to energize (pressure switch opens again) and the timer solenoid valve (3, Figure 42-3), allowing turns off. hydraulic oil provided by the truck steering 7. After the pump solenoid valve is de-energized, pump circuit to flow to the pump motor and hydraulic pressure in the manifold drops and initiate a pumping cycle. vent valve (11, Figure 42-3) will open, releasing 3. The hydraulic oil pressure from the steering grease pressure in the lines to the injector circuit is reduced to 2241 - 2413 kPa (325 - 350 banks. When this occurs, the injectors are then psi) by pressure reducing valve (4) before able to recharge for the next lubrication cycle. entering the motor. In addition, the amount of oil 8. The system will remain at rest until the supplied to the pump is limited by flow control lubrication cycle timer turns on and initiates a valve (6). Pump pressure can be read using new grease cycle. pressure gauge (5) mounted on the manifold. 9. During the normal lubrication cycle, if grease 4. With oil flowing into the hydraulic motor, the pressure fails to reach 13,790 kPa (2000 psi) at grease pump will operate, pumping grease from the pressure switch located on the rear axle the reservoir to injectors (13), through check housing, an amber indicator light will illuminate valve (10), and to vent valve (11). on the overhead panel. 5. During this period, the injectors will meter the appropriate amount of grease to each lubrication point. FIGURE 42-3. HYDRAULIC SCHEMATIC 1. Hydraulic Oil Return 6. Flow Control Valve 11. Vent Valve 2. Hydraulic Oil Supply 7. Hydraulic Motor 12. Orifice 3. Solenoid Valve 8. Grease Pump 13. Injector Bank 4. Pressure Reducing Valve 9. Pressure Switch (N.O.) 5. Pressure Gauge 10. Check Valve
OM4209 11/07 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) - Use NLGI No. 2 multipurpose grease (MPG). • -32° to 32°C (-25° to 90°F) - Use NLGI No. 1 multipurpose grease (MPG). • Below -32°C (-25°F) - Refer to local supplier for extreme cold weather lubricant requirements. System Priming The system must be full of grease and free of air pockets to function properly. After maintenance, if the primary or secondary lubrication lines were replaced, it will be necessary to prime the system to eject all entrapped air. 1. Fill lube reservoir with lubricant, if necessary. 2. To purge air from the main supply line, remove the main supply line at the grease canister. Connect an external grease supply to the line. 3. Remove plugs from each injector group in sequence (right front, left front, and rear axle). 4. Using the external grease source, pump grease until grease appears at the group of injectors and re-install the pipe plug. Repeat for remaining injector groups. 5. Remove the caps from each injector and connect an external grease supply to the zerk on the injector and pump until grease appears at the far end of the individual grease hose or FIGURE 42-4. FILTER ASSEMBLY the joint being greased. 1. Housing 6. Spring 2. Bypass Indicator 7. Bowl 3. O-Ring 8. O-Ring Filter Assembly 4. Backup Ring 9. Plug Filter assembly element (5, Figure 42-4) must be 5. Element replaced if bypass indicator (2) shows excessive element restriction.
Automatic Lubrication System - Section 42 11/07 OM4209 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 1000 hour intervals. To add oil, remove pipe plug (4, Figure 42-5) and fill housing to bottom of plug hole. Pump Pressure Control High pressure hydraulic fluid from the truck steering system is reduced to 2240 - 2413 kPa (325 - 350 psi) by the pressure reducing valve located on the manifold on top of the pump motor. This pressure can be read on the gauge installed on the manifold and should be checked occasionally to verify pressure is within the above limits. Pressure Control Valve Adjustment 1. With the truck engine on, activate override FIGURE 42-5. PUMP CONTROLS switch (2, Figure 42-5) to start the hydraulic 1. Pump Pressure Control 4. Oil Level Plug motor and pump. 2. Override Switch 5. Flow Control Valve 2. Loosen the locknut on pressure control (1, 3. Pressure Gauge Figure 42-5) by turning the nut counterclockwise. 3. Turn the valve stem counterclockwise until it no longer turns. (The valve stem will unscrew until it reaches the stop - it will not come off.) NOTE: This is the minimum pressure setting, which is approximately 1172 kPa (170 psi). 4. With the pump stalled against pressure, turn the pressure control valve stem clockwise until 2240 - 2413 kPa (325 - 350 psi) is attained on manifold pressure gauge (3). 5. Tighten the locknut to lock the stem in position. NOTE: Flow control valve (5) is factory adjusted to 9.5 lpm (2.5 gpm). Do not change this setting.
OM4209 11/07 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 fit- ting to allow the use of external lubricating equipment. • Injector output volume: Maximum output = . . . . . . 1.31 cc (0.08 in3). Minimum output = . . . . . . 0.13 cc (0.008 in3). • Operating Pressure: Minimum - . . . . . . . . . 12,755 kPa (1850 psi) Maximum - . . . . . . . . . 24,133 kPa (3500 psi) Recommended - . . . . 17,238 kPa (2500 psi) • Maximum Vent Pressure - (Recharge) . . . . . . . . . . . . . . . . . . . 4137 kPa (600 psi) Injector Adjustment The injectors may be adjusted to supply from 0.13 - FIGURE 42-6. TYPE SL-1 INJECTOR 1.31 cc (0.008 - 0.08 in3) of lubricant per injection 1. Adjusting Screw 11. Spring Seat cycle. The injector piston travel distance determines 2. Locknut 12. Plunger the amount of lubricant supplied. This travel is in turn 3. Piston Stop Plug 13. Viton Packing controlled by an adjusting screw in the top of the 4. Gasket 14. Inlet Disc injector housing. 5. Washer 15. Viton Packing Turn adjusting screw (1, Figure 42-6) 6. Viton O-Ring 16. Washer counterclockwise to increase lubricant amount 7. Injector Body Assy. 17. Gasket delivered and clockwise to decrease the lubricant 8. Piston Assembly 18. Adapter Bolt amount. 9. Fitting Assembly 19. Adapter 10. Plunger Spring 20. Viton Packing When the injector is not pressurized, maximum injector delivery volume is attained by turning the NOTE: The piston assembly (8) has a visible adjusting screw (1) fully counterclockwise until the indicator pin at the top of the assembly to verify indicating pin just touches the adjusting screw. At the injector operation. maximum delivery point, about 9.7 mm (0.38 inch) adjusting screw threads should be showing. Decrease the delivered lubricant amount by turning the adjusting screw clockwise to limit injector piston travel. If only half the lubricant is needed, turn the adjusting screw to the point where about 4.8 mm (0.19 inch) threads are showing. The injector will be set at minimum delivery point with about 0.22 mm (0.009 inch) thread showing. NOTE: The above information concerns adjustment of injector delivery volume. The timer adjustment should also be changed, if overall lubricant delivery is too little or too much. Injector output should NOT be adjusted to less than one-fourth capacity.
Automatic Lubrication System - Section 42 11/07 OM4209 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 (1) above the injector piston (2). STAGE 2. When the slide valve (5) uncovers the passage (4), lubricant (6) is admitted to the measuring chamber (1) above the injector piston (2) which forces lu- bricant from the discharge chamber (3) through the outlet port (7) to the bearing. STAGE 3. As the injector piston (2) completes its stroke, it pushes the slide valve (5) past the passage (4), cutting off further admission of lubricant (6) to the pas- sage (4) and measuring chamber (1). The injector piston (2) and slide valve (5) remain in this position until lubri- cant pressure in the supply line (6) is vented. STAGE 4. After venting, the injector spring ex- pands, causing the slide valve (5) to move, so that the passage (4) and discharge chamber (3) are connected by a valve port (8). Further expansion of the spring causes the piston to move upward, forcing the lubricant in the measuring chamber (1) through the passage (4) and valve port (8) to refill the discharge chamber (3). Injector is now ready for the next cycle.
OM4209 11/07 Automatic Lubrication System - Section 42 Page 42-9 PREVENTIVE MAINTENANCE PROCEDURES 4. Inspect all bearing points for a bead of lubricant Use the following maintenance procedures to ensure around the bearing seal. proper system operation. It is good practice to manually lube each bear- ing point at the grease fitting provided on each Daily Lubrication System Inspection Injector. This will indicate if there are any frozen 1. Check grease reservoir level. or plugged bearings, and will help flush the Inspect grease level height after each shift of bearings of contaminants. operation. Grease usage should be consistent 5. System Checkout from day-to-day operations. a. Remove all SL-1 injector cover caps to allow Lack of lubricant usage would indicate an inop- visual inspection of the injector cycle erative system. Excessive usage would indicate indicator pins during system operation. a broken supply line. b. Start truck engine. 2. Check filter bypass indicator when filling reservoir. Replace element if bypassing. c. Actuate override switch (6, Figure 42-1). The 3. Check all grease hoses from the SL-1 Injectors hydraulic motor and grease pump should to the lubrication points. operate. a. Repair or replace all damaged feed line d. With the grease under pressure, check each hoses. SL-1 injector assembly. The cycle indicator pin should be retracted b. Ensure that all air is purged and all new feed inside the injector body. line hoses are filled with grease before sending the truck back into service. e. When the system attains 17,237 kPa (2500 psi), the pump should shut off and the 4. Inspect key lubrication points for a bead of pressure in the system should drop to zero, lubricant around seal. If a lubrication point venting back to the grease reservoir. appears dry, troubleshoot and repair problem. f. With the system vented, check all of the SL-1 250 Hour Inspection injector indicator pins; all of the pins should be visible. Replace or repair injectors, if 1. Check all grease hoses from the SL-1 Injectors defective. to the lubrication points (see Figure 42-2). g. Reinstall all injector cover caps. a. Repair or replace all worn / broken hoses. h. Check timer operation. b. Ensure that all air is purged and all new feed line hoses are filled with grease before NOTE: With the engine on, the lube system should sending the truck back into service. activate within five minutes. The system should build 2. Check all grease supply line hoses from the 13,790 - 17,237 kPa (2000 - 2500 psi) within 25-40 pump to the SL-1 injectors. seconds. a. Repair or replace all worn / broken supply i. If the system is working properly, the lines. machine is ready for operation. b. Ensure that all air is purged and all new j. If the system is malfunctioning, refer to the supply line hoses are filled with grease troubleshooting chart. before sending the truck back into service. 3. Check grease reservoir level. 1000 Hour Inspection a. Fill reservoir if low. Check filter bypass indicator when filling reservoir. Replace 1. Check pump housing oil level. Refill to bottom element if bypassing. of level plug with SAE 10W-30 motor oil if necessary b. Check reservoir for contaminants. Clean, if required. c. Check that all filler plugs, covers and breather vents on the reservoir are intact and free of contaminants.
Automatic Lubrication System - Section 42 11/07 OM4209 Page 42-10 SYSTEM CHECKOUT The third dip switch is for selecting the units for the To check system operation (not including timer), “off time” to be used in conjunction with off time proceed as follows: switch (1). Hours or minutes may be selected. 1. Start the engine. The fourth dip switch is used to select “memory off” or “memory on”. When the switch is set to “memory 2. Actuate the test switch at the reservoir/pump off”, a lube cycle will occur each time power is turned assembly. on. The lube cycle will start at the beginning of the on 3. The motor and pump should operate until the time setting. system attains 17,237 kPa (2500 psi). When the switch is set to “memory on”, the controller 4. Once the required pressure is achieved, the will function as follows: pump motor should turn off and the system should vent. 1. When power is turned off during ‘off time’ 5. Check for pump, hose or injector damage or (between cycles), the lube cycle will resume at leakage with the system under pressure. the point of interruption after power is restored. In other words, the controller will remember its 6. After checking system, stop the engine. position in the cycle. Observing normal precautions regarding high voltage present in the propulsion system before 2. When power is turned off during ‘on time’ attempting to repair lube system. (during a cycle), the controller will reset to the beginning of the lube cycle after power is Lubrication Controller Check restored. Pressing the manual lube button on the enclosure cover will initiate a lube event (see Figure 42-7). Off time switch (1) is used to select units of time. Possible time intervals are: 0.5, 1, 2, 4, 8, 15, 24 or Lubrication Controller Operation 30. The mode switch determines whether the off time The time between lube events is determined by the units will be minutes or hours. setting of the rotary switch, which selects the Cover (3) contains three LED windows and a manual numeral setting, and the dip switch, which selects the lube switch. The LEDs indicate system operation and units in either minutes or hours. status. When power is on, a green LED will Lubrication Controller Components illuminate. When the pump is on, another green LED will illuminate. A red LED will illuminate when an Mode switch (2, Figure 42-7) consists of four dip alarm condition occurs. switches. The first dip switch controls the maximum amount of “on time”, either 30 seconds or 120 seconds. Lubrication Controller Adjustment The second dip switch controls the mode, either The lubrication controller is factory adjusted to the timer mode or controller mode. When the switch is following switch settings: set to the timer mode, the amount of time that the pump is on will be determined by the setting of the Dip Switch 1 - 120 SEC dip switch (30 seconds or 120 seconds). When the Dip Switch 2 - TIMER switch is set to the controller mode, a pressure switch must be installed in the lube supply line. The Dip Switch 3 - MINUTES pressure switch will detect supply line pressure, and Dip Switch 4 - MEMORY OFF will reset the timer at a set pressure. If the pump fails to reach the set pressure within the dip switch setting Rotary Switch - 15 minutes (30 seconds or 120 seconds), the controller will initiate an alarm.
OM4209 11/07 Automatic Lubrication System - Section 42 Page 42-11 FIGURE 42-7. LUBRICATION CYCLE TIMER 1. Off Time Switch 3. Cover 2. Mode Switch
Automatic Lubrication System - Section 42 11/07 OM4209 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. Electrical power loss. Locate cause of power loss and repair. 24 VDC power required. Ensure key switch is ON. Timer malfunction. Replace timer assembly Solenoid valve malfunctioning. Replace the solenoid valve assembly Pump Does Not Operate Relay malfunctioning Replace relay Motor or pump malfunction. Repair or replace motor and/or pump assembly. (Refer to shop manual for rebuild instructions.) NOTE: On initial startup of the lube system, the timing capacitor will not contain a charge, therefore the first timing cycle will be about double in length compared to the normal interval. Subsequent timer cycles should be as specified. Low lubricant supply. Dirt in reservoir, pump inlet clogged, filter Pump Will Not Prime clogged. Air trapped in lubricant supply line. Prime system to remove trapped air. Lubricant supply line leaking. Check lines and connections to repair Pump Will Not Build leakage. Pressure Vent valve leaking. Clean or replace vent valve. Pump worn or scored. Repair or replace pump assembly. (Refer to shop manual for rebuild instructions.) NOTE: Normally, during operation, the injector indicator stem will move into the body of the injector when pressure builds properly. When the system vents (pressure release) the indicator stem will again move out into the adjusting yoke. Malfunctioning injector - usually Replace individual injector assembly. Injector Indicator Stem indicated by the pump building Does Not Operate pressure and then venting. All injectors inoperative - pump Service and/or replace pump assembly. build up not sufficient to cycle (Refer to shop manual for rebuild injectors. instructions.) No system pressure to the pump Check hydraulic hose from steering motor. system. No 24 VDC signal at pump Determine problem in 24 VDC electric solenoid. system. Pressure Gauge Does Not Pressure reducing valve set too Refer to “Pressure Control Valve Register Pressure low. Adjustment”. Replace relay. 24V Relay (RB7K8 or RB7K5) may be defective.
OM4209 11/07 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. Controller Does Not No electric power to controller. “POWER” LED should light, “PUMP ON” Operate LED should light when “MANUAL LUBE” is pressed. “PUMP ON” LED Lights, But Load Connected To Printed circuit board failure. Remove and replace. Terminals 3 & 4 Will Not Energize Load Connected To Printed circuit board failure or Remove and replace. Terminals 3 & 4 keypad failure. Energized, But “PUMP ON” LED Does Not Light Controller memory mode is to OFF. Switch controller memory mode to ON. Bearing Points Excessively Lubricated Injector output adjustment setting Readjust to lower setting. too high. Timer/controller cycle time setting Set to longer cycle time or reevaluate lube too low. requirements. Injector output adjustment setting Readjust injector output setting. too low. Bearing Points Are Not Sufficiently Lubricated Timer/controller cycle time setting Set to shorter cycle time or reevaluate does not deliver lubricant often lube requirements. enough. System too large for pump output. Calculate system requirements per planning manual.
OM5040 3/06 Specifications - Section 50 Component Description Page 50-1 MAJOR COMPONENT DESCRIPTION Truck And Engine Operator's Cab The 830E-AC 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 385 852 kg (850,650 lbs.). The engine is a the truck. The cab provides wide visibility, with an inte- Komatsu SDA16V160 rated @ 1865 kW (2500 HP). gral 4-post ROPS/FOPS structure, and an advanced analog operator environment. It includes a tinted Alternator (GTA-41) safety-glass windshield and power-operated side win- dows, a deluxe interior with a fully adjustable seat with The diesel engine drives an in-line alternator at engine lumbar support, a fully adjustable tilt/telescope steering speed. The alternator produces AC current which is wheel, controls mounted within easy reach of the oper- rectified to DC within the main control cabinet. The rec- ator, and an analog instrument panel which provides tified DC power is converted back to AC by groups of the operator with all instruments and gauges which are devices called "inverters", also within the main control necessary to control and/or monitor the truck's operat- cabinet. Each inverter consists of six "phase modules" ing systems. under the control of a "gate drive unit" (GDU). The GDU controls the operation of each phase module. Power Steering Cooling air for the control / power group and wheel The truck is equipped with a full time power steering motors, as well as the alternator itself, is provided by system which provides positive steering control with dual fans mounted on the alternator shaft. minimum operator effort. The system includes nitro- gen-charged accumulators which automatically provide AC Induction Traction Motorized Wheels emergency power if the steering hydraulic pressure is reduced below an established minimum. The alternator output supplies electrical energy to the two wheel motors attached to the rear axle housing. Dynamic Retarding The motorized wheels use three-phase AC induction motors with full-wave AC power. The dynamic retarding is used to slow the truck during normal operation or control speed coming down a The two wheel motors convert electrical energy back to grade. The dynamic retarding ability of the electric sys- mechanical energy through built-in gear trains within tem is controlled by the operator through the activation the wheel motor assembly. The direction of the wheel of the retarder pedal in the operators cab and by set- motors is controlled by a forward or reverse hand ting the RSC (Retarder Speed Control). Dynamic selector switch located on the center console. Retarding is automatically activated, if the truck speed goes to a preset overspeed setting. Suspension Brake System HYDRAIR®II suspension cylinders located at each wheel provide a smooth and comfortable ride for the The braking system consists of an all hydraulic actua- operator and dampens shock loads to the chassis dur- tion system. Depressing the brake pedal actuates ing loading and operation. wheel-speed single disc front brakes and armature- speed dual disc rear brakes. The brakes can also be activated by operating a switch on the instrument panel. The brakes will be applied automatically if sys- tem pressure decreases below a preset minimum. The parking brake is intregal with the service brake cal- iper, and is spring-applied and hydraulically-released. The park brake is applied by moving the directional control lever to the PARK position.
OM6009 2/05 Payload Meter III - Section 60 Page 60-3 INTRODUCTION Data Gathering Payload Meter III (PLMIII) measures, displays and Windows 95/98/NT software is available to records the weight of material being carried by an off- download, store and view payload and fault highway truck. The system generally consists of a information. The PC software will download an entire payload meter, a gauge display, deck-mounted lights, truck fleet into one Paradox database file. Users can and sensors. The primary sensors are four query the database by date, time, truck type and suspension pressures and an inclinometer. Other truck number to produce reports, graphs and export inputs include a body up signal, brake lock signal, the data. The software can export the data in '.CSV' and speed. format that can be easily imported into most spreadsheet applications. The Windows software is not compatible with the Payload Meter II system. Data Summary It is important that each payload meter be configured 5208 haul cycles can be stored in memory. The for each truck using the PC software. The information following information is recorded for each haul cycle: for frame serial number and truck number is used by • Payload the database program to organize the payload data. In addition, the payload meter must be configured to • Operator ID number (0000-9999) make calculations for the proper truck model. • Distance traveled loaded and empty Improper configuration can lead to data loss and inaccurate payload calculations. • The amount of time spent empty run/stop, loading, loaded run/stop, and dumping • Maximum speed loaded and empty with time of day • Average speed loaded and empty • Empty carry-back load • Haul-cycle, loading, dumping start time of day. • Peak positive and peak negative frame torque with time of day • Peak sprung load with time of day • Tire ton-mph for each front and average per rear tires The payload meter stores lifetime data that cannot be erased. This data includes: • Top 5 maximum payloads and time stamps. • Top 5 positive and negative frame torque and time stamps • Top 5 maximum speeds and time stamps
Payload Meter III - Section 60 OM6009 2/05 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 for the pressure sensor is 4000 psi (281 kg/cm2) and speedometer and payload display. The top display is the overload limit is 10,000 psi (700 kg/cm2). One used for speed and can display metric (km/h) or wire to the sensor is the supply voltage and the other English (mph) units. Grounding terminal #4 on the is the signal. The 0-4000 psi range is converted into back of the speedometer will switch the meter to an electrical current between 4-20 ma. The supply display metric units. Leaving terminal #4 voltage for the sensor is nominally +18vdc. Each unconnected will cause the gauge to display English pressure sensor has an 118 in. (3000 mm) length of units. The speedometer can be adjusted using a cable. The cable is specially shielded and reinforced calibration potentiometer in the back just like existing to provide mechanical strength and electronic noise speedometers. immunity. The payload meter uses the lower display for payload information. The normal display mode Inclinometer shows the current payload. The display can be The inclinometer is used to increase the accuracy of changed to show the load and total tons counter or load calculations on an incline. The inclinometer the Operator ID. Using the operator switch on the uses three wires. For the sensor, red is the +18vdc dash panel, the current suspension pressures and supply voltage, black is ground and the white is the incline can be displayed. The units for display are set signal. The incline signal is a voltage between 1 and using the PC software. Payloads can be displayed in 4 volts. Zero degrees of incline is represented by short tons, long tons or metric tons. 2.6vdc on the signal line. The voltage signal will be decreased by 0.103vdc for every degree of nose up incline.
OM6009 2/05 Payload Meter III - Section 60 Page 60-5 Operator Switch Payload Meter The payload operator switch is used to set, view and The payload meter is housed in a black aluminum clear the total load counter and total ton counter. It is housing. There is a small window on the face of the also used to enter the operator ID number (0-9999). unit. Status and active alarm codes can be viewed This switch can also be used to view the suspension through the window. During normal operation, a two- pressures and inclinometer. The payload meter digit display flashes 0 back and forth. Active fault operator switch is located on the dashboard. It is a codes will be displayed for two seconds. These two-way momentary switch. The top position is the codes are typically viewed using the laptop computer SELECT position. The SELECT position is used step connected to the serial communications port. through the different displays. The lower position is There is one 40-pin connector on the payload meter. the SET position. The SET position is used to set the A jack-screw is used to hold the payload meter and operator ID or clear the load and total ton counters. wire harness connector housings together. This Normally the inputs from the switch to the payload screw requires a 4mm or 5/32 hex wrench. The meter are open circuit. The switch momentarily correct tightening torque for this screw is 25 lb-in. connects the circuit to ground. Four bolts hold the payload meter housing to its Speed Input mounting bracket in the cab. PLMIII uses a speed signal to calculate speed, The circuit board inside the payload meter housing is distance, and other performance data. This input is made from multi-layer, dual-sided surface-mount critical to the proper operation of the system. PLMIII electronics. There are no field serviceable receives this signal from the speedometer/operator components inside. The electronics are designed to display on the dashboard. The same signal displayed withstand the harsh operating environment of the to the operator is used by the system. Distance mining industry. Opening the payload meter housing calculations are made based on the rolling radius of will result in voiding the warranty. the tires for a particular truck. Communications Ports Body-Up Switch The payload meter has two RS232 serial The body-up input signal is received from a magnetic communications ports and two CAN ports. switch located on the inside of the truck frame, Connections for the two serial ports are available forward the pivot pin of the truck body. This is the inside the payload meter junction box. The two CAN same switch typically used for input to the drive ports are available for future electronics systems. system. When the body is down, the switch closes Serial port #1 is used to communicate with the and completes the circuit to 71-control power. 24vdc dashboard display. It is also used to connect to the indicates the body is down. Open circuit indicates laptop computer. The display gauge will remain blank that the body is up. when the PC is using the serial port. This port initially operates with serial settings at 9600,8,N,1. These Brake Lock Switch settings change automatically to increase the The brake lock is used to lock the rear brakes on the communications rate when the PC is using the port. truck. It is necessary for the accurate calculation of This serial port uses a 3-wire hardware connection. swingloads during the loading process. Without the Serial port #2 is used to communicate to other on- brake lock applied, the payload meter will not board electronics like Modular Mining's Dispatch® calculate swingloads during the loading process. system or the scoreboard from Komatsu. This port Without the brake lock, the payload meter will uses a 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 functions will be normal regardless of brake lock technical information is available depending on usage. The brake lock input comes from the switch licensing. located on the dash panel. The brake lock switch connects the circuit to ground. Open circuit indicates brake lock off. Ground indicates brake lock on.
Payload Meter III - Section 60 OM6009 2/05 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. The payload meter does not receive the truck. The load lights are illuminated only when its electrical power from the key switch circuit. The the brake lock is applied. The lights are controlled by payload meter will remain on for several seconds the payload meter through a series of relays in the after key switch is removed. When the key switch junction box. The payload meter controls the relays power is removed, payload meter performs a series with 24vdc outputs. A 24vdc signal from the payload of internal memory operations before turning itself meter powers the relay coil and connects battery off. To allow for these operations, the key switch power to the load light. When the relay is not should be turned off for at least 15 seconds before powered by the payload meter, a pre-warm resistor turning the key switch back on. The payload meter connects the load light to a reduced voltage. This will automatically reset itself without error if not circuit pre-warms the load light filaments and reduces enough time is given for these operations. The the inrush current when the light is fully illuminated. display may blink briefly. This lengthens the operating life of the load lights. The load lights progressively indicate to the shovel operator the approximate weight of the material in Payload Meter Power the truck. The payload meter receives its power from the A flashing green light indicates the next swingload battery circuit on the truck. Removing battery power will make the measured load greater than 50% of from the payload meter before removing key switch rated load. A solid green light indicates that the and waiting 15 seconds may result in lost haul cycle current load is greater than 50% of rated capacity. data. The payload meter turns itself off approximately 15 seconds after the key switch power is removed. A flashing amber light indicates the next swingload Some haul cycle data will be lost if battery power is will make the measured load greater than 90% of removed before waiting 15 seconds. The payload rated load. A solid amber light indicates that the meter system operates at a nominal voltage of 24vdc current load is greater than 90% of rated capacity. at 1 to 2 amps depending on options. The payload A flashing red light indicates the next swingload will meter is designed to turn itself off if the supply make the measured load greater than 105% of rated voltage rises above 36vdc. The payload meter is also load. A solid red light indicates that the current load is protected by a 5 amp circuit breaker located in the greater than 105% of rated capacity. junction box. The optimal loading target is a solid green and amber Power to the load lights comes from the same battery lights with a flashing red light. This indicates that the circuit. The load lights are powered through a relay. load is between 90% and 105% of rated load for the The key switch circuit controls the relay. The load truck and the next swingload will load the truck over lights are also protected by a 15 amp circuit breaker 105%. in the junction box.
OM6009 2/05 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. This wire is typically terminated with a #10 ring terminal. Most connections for the PLMIII system are made in the payload meter junction box. TCI Outputs The GE drive system on the 930E/960E requires information from the payload meter regarding the loaded condition of the truck. There are three outputs from the payload meter to GE to indicate the relative load in the truck. 24 vdc on the 73MSL circuit indicates that the load is 70% of rated load. 24 vdc on the 73FSL circuit indicates the truck is 100% loaded. The 73OSL circuit is not currently used.
Payload Meter III - Section 60 OM6009 2/05 Page 60-8 OPERATOR’S DISPLAY AND SWITCH Using the Operator ID Reading the Speedometer The current operator ID number is recorded with each haul cycle. The number can be between 0 and The top window of the speedometer/display gauge is 9999. the speedometer section. The display shows the speed indicated by the frequency being received by To set the Operator ID: the gauge. This can be adjusted using the 1. Press the “SELECT” switch until Id= is potentiometer on the back of the gauge. In addition, displayed. the units for the display can be changed. Terminal #4 2. Hold the “SET” button until 0000 is displayed. controls the displayed units. If #4 is grounded, the The first digit should be flashing. display will be metric. If terminal #4 is left open, the display will be in English units. 3. Press the “SET” button again to change the digit. 4. Press the “SELECT” button once to adjust the Reading the Load Display second digit. 5. Use the “SET” button again to change the digit. The lower display on the speedometer/display gauge is used for payload information. The SELECT 6. Press the “SELECT” button once to adjust the position on the operator switch allows the user to third digit. scroll through a number of useful displays. The order 7. Use the “SET” button again to change the digit. for the displays is as follows: 8. Press the “SELECT” button once to adjust the fourth digit. 9. Use the “SET” button again to change the digit • PL= Payload 10. Press the “SELECT” button one more time to enter the ID. • Id= Operator ID • tL= Total Shift Tons If no buttons are pressed for 30 seconds, the display • LC= Shift Load Counter will return to normal operation. The number being entered will be lost and the ID number returns to the • LF= Left Front Suspension Pressure previous ID number. • rF= Right Front Suspension Pressure • Lr= Left Rear Suspension Pressure • rr= Right Rear Suspension Pressure Using the Load and Ton Counter • In= Inclinometer PLMIII allows the truck operator to monitor and track the total tons hauled and the number of haul cycles The display holds the displayed information until the during the shift. This display can be cleared at the SELECT switch is pressed again. The suspension beginning of each shift to allow the operator to record pressures, inclinometer, and payload displays are how many loads and tons have been hauled during based on current sensor inputs. the shift. Communications to the display use the same serial Total Ton Counter link as the download connection. Whenever another The total ton counter records the number of tons computer is connected to serial port #1 to download hauled since the last time it was cleared. This display or configure the system, the lower display will blank. is in 100’s of tons. For example, if the display shows This is not the same connection used by mine 432 the total tons is 43,200. This display can be dispatch systems. cleared at the beginning of each shift to allow the operator to record how many tons have been hauled during the shift. The units are selected using the PC software. • To view the total ton counter press and release the “SELECT” switch until tL= is displayed on the gauge.
OM6009 2/05 Payload Meter III - Section 60 Page 60-9 Total Load Counter The inclinometer displays whole degrees of incline. Positive incline is truck nose up. The gauge will The total load counter records the number of loads quickly display the type of information shown every hauled since the last time it was cleared. This display 10 seconds. For example, if the left-front pressure is can be cleared at the beginning of each shift to allow the operator to record how many loads have been being displayed, Lf= will flash on the display every hauled during the shift. minute. Only the payload display, PL= does not • To view the total load counter press and release display this information. the “SELECT” switch until LC= is displayed on • Left Front Pressure - To display the pressure in the gauge. the left-front suspension, press and release the “SELECT” switch until Lf= is displayed. • Right Front Pressure - To display the pressure in Clearing the Counters the right-front suspension, press and release the Clearing the total ton counter or total load counter “SELECT” switch until rf= is displayed. clears both records. • Left Rear Pressure - To display the pressure in the left-rear suspension, press and release the To clear the total ton and total load counter: “SELECT” switch until Lr= is displayed. 1. Press the “SELECT” switch until tL= or LC= • Right Rear Pressure - To display the pressure in is displayed. the right-rear suspension, press and release the 2. Hold the “SET” button until the display clears. “SELECT” switch until rr= is displayed. • Inclinometer - To display the truck incline, press and release the “SELECT” switch until In= is Viewing Live Sensor Data displayed. The display can also be used to quickly show the current readings from the four suspension pressure sensors and the inclinometer. This can be used during regularly scheduled service periods to check the state of the suspensions. These displays are live Other Display Messages and will update as the values change. On startup of the payload meter system, the gauge The live displays cannot be cleared and the SET display will scroll the truck type that the PLMIII is button will have no effect. configured for. For example, on a 930E, the gauge The units for the display are controlled by the will scroll, ---930E---. configuration of the payload meter. If the payload meter is set to display metric units, the pressures will be displayed in tenths of kg/cm2. For example, if the If the PLMIII encounters memory problems, it will display shows 202 the actual value is 20.2 kg/ display ER88 ,where 88 is the specific memory cm2. If the payload meter is set to display short tons, error. In this very rare circumstance, the system should be turned off for 30 seconds and restarted. the pressures will be displayed in psi (lbs/in2). Multiply by 14.2 to convert kg/cm2 to psi. (example -- 1kg/cm2 x 14.2 = 14.2 psi). There is no way to detect the units setting for the gauge without the PC software.
Payload Meter III - Section 60 OM6009 2/05 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 The typical haul cycle can be broken down into eight allow the operator to reposition the truck under the distinct stages or states. Each state requires the shovel. More payload can be added anytime within payload meter to make different calculations and the maneuvering zone. Once the truck travels 160m store different data. (0.1 miles) the payload meter switches to the final_zone and begins calculating payload. If the 1. Tare Zone body is raised while the payload meter is in the 2. Empty maneuvering state, the no_final_load flag will be 3. Loading recorded in the haul cycle record, no payload will be calculated, and the meter will switch to the dumping 4. Maneuvering state. 5. Final Zone While in the final_zone moving faster than 5 km/h (3 6. Hauling mph), the payload meter calculates the loaded 7. Dumping sprung weight of the truck. The same advanced algorithm is used to calculate the empty and loaded 8. After Dump sprung weights. The payload meter will switch from Haul Cycle Description the final_zone to the dumping state if the Body-Up signal is received. If the truck has moved for less A new haul cycle is started after the load has been than 1 minute in the final_zone, the payload meter dumped from the previous cycle. The payload meter will calculate the final payload using an averaging will stay in the after_dump state for 10 seconds to technique which may be less accurate. If this confirm that the load has actually been dumped. If happens, the average_load flag will be recorded in the current payload is less than 20% of rated load, the haul cycle. the payload meter will switch to the tare_zone and begin calculating a new empty tare. If, after dumping, The payload meter switches to the dumping state the payload has not dropped below 20% of rated when the dump body rises. The payload meter will load the meter will return to the maneuvering or switch from dumping to after_dump when the dump hauling states. In this case, the false_body_up flag body comes back down. will be recorded in the haul cycle record. From the after_dump, the payload meter will switch While in the tare_zone state, and moving faster than to one of three states: 5 km/h (3 mph), the payload meter calculates the 1. If the average payload is greater than 20% of empty sprung weight of the truck. This tare value will rated load and no final payload has been be subtracted from the loaded sprung weight to calculated, the payload meter will return to the calculate the final payload. The payload meter will maneuvering state. After the truck travels 160m switch from the tare_zone or empty to the loading (0.1 mile) the meter will switch to the final_zone state if swingloads are detected. By raising the dump and attempt to calculate the payload again. The body while in the empty state the payload meter can false_body_up flag will be recorded in the haul be manually switched back to the tare_zone to cycle record. calculate a new tare. 2. If the average payload is greater than 20% of From the empty state, the payload meter will switch rated load and the final payload has been to the loading state through one of two means. If the calculated, the payload meter will switch back to brake lock is applied, the payload meter will be the hauling state. The false_body_up flag will analyzing the suspension pressures to detect a be recorded in the haul cycle record. swingload. If a swingload is detected, the meter will 3. If the average payload is less than 20% of rated switch to the loading state. The minimum size for load, the payload meter will switch to the swingload detection is 10% of rated load. Swingload tare_zone and begin to calculate a new empty detection usually takes 4-6 seconds. The second tare. method to switch from empty to loading is through continuous loading. This can happen if the brake lock is not used during loading. If the load increases above 50% of rated load for 10 seconds without the brake lock applied, the meter will switch to loading and record the continuous_loading flag in the haul cycle.
OM6009 2/05 Payload Meter III - Section 60 Page 60-11 Load Calculation SOURCES FOR PAYLOAD ERROR The final load calculation is different from the last Payload Error swingload calculation. The accuracy of the swing load calculation depends on loading conditions and The number one source of error in payload the position of the truck during loading. The last calculation is improperly serviced suspensions. The swingload calculation is not the value recorded in payload meter calculates payload by measuring memory as the final load. The final load is differences in the sprung weight of the truck when it determined by a series of calculations made while is empty and when it is loaded. The sprung weight is the truck is traveling to the dump site. the weight of the truck supported by the suspensions. The only method for determining sprung weight is by measuring the pressure of the nitrogen gas in the Carry Back suspensions. If the suspensions are not properly maintained, the payload meter cannot determine an Carry back is calculated as the difference between accurate value for payload. The two critical factors the current truck tare and the clean truck tare. The are proper oil height and proper nitrogen charge. clean truck tare is calculated using the PC software. When the suspensions are serviced or changes are If the suspensions are overcharged, the payload made that may affect the sprung weight of the truck, meter will not be able to determine the empty sprung a new clean truck tare should be calculated. weight of the truck. The suspension cylinder must be able to travel up and down as the truck drives empty. The pressure in an overcharged suspension can push the suspension rod to full extension. In this Measurement Accuracy case, the pressure inside the cylinder does not Payload measurements are typically repeatable accurately represent the force necessary to support within 1%. Accuracy for a particular scale test that portion of the truck. depends on specific combinations of pressure If the suspensions are undercharged, the payload sensors and payload meters as well as the specifics meter will not be able to determine the loaded sprung of each scale test. Comparisons from different scale weight of the truck. The suspension cylinder must be tests are often made without considering the able to travel up and down as the truck drives loaded. differences introduced by the specific installation and If the pressure in an undercharged suspension operation of the scales for each test. In addition, cannot support the load, the suspension will collapse each pressure sensor and payload meter introduces and make metal-to-metal contact. In this case, the it's own non-linearity. Each truck becomes an pressure inside the cylinder does not accurately individual combination of sensors and payload meter. represent the force necessary to support that portion Errors from these sources can introduce up to a ±7% of the truck. bias in the payload meter calculations for a specific scale test, for an individual truck. Low oil height can also introduce errors by not correctly supporting a loaded truck. This is why the Because the PLMIII calculates a new empty tare for correct oil height and nitrogen charge are the most each payload, a detailed scale test must weigh the critical factors in the measurement of payload. If the trucks empty and loaded for each haul cycle. Using a suspensions are not properly maintained, accurate simple average of 2 or 3 empty truck weights as an payload measurement is not possible. In addition, empty tare for the entire scale test will introduce suspension maintenance is very important to the life significant error when comparing scale weights to of the truck. PLMIII weights.
Payload Meter III - Section 60 OM6009 2/05 Page 60-12 Loading Conditions HAUL CYCLE DATA 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. This memory does not require a separate calculated as the truck travels away from the shovel. battery. The data is available through the download Variations in road conditions and slope are software. compensated for in the complex calculations performed by the payload meter. PLMIII can store 5208 payload records. When the memory is full, the payload meter will erase the oldest 745 payload records and continue recording. Pressure Sensors PLMIII can store 512 alarm records in memory. When the memory is full, the payload meter will Small variations in sensors can also contribute to erase the oldest 312 alarm records and continue payload calculation error. Every pressure sensor is recording. slightly different. The accuracy differences of individual sensors along the range from 0 to 4000 psi All data is calculated and stored in metric units within can add or subtract from payload measurements. the payload meter. The data is downloaded and This is also true of the sensor input circuitry within stored in metric units within the Paradox database on individual payload meters. These differences can the PC. The analysis program converts units for stack up 7% in extreme cases. These errors will be displays, graphs and reports. consistent and repeatable for specific combinations The units noted in the Table 1 are the actual units of payload meters and sensors on a particular truck. stored in the data file. The value for the haul cycle start time is the number of seconds since January 1, 1970 to the start of the haul cycle. All other event Swingloads times are referenced in seconds since the haul cycle start time. The PC download and analysis program Swingload calculations can be affected by conditions converts these numbers into dates and times for at the loading site. Parking the truck against the berm graphs and reports. or large debris can cause the payload meter to inaccurately calculate individual swingloads. While the PLMIII system uses an advanced calculation algorithms to determine swingloads, loading site conditions can affect the accuracy. Speed and Distance The payload meter receives the same speed signal as the speedometer. This signal is a frequency that represents the speed of the truck. The payload meter uses this frequency to calculate speeds and distances. The meter assumes a single value for the rolling radius of the tire. The rolling radius may change at difference speeds by growing larger at higher speeds. The actual rolling radius of the tire will also change between a loaded and empty truck. The payload meter does not compensate for these changes. NOTE: Earlier 730E and 830E models are subject to incorrect speed data due to electrical interference. The incorrect speeds are generated while the truck is stopped. An attenuator was added to newer production models to prevent this error from occurring. A kit was released to update older PLMIII systems with the attenuator. Consult your area service representative for details.
OM6009 2/05 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. Haul Cycle Start Date/Time seconds Number of seconds from 1/1/70 to the start of the haul cycle, haul cycle starts when the meter transitions from dumping to empty state after the previous haul cycle, download program converts seconds into date and time for display Payload tons Stored as metric, download program allows for conversion to short or long tons. Number of Swingloads number The number of swingloads detected by the payload meter Operator ID number This is a 4 digit number that can be entered by the operator at the start of the shift. Warning Flags alpha Each letter represents a particular warning message about the haul cycle, details are located on page 19. Carry-back load tons The difference between the latest empty tare and the clean truck tare Empty haul time seconds Number of seconds in the tare_zone and empty states with the truck moving Empty stop time seconds Number of seconds in the tare_zone and empty states with the truck stopped Loading time seconds Number of seconds in the loading state Loaded haul time seconds Number of seconds in the maneuvering, final_zone and loaded states with the truck moving Loaded stop time seconds Number of seconds in the maneuvering, final_zone and loaded states with the truck stopped Dumping time seconds Number of seconds in the dumping state Loading start time seconds Number of seconds from the start of the haul cycle to when the meter transitions from empty to loading state Dump start time seconds Number of seconds from the start of the haul cycle to the time when the meter switches from loaded to dumping state Loaded haul distance m Distance traveled while loaded Empty haul distance m Distance traveled while empty Loaded max speed km/h Maximum speed recorded while the truck is loaded Loaded max speed time seconds Number of seconds from the start of the haul cycle to the time when the max speed occurred Empty max speed km/h Maximum speed recorded while the truck is empty Empty max speed time seconds Number of seconds from the start of the haul cycle to the time when the max speed occurred Peak positive frame torque ton-meter Positive frame torque is measured as the frame twists in the clockwise direction as viewed from the operator’s seat. Peak frame torque time seconds Number of seconds from the start of the haul cycle to the peak torque, download program converts to time for display Peak negative frame torque ton-meter Negative frame torque is measured as the frame twists in the counter-clockwise direction as viewed from the operator's seat. Peak frame torque time seconds Number of seconds from the start of the haul cycle to the peak torque, download program converts to time for display Peak sprung load tons Peak dynamic load calculation Peak sprung load time seconds Number of seconds from the start of the haul cycle to the peak instantaneous load calculation Front-left tire-ton-km/h t-km/h Tire ton-km/h for haul cycle Front-right tire-ton-km/h t-km/h Tire ton-km/h for haul cycle Average rear tire-ton-km/h t-km/h Tire ton-km/h for haul cycle Truck Frame Serial Number alpha The truck serial number from the nameplate on the truck frame Reserved 1-10 number These values are internal calculations used in the continued development of the PLMIII system and should be ignored
Payload Meter III - Section 60 OM6009 2/05 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. Several payload indicating that the operator has dumped the events within the haul cycle can cause a warning flag load. It may also be generated if the body-up signal is to be generated. Each one indicates an unusual not properly reaching the payload meter and the occurrence during the haul cycle. They do not weight in the truck falls dramatically while the truck is necessarily indicate a problem with the payload calculating the final payload. meter or payload calculation. H: False Body Up A: Continuous Loading This message indicates that the body was raised This message is generated when the truck is loaded during the haul cycle without the load being dumped. over 50% full without the payload meter sensing The body-up signal indicated that the truck was swingloads. This indicates that a continuous loading dumping, but the weight of the truck did not fall below operation was used to load the truck. It may also 20% of the rated load. indicate that the payload meter did not receive the brake lock input while the truck was being loaded. I: Body Up Signal Failed There may be a problem with the wiring or the brake This message indicates that the load was dumped lock was not used. The payload meter will not without a body-up signal being received by the measure swingloads unless the brake lock is used payload meter. The weight of the truck fell below during the loading process. 20%, but the payload meter did not receive a body- up signal from the sensor. B: Loading to Dumping Transition This message is generated when the payload meter J: Speed Sensor Failed senses a body up input during the loading process. This message indicates that the payload meter This message is usually accompanied by a sensed the truck loading and dumping without no_final_load flag. receiving a speed signal. C: No Final Load K: New Tare Not Calculated This message is generated when the payload meter The payload meter was not able to accurately is unable to determine the final payload in the truck. calculate a new empty sprung weight for the truck to Typically, this means that the payload meter switched use as the tare value for the haul cycle. The tare from a loaded state to the dumping state before the value from the last haul cycle was used to calculate load could be accurately measured. payload. D: Maneuvering to Dumping Transition L: Incomplete Haul Cycle This message is generated when the payload meter The payload meter did not have proper data to start senses a body-up input during the maneuvering or the haul cycle with after powering up. When the repositioning process indicating that the operator has PLMIII powers off, it records the data from the haul dumped the load. It may also be generated if the cycle in progress into memory. This flag indicates body-up signal is not properly reaching the payload that this data was not recorded the last time the meter and the weight in the truck falls dramatically payload meter was shut down. This can happen while the truck is maneuvering or repositioning. when the main battery disconnect is used to shut the truck down instead of the key switch. A haul cycle E: Average Load or Tare Used with this warning flag should not be considered This message indicates that the recorded payload accurate. Haul cycles with this warning are displayed may not be as accurate as a typical final load in red on the Payload Summary window and are not calculation. Typically, this is recorded when loading included in the summary statistics for reports or begins before an accurate tare is calculated or the display. load is dumped before the load can be accurately measured.
OM6009 2/05 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. This value naturally rises and times stored for particular events may not be falls for a loaded truck depending on road and driving accurate. This does not affect the payload conditions. The payload meter records the top 5 calculation. highest payload calculations and the time they occurred. This information is stored in permanent N: Sensor Input Error memory inside the meter. An alarm was set for one of the 5 critical sensor inputs during the haul cycle. The five critical sensors are the four pressure sensors and the inclinometer. Maximum Speed Data Without these inputs, the payload meter cannot The payload meter records the top 5 highest speeds calculate payload. A haul cycle with this warning flag and the time they occurred. This information is stored should not be considered accurate. Haul cycles with in permanent memory inside the meter. this warning are displayed in red on the Payload Summary window and are not included in the summary statistics for reports or display. Alarm Records The payload meter stores alarm records to give service personnel a working history of the system. All codes are viewed using the PC connected to the Frame Torque Data payload meter. Active codes are also displayed on Payload meter records the top 5 peak positive and the two-digit display on the meter itself. Each code negative frame torque values and the time they has a specific cause and should lead to an occurred. The frame torque is a measure of the investigation for correction. Some failures can be twisting action along the centerline of the truck. overcome by the payload meter. Haul cycle data will Positive frame torque is measured when the indicate if an alarm condition was present during the suspension forces on the front of the truck act to twist cycle. Failures with the suspension or inclinometer the frame in the clockwise direction as viewed from sensors cannot be overcome. the operator's seat. Negative frame torque is measured when the forces from the suspensions act in the opposite direction. For example, if the left front and right rear pressure rises as the right front and left rear pressure drops, the truck frame experiences a twisting motion along the longitudinal centerline. In this case, the payload meter will record a positive frame torque. The 5 highest values in the positive and negative direction are stored in permanent memory within the payload meter.
Payload Meter III - Section 60 OM6009 2/05 Page 60-16 Fault Code Data Table 2: Fault Code Name Description 1 Left front pressure high Input current > 22 ma 2 Left front pressure low Input current < 2 ma 3 Right front pressure high Input current > 22 ma 4 Right front pressure low Input current < 2 ma 5 Left rear pressure high Input current > 22 ma 6 Left rear pressure low Input current < 2 ma 7 Right rear pressure high Input current > 22 ma 8 Right rear pressure low Input current < 2 ma 9 Inclinometer high Input voltage < 0.565 vdc 10 Inclinometer low Input voltage > 5.08 vdc 11 Speed input failure Not Used 12 Brake lock input failure Not Used 13 Body-up input failure Payload meter detected dumping activity without receiving a body up signal 16 Memory write failure Indicates possible memory problem at power start up. Cycle power and recheck. 17 Memory read failure Indicates possible memory problem at power start up. Cycle power and recheck. 18 Rear right suspension flat Payload meter detected an undercharged suspension condition on the rear right suspension. 19 Rear left suspension flat Payload meter detected an undercharged suspension condition on the rear left suspension. 20 Time change Payload meter time was changed by more than 10 minutes. The Alarm Set time indicates original time. The Alarm Clear time indicates the new time. 21 Tare value reset The user manually forced the payload meter to reset the haul cycle empty (tare) sprung weight. This forced the meter into the tare_zone state and lost all data for the previous haul cycle. 22 Excessive carryback The payload meter detected an empty carryback load in excess of the user-defined carryback threshold on two consecutive haul cycles. 26 User switch fault - SELECT Select switch on for more than 2 minutes, may indicate short to ground 27 User switch fault - SET Set switch on for more than 2 minutes, may indicate short to ground
OM6009 2/05 Payload Meter III - Section 60 Page 60-17 PC SOFTWARE OVERVIEW Installing the PLMIII Software PC Overview The CD-ROM containing the Payload Data Management (PDM) software will automatically begin The PC software has several basic functions: installation when it is inserted into the drive on the • Configure the PLMIII system on the truck. PC. If this does not happen, the software can be installed by running the Setup.exe program on the • Troubleshoot and check the PLMIII system. CD-ROM. • Download data from the PLMIII system. The minimum PC requirements for running the • Analyze data from the payload systems. software is a Pentium 133Mhz with 64 MB of ram and at least 300 MB of free hard drive space available. For improved performance, the recommended PC Configuration, troubleshooting and downloading would have a Celeron, AMD K6-2 or better processor require a serial connection to the payload meter on with 128 MB of ram running at 400 Mhz. The PDM the truck. Analysis can be done at any time without a software uses a powerful database to manipulate the connection to the payload meter. large amounts of data gathered from the PLMIII system. Using a more powerful computer and added Payload data is downloaded from several trucks into memory to run the software can result in a significant one database on the PC. The database can be improvement in performance. The software is written queried to look at the entire fleet, one truck or truck to use a minimum 800x600 screen resolution. model. The data can be graphed, reported, imported or exported. The export feature can take payload data and save it in a format that spreadsheet programs like Excel or word processing programs can easily import. System Configuration PLMIII needs to be configured for operation when it is first installed on the truck. This process requires several steps and uses the laptop computer to make the necessary settings. The setup procedure can be broken down into several steps: • Connecting the laptop to the PLMIII system. • Starting communications • Setting the time & date • Setting the truck type • Setting the truck ID • Setting the speedometer/display gauge units
Payload Meter III - Section 60 OM6009 2/05 Page 60-18 DOWNLOADING DATA To download the payload meter: PLMIII records many types of data. The PLMIII PC 1. Connect to the payload meter and start the PC software is designed to download the data from a software. whole truck fleet. Instead of creating one data file for 2. From the main menu, select "Connect to each truck, the PC software combines all the data Payload Meter". The PC will request the latest from many trucks into one database on the hard status information from the payload meter. The drive of the computer. The software then allows number of haul cycles and alarms will be users to query the database to create custom reports displayed. and graphs. Data for individual trucks or groups of 3. Select the " Begin Download" button. The PC trucks can be easily analyzed. This same data can will request the payload and alarm data from the be exported for use in other software applications like payload meter and save it into the database. word processors and spreadsheet applications. This may take several minutes. A progress bar As the database grows, performance of the PC at the bottom will show the approximate time software for analysis will slow down. It may be helpful left. to periodically export data. For example, query the database to show the oldest quarter, month, or half year and print out a summary report. Then export the data to a compressed format and save the file in a secure location. Once the data is exported, delete the entire query results from the database. If necessary, the data can easily be imported back into the main database for analysis at a future date. Removing this older data will improve performance. The PC software downloads the data from the payload meter into a single Paradox database. The data from all the trucks is added to the same database. Downloading the payload meter can take several minutes. The data is added to the database on the laptop used to download. To move the data to another computer, a query must be run to isolate the particular data for export. Do not press the operator switch on the dashboard while downloading
OM6009 2/05 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. Long Tons: Payload is displayed in long tons, distances and speeds are displayed in Miles Time Units Minutes and Seconds Example: Five minutes and thirty-two seconds = 5:32 Decimal Minutes Example: Five minutes and thirty-two seconds = 5.53 Connection Menu Before connecting to the payload meter, select "Change Program Options" and confirm that the program has selected the correct laptop serial port. Most laptops use Comm 1 for serial communications. The units displayed for reports and graphs by the PC software can be set on this form. Click “Done” to return to the main menu. The connection screen displays basic system information to the user. • Frame S/N should agree with the truck serial number from the serial plate located on the truck frame. • Truck Number is an ID number assigned to the truck by the mine. • The Payload Meter Date / Time values come from the payload meter at the moment of From the main menu, click the "Connect to Payload connection. Meter" button. The PC will try to connect to the • Number of Haul Cycle Records is the number of payload meter and request basic information from haul cycles records stored in memory and the system. In the event of communications trouble, available for download. the PC will try 3 times to connect before "timing-out". • Number of Active Alarms shows how many This may take several seconds. alarms are currently active in the system at the time of connection. If there are active alarms, the "Display Active Alarms" button is available. Displayed Payload Units • Number of Inactive Alarms shows how many Three options are available for the display of units in alarms have been recorded in memory and are available for download. the PC software, reports, and graphs:
• PLM Software Version displays the current version of software in the payload meter. The information on the connection menu comes from the configuration of the payload system on the truck.
Payload Meter III - Section 60 OM6009 2/05 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. The connection menu is displayed after a serial The time shown on the form is the time transmitted connection has been established and the PC from the payload when the connection was first software has connected to the payload meter. established. Connecting to the Payload Meter Communications to the PLMIII requires a laptop computer running the PDM software. The software connects to the payload meter through the meter's serial port #1. This is the same port used by the speedometer/display gauge. When the laptop is using the serial port, the lower display on the operator gauge on the dashboard will be blank. This The date and time are maintained by a special chip does not affect the operation of the speedometer. on the PLMIII circuit board. The memory for this chip • Connect the laptop to the system using the is maintained by a very large capacitor when the EF9160 communications harness. The download power is removed from the payload meter. This will connector is typically located on the housing maintain the date and time settings for approximately mounted in the cab to the back wall. The PLMIII 30 days. After this time, it is possible for the payload system uses the same connection as the meter to lose the date and time setting. It is Payload Meter II system. recommended that the system be powered every 20 days to maintain the date and time. If the date and Configure the Payload Meter time is lost, simply reset the information using this Configuration of the payload meter requires a serial procedure. It takes approximately 90 minutes to connection to the PLMIII system. Clicking the recharge the capacitor. "Configure Payload Meter" button will bring up the Changing the date and time will affect the haul cycle Truck Configuration screen and menu. This screen in progress and may produce unexpected results in displays the latest configuration information stored the statistical information for that one haul cycle. on the payload meter. To change the time: When changes are made to the configuration, the "Save Changes" button must be pressed to save the 1. Click on the digit that needs to be changed. changes into the payload meter. To confirm the 2. Use the up/down arrows to change or type in changes, exit to the main menu and re-connect to the the correct value. payload meter. 3. Press the "Save Changes" button to save the new time in the payload meter. To change the date: 1. Click on the digit that needs to be changed. 2. Type in the correct value or use the pull-down calendar to select a date. 3. Press the "Save Changes" button to save the new time in the payload meter.
OM6009 2/05 Payload Meter III - Section 60 Page 60-21 Setting the Truck Type Setting the Truck Number Most mining operations assign a number to each piece of equipment for quick identification. This number or name can be entered in the Truck Number field. It is very important to enter a unique truck 1. From the Truck Configuration screen, use the number for each truck using the PLMIII system. This pull-down menu to select the truck type that the number is one of the key fields used within the haul payload meter is installed on. cycle database. The field will hold 20 alpha-numeric 2. Press the "Save Changes" button to program characters. the change into the meter. 1. On the Truck Configuration screen, enter the Setting the Gauge Display Units truck number in the appropriate field. The payload meter speedometer / display gauge 2. Press the "Save Changes" button to program displays the speed on the upper display. The units for the change into the payload meter. the speed display are selected using a jumper on the rear of the case. Setting the Komatsu Distributor The payload units on the lower display can be changed from metric to short tons or long tons using This field in the haul cycle record can hold the name the Truck Configuration screen. This selection also of the Komatsu distributor that helped install the switches between metric (kg/cm2) and psi (lbs/in2) for system. Komatsu also assigns a distributor number the live display of pressure on the gauge. to each distributor. This number is used on all warranty claims. This Komatsu distributor number 1. From the Truck Configuration screen, select the can also be put into this field. The field will hold 20 payload units to be used on the lower display of alpha-numeric characters. the speedometer/display gauge. 2. Press the "Save Changes" button to program the change into the payload meter. 1. On the Truck Configuration screen, enter the distributor name or number in the appropriate field. Setting the Frame Serial Number 2. Press the "Save Changes" button to program the change into the payload meter. Setting the Komatsu Customer This field in the haul cycle record can hold the name of the mine or operation where the truck is in service. Komatsu also assigns a customer number to each The frame serial number is located on the plate customer. This number is used on all warranty mounted to the truck frame. The plate is outboard on claims. This Komatsu customer number can also be the lower right rail facing the right front tire. It is very put into this field. The field will hold 20 alpha-numeric important to enter the correct frame serial number. characters. This number is one of the key fields used within the haul cycle database. The field will hold 20 alpha- numeric characters. 1. On the Truck Configuration screen, enter the 1. On the Truck Configuration screen, enter the customer name or number in the appropriate truck frame serial number in the appropriate field. field. 2. Press the "Save Changes" button to program 2. Press the "Save Changes" button to program the change into the payload meter. the change into the payload meter.
Payload Meter III - Section 60 OM6009 2/05 Page 60-22 Clean Truck Tare Inclinometer Calibration The payload meter uses the clean truck tare value to The inclinometer calibration procedure is designed to calculate carry-back load for each haul cycle. The compensate for variations in the mounting attitude of carry-back stored in the haul cycle record is the new the inclinometer. The inclinometer input is critical to empty tare minus the clean truck tare. the payload calculation. This procedure should be performed after service to This procedure should be performed on relatively flat the suspensions or when significant changes are ground. Often the maintenance area is an ideal made to the sprung weight of the truck. Before location for this procedure. performing this procedure, be sure the suspensions are properly filled with oil and charged. It is critical to 1. After cleaning debris from the truck and payload measurement that the proper oil height and checking to see that the suspensions are gas pressure be used. properly serviced, use the PLMIII software to connect to the payload meter. Once the clean tare process is started, the payload meter will begin to calculate the clean empty sprung 2. From the "Truck Configuration" screen, select weight of the truck. This calculation continues while "Inclinometer". the truck drives to the next loading site. Once the 3. With the truck stopped and the brake lock on, procedure is started, there is no reason to continue press the “Start” button. This instructs the to monitor the process with the PC. The truck does payload meter to sample the inclinometer once. not need to be moving to start this procedure. 4. Turn the truck around. Drive the truck around 1. After cleaning debris from the truck and and park in the exact same spot as before, checking to see that the suspensions are facing the other direction. properly serviced, use the PLMIII software to 5. With the truck stopped and the brake lock on, connect to the payload meter. press the “Start” button. This instructs the 2. From the "Truck Configuration" screen, select payload meter to sample the inclinometer again. "Clean Truck Tare". The payload meter will average the two samples to determine the average offset. 3. Be sure to follow the screen instructions. 6. Be sure to follow the screen instructions.
OM6009 2/05 Payload Meter III - Section 60 Page 60-23 DATA ANALYSIS PAYLOAD SUMMARY FORM The data analysis tools allow the user to monitor the Sorting on Truck Unit Number performance of the payload systems across the fleet. The truck unit number is the truck unit number Analysis begins when the "View Payload Data" entered into the payload meter when it was button is pressed. This starts an "all trucks, all dates, configured at installation. The query can be set to all times" query of the database and displays the look for all trucks or one particular truck number. results in the Payload Summary Form. When the program begins, it searches through the The user can change the query by changing the database for all the unique truck numbers and dates, times, or trucks to include in the query for creates a list to select from. display. Choosing one particular truck number will limit the Haul cycles in the data grid box at the bottom can be data in the displays, summaries and reports to the double-clicked to display the detailed results of that one selected truck. To create reports for truck haul. number 374, select 374 from the pull-down menu and hit the "Query Database and Display" button. Creating a Query The program defaults to show all trucks, all types, all dates and all times for the initial query. The display Sorting on Truck Type can be narrowed by selecting which trucks or types 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. For example, a separate report can be will sort the data for that truck number AND the date generated for 830E and 930E trucks. range.
Payload Meter III - Section 60 OM6009 2/05 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. Select truck 374 from the Truck Unit pull-down menu. 3. Change the “To” date to January 8, 2000. 4. Change the “From” time to 06:00. 5. Change the “To” time to 18:00. 6. Press the "Query Database and Display" to
view the results. 2. Change the “From” date to July 1, 2000. This query will display haul cycles from January 5 to January 8, from 6:00 AM to 6:00 PM. Date Time Jan 5, 2000 Jan 6, 2000 Jan 7, 2000 Jan 8, 2000 Jan 9, 2000 0:00
6:00 3. Change the “To” date to July 31, 2000. 4. Press the "Query Database and Display" to view the results. 12:00 Sorting on Time Range 18:00 The time range sorts the times of the day for valid dates. Changing the time range to 6:00AM to 6:00PM will limit the payloads displayed to the loads that 24:00 occurred between those times for each day of the Query : Date: 1/5/00 to 1/8/00 date range. Times are entered in 24:00 format. To Haul Cycles Included in the Query Daily Shift Time: 6:00 to 18:00
view the haul cycle reports from the first shift for truck 374 from January 5, 2000 to January 8, 2000: 1. Select truck 374 from the Truck Unit pull-down menu. 2. Change the “From” date to January 5, 2000.
OM6009 2/05 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. From the “Payload Summary” to query the 6:00 PM (18:00) to 6:00 AM (06:00) shift, screen, double-click on any haul cycle to display the the results would extend into the morning of the 9th. detail. This can been seen in the following example: Date Time Jan 5, 2000 Jan 6, 2000 Jan 7, 2000 Jan 8, 2000 Jan 9, 2000 0:00 6:00 12:00 18:00 24:00 Query : Date: 1/5/00 to 1/8/00 Haul Cycles Included in the Query Daily Shift Time: 18:00 to 6:00 Creating Reports Reports can be generated and viewed on the screen or printed. These reports are generated from the query displayed on the Payload Summary Screen. From the example in "Sorting on Time Range", the report printed would only contain data from truck 374 during the month of July 2000, from 8:00 AM to 5:00 PM. It is important to carefully select the query data and press the "Query Database & Display" button before printing a report.
Payload Meter III - Section 60 OM6009 2/05 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. Summary - one page report A summary of the queried data can be printed onto 1 page. The cycle data is summarized onto one sheet. Displayed is the speeds, cycle times, load statistics, frame and tire data. Detailed - multi-page report The detail report starts with the summary report and follows with pages of data for each haul cycle. The detailed report prints date, time, payload, cycle times, and cycle distances, speeds and the number of swing loads.
OM6009 2/05 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” screen. From the "Sorting on Time Range" example, the graph that is printed would only contain data from truck 374 during the month of July 2000, from 8:00 AM to 5:00 PM. It is important to carefully select the query data and press the "Query Database & Display" button before creating a graph. The data from the database can be exported for use 1. From the Payload Summary Screen select the with other software applications. The data is selected “Graph” button at the bottom. The Histogram from the currently displayed query. The exported Setup screen will display data can be put into a ".CSV" file or a compressed ".zip" file. • The “.CSV” format allows data to be easily imported into spreadsheet applications and word processing applications. • The “.Zip” format allows data to be transferred from one computer to the PDM Software database on another computer. This offers a compact way to transfer data from one computer to another. CSV Export 2. Enter the "Lowest Value". This will be the lowest payload on the graph. Any payloads less than this value will be summed in the first bar. 3. Enter the "Highest Value". This will be the highest value on the graph. Payloads over this value will be summed in the last bar. 4. Enter the "Incremental Change". This will determine the number of bars and the distance between them. The program limits the number of bars to 20. This allows graphs to fit on the screen and print onto 1 page. CSV stands for Comma Separated Value. This is an ASCII text file format that allows spreadsheet 5. Press the “Create Graph” button. applications like Excel and Lotus 123 to import data The graph will be displayed based on the query easily. To export the data into a ".csv" file, press the settings from the Payload Summary screen. The "Export" button at the bottom of the payload graph can be customized and printed. summary screen and select "To CSV". The program will request a filename and location for the file.
Payload Meter III - Section 60 OM6009 2/05 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. Two sets of data are exported. At the top of the file will be the haul cycle data. The columns, left to right are: • Truck number The second series of data below the haul cycle data • Haul cycle start date is the alarms. The alarm columns, left to right are: • Haul cycle start time • Payload • The alarm type • Swingloads • The date the alarm was set • Operator ID • The time the alarm was set • Warning Flags • Alarm description • Ca rry Back • The date the alarm was cleared • Total Haul Cycle time • The time the alarm was cleared • Empty Running Time • Empty stop time • Loading time Compressed • Loaded running time • Loaded stopped time • Dumping time • Loading start time • Dumping start time • Loaded haul distance • Empty haul distance • Loaded maximum speed • Time when loaded maximum speed occurred • Empty maximum speed • Time when loaded maximum speed occurred • Maximum + frame torque • Time when the maximum + frame torque occurred This export function allows the data from one laptop • Maximum - frame torque to be transferred to another computer. This can be • Time when the maximum - frame torque useful when a service laptop is used to download occurred • Maximum sprung weight calculation multiple machines and transfer the data to a central • Time when the maximum sprung weight computer for analysis. This can also be used to copy calculation occurred haul data from a particular truck onto a diskette for • Left Front Tire-kilometer-hour analysis. • Right Front Tire-kilometer-hour The file format is a compressed binary form of the • Average Rear Tire-kilometer-hour • Frame serial number displayed query. The file can only be imported by another computer running the PDM software.
OM6009 2/05 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" button at the bottom of the 2. From the payload summary screen, press the “Payload Summary” screen. The program will display "EXPORT" button and select "To ZIP". a summary of the records from the displayed query. To delete a record, select one at a time and press the 3. The program will ask for a filename and "Delete" button. It is recommended that records be location. exported to a zip file for archival purposes before deletion. Multiple records may be selected by holding down the Shift key. Pressing the "Delete All" button Importing Data will select all the records from the current query and This import function allows the data from one laptop delete them. to be transferred to another computer. This can be useful when a service laptop is used to download multiple machines and transfer the data to a central NOTE: There is no recovery for records that have computer for analysis. This can also be used to copy been deleted from the main database. It is highly haul data from a particular truck from a diskette into a recommended that all records be exported and database for analysis. archived in a compressed file format for future reference before being deleted. To import data, press the "IMPORT" button at the bottom of the “Payload Summary” screen. The program will ask for a ".zip" file to import, locate the file and press "Open". The program will only import ".zip" files created by another computer running the PDM Software.
Payload Meter III - Section 60 OM6009 2/05 Page 60-30 Viewing Alarms Deleting Alarm Records From the Payload Summary screen, click the To delete alarm records from the main database, “Alarms” button to display the alarm screen. The press the "Delete" button at the bottom of the “Alarm alarms are sorted by the query settings from the Display” screen. The program will display a summary Payload Summary screen. Alarms can be displayed of the alarms from the query. To delete an alarm, as Active or Inactive. select one at a time and press the "Delete" button. It is recommended that the query data be exported to a “.zip” file for archival purposes before deletion. Multiple records may be selected by holding down the Shift key. Pressing the "Delete All" button will select all the alarms from the current query and delete them. NOTE: There is no recovery for alarms that have been deleted from the main database. It is highly recommended that all records be exported and archived in a compressed file format for future reference before being deleted.
OM6009 2/05 Payload Meter III - Section 60 Page 60-31 NOTES
Payload Meter III - Section 60 OM6009 2/05 Page 60-32 NOTES PORTIONS OF THIS PRODUCT RELATING TO PAYLOAD MEASURING SYSTEMS ARE MANUFACTURED UNDER LICENSE FROM L.G. HAGENBUCH holder of U.S. Patent Numbers 4,831,539 and 4,839,835
OM7004 4/05 Radio / Cassette Player - Section 70 Page 70-1 RADIO / CASSETTE PLAYER FIGURE 70-1. RADIO / CASSETTE PLAYER GENERAL RECEIVER FUNCTIONS Setting The Default Display Turning The Power On And Off 1. Press and hold DSPL/TM (9) for two seconds until the hour digits flash. 1. Turn the key switch to ON. 2. Press push-button 6/FF (15) to change the 2. Press PWR (1, Figure 70-1) to turn the receiver default display. on and off. Pushing ON/AUDIO (6) also turns After five seconds of inactivity has elapsed, the the receiver power on. selected default will display. Display With the receiver off, the clock will be displayed. Adjusting Display Brightness Momentarily pressing DSP/TM SET (9) with the 1. Press and hold DIM (14) until DIM appears on receiver on will allow the operator to toggle between the display. displays. 2. Rotate ON/AUDIO knob (6) clockwise or coun- • When the receiver is in AM, FM1, FM2, or WX, terclockwise until the desired brightness is the display will toggle between the frequency and obtained. the clock. • When the receiver is in an active satellite mode and the provider is transmitting the available information, the display will toggle between the clock, frequency, station name, artist, song title and music type. • When the receiver is in the cassette mode, the display will toggle between TP SIDE 1 or TP SIDE 2, and the clock.
Radio / Cassette Player - Section 70 OM7004 4/05 Page 70-2 SETTING THE TIME SEEK Mode 1. Turn the key switch ON. Hold either the TUNE or SEEK buttons for more 2. Press and hold DSPL/TM SET (9, Figure 70-1) than 0.5 seconds to enter the seek mode. SEEK will for two seconds. When the number display appear on the display when this mode is activated. In flashes, time set mode is active. this mode, the radio will scroll through stations and 3. Press TUNE / SEEK (7 & 8) to change the stop on the next station with a strong signal. hour setting. NOTE: If the receiver can not find a strong enough 4. Press the DSPL/TM button to switch to minutes. signal after two band cycles, the seek mode will The minute digits will flash when in this mode. discontinue and the receiver will return to the initial starting point. 5. Press TUNE / SEEK to change the minute setting. When in satellite mode, press TUNE or SEEK to navigate through the channels. Pressing and holding After five seconds of inactivity, the display will return either of the two buttons for more than two seconds to the default mode. The clock will now display the will increase the cycle speed through the channels. correct time of day. The increase cycle speed is approximately 10 chan- nels per second. SCAN OPERATING THE RADIO Press SCAN button (10) to scan all stations on the BAND current band. When a strong frequency is found, the receiver will pause on that station for about five sec- Press BAND (2, Figure 70-1) to switch between FM1, onds and then continue scanning. Scan will appear FM2, AM, and WX Weather (US) and Satellite (XM1, on the display along with the frequency when this XM2 or SR1, SR2). If a separate satellite receiver is mode is active. To stop scanning, press the SCAN not connected to your radio and operational, the sat- button again. ellite bands will not appear in the display. AUTO TUNE/SEEK AUTO (12) allows the receiver to store the six stron- TUNE (7) / SEEK (8) allows you to move up or gest stations onto push-buttons 1 through 6. Press down in frequency to other stations. There are two AUTO until AUTO and AS appear on the display. The modes of operation for finding other stations, manual presets on the current band only will now be pro- tuning and seek mode. grammed with the six strongest frequencies. Presets on the other inactive bands will not be changed. Press and hold both TUNE (8) and BAND (2) for Pressing AUTO again will delete the stations and two seconds to toggle between the two modes. The default to the original preset stations. display will read either MANUAL or SEEK to indicate NOTE: The AUTO function is not functional on the the mode the receiver is in. satellite band. Manual Tuning Press TUNE (8) to tune to the next higher fre- quency. Press SEEK (7) to tune to the next lower frequency. Holding either of the buttons for more than 0.5 seconds will activate fast tuning for increased speed. When in satellite mode, press and release either the TUNE or the SEEK buttons to navigate to the next channel. Pressing and holding either of the two buttons for more than 0.5 seconds will increase the cycle speed through the channels. The increase cycle speed is approximately 10 channels per sec- ond.
OM7004 4/05 Radio / Cassette Player - Section 70 Page 70-3 ADJUSTING THE RECEIVER SETTINGS OPERATION OF THE WEATHERBAND (U.S.) VOLUME: Rotate ON/AUDIO (6, Figure 70-1) knob clockwise to increase the volume and counter-clock- NOAA - weather radio is a service of the National wise to decrease the volume. VOL will be displayed Weather Service. It provides continuous broadcasts along with the volume level. of the latest weather information directly from the National Weather Service offices. Taped weather BASS: Push and release ON/AUDIO (6) knob until messages are repeated every four to six minutes and BASS and the current bass level is displayed. Rotate are routinely revised every one to three hours, or the knob clockwise to increase the bass and counter- more frequently if needed. Most of the stations oper- clockwise to decrease the bass. ate 24 hours, daily. TREBLE: Push and release ON/AUDIO (6) knob until The weather for the area you are in may be found on TREB and the current treble level is displayed. one of seven stations. When in the Weatherband Rotate the knob clockwise to increase the treble and mode, the display will show the WX icon and CHAN # counter-clockwise to decrease the treble. to indicate the channel. The channel may be FADE: Push and release ON/AUDIO (6) knob until adjusted through the TUNE /SEEK buttons, and FADE and the current level is displayed. Rotate the may be preset as in the radio mode. knob clockwise to move the sound to the front speak- The frequency associated with each channel is as ers and counter-clockwise to move the sound to the follows: rear speakers. BALANCE: Push and release ON/AUDIO (6) knob 1. 162.550 MHz 5. 162.450 MHz until BAL and the present level is displayed. Rotate 2. 162.400 MHz 6. 162.500 MHz the knob clockwise to move the sound to the right 3. 162.475 MHz 7. 162.525 MHz speakers and counter-clockwise to move the sound 4. 162.425 MHz to the left speakers. SPEAKER: Push and release ON/AUDIO (6) knob until SPKR and the current setting is displayed. The National Weather Service operates approxi- Rotate the ON/AUDIO knob to select two-speaker or mately 372 stations. Close to 90 percent of the four-speaker operation. With two-speaker operation nation's population is within the listening range of a active, the rear speakers are muted and the FADE NOAA weather radio broadcast. option will not appear on the menu. PROGRAMMING PRESET STATIONS Presets are stations that are stored on each of the 6 push-buttons. After a station has been programmed into one of the preset buttons, pushing the preset provides a quick return to that station. The six but- tons can each store a preset channel per band. NOTE: The receiver is equipped with two FM radio bands: FM1 and FM2. The two bands are identical. However, each one allows the operator to set 6 preset channels for a total of 12 FM presets. Perform the following steps to program the presets: 1. Turn the receiver on. 2. Select the band and the desired station. 3. Press and hold one of the six push-buttons for at least two seconds. During this period, receiver output will be muted and the push-but- ton number will not show on the display. When the station has been committed to memory, the audio and the preset icon will return.
Radio / Cassette Player - Section 70 OM7004 4/05 Page 70-4 SATELLITE RADIO Operating Satellite Radio To use the satellite radio function on your radio, a 1. Use the BAND button to select the proper satel- subscription must be ordered from a provider. There lite radio band. (XM1, XM2, SR1, SR2) are currently two providers in the U.S.: XM and Sirius 2. Use the TUNE and SEEK buttons to navi- Satellite Radio. When a subscription is ordered, you gate through the channels. will need to get an additional receiver and antenna from your provider. To activate the external satellite receiver, you must Program Type Search (PTY) supply the provider with your Electronic Serial Num- ber (ESN). To find the ESN, first install the satellite XM and Sirius both allow you to search by music receiver per the instructions from the your provider. type. Program Type Search (PTY) allows you to per- Next, follow the instructions below. form a music search by type. Perform the following steps in order to do a PTY search. XM Satellite Radio: 1. Turn both the radio and the satellite receiver on. Press the BAND button on the radio and select 1. Press SCAN and push-button 1 at the same either XM1 or XM2. time. PTY will appear on the display. 2. Tune your satellite receiver to channel 0 to see 2. Continue to press push-button 1 until the the ESN display. desired genre of programming is displayed. Record the ESN. 3. Once the desired genre has been selected, press the TUNE and SEEK buttons to scroll The display will return to the default setting after through the different channels in that genre. five seconds. Station names will appear on the display as Sirius Satellite Radio: your scroll. 1. Turn the radio on and with the display showing You may also scan through the channels using the clock, press and hold the DSPL/TM SET the scan feature. Press the SCAN button to button until the hours segment is flashing. begin scanning the channels. Press the SCAN 2. Press the BAND button and the ESN will be dis- button again to stop at the desired channel. played. Record the ESN. The display will return to the default setting after five seconds. NOTE: Only one satellite receiver can be installed and connected to your receiver at one time. Obstructions in the satellite signal may impair your satellite radio reception. Contact your provider for satellite radio reception problems.
OM7004 4/05 Radio / Cassette Player - Section 70 Page 70-5 CASSETTE PLAYER Cassette Functions The cassette player that the radio is equipped with The 4/REV button (17) rewinds the cassette. The works best with cassettes that range from 30 to 90 cassette will continue to rewind until the button is minutes long. Cassettes that are longer than 90 min- pressed again, or until the cassette reaches the end utes have thinner tape, and do not work well in this of the tape. <REW will appear on the display as the model cassette player. cassette is rewinding. It is also important to only use cassettes that are in The 6/FF button (15) fast forwards the cassette. The good condition. Cassettes that are dirty, damaged, or cassette will continue to fast forward until the button have been exposed to excessive heat and/or sunlight is pressed again, or until the cassette reaches the could cause damage to the cassette player and pos- end of the tape. FWD> will appear on the display as sible failure. the cassette is fast forwarding. The cassette player is equipped with automatic equalization and metal tape sensing functions. An M Press Eject (5) to remove the cassette from the will appear on the display when a metal tape is player. When the eject button is held, it acts as a stop sensed. button. Cleaning the cassette player is a recommended maintenance item. Clean the player at 35 hour (cas- The button (4) causes the cassette player to sette play) intervals. Failure to clean the cassette reverse directions and play the opposite side of the player may diminish sound quality and cause cas- cassette. Pressing the button a second time will sette player failure. reverse the cassette back to the original side. NOTE: The cassette will automatically flip to the opposite side when the end of the tape is reached. Playing A Cassette 1. Turn the receiver ON. 2. Insert a cassette into the player. The cassette Programmable Eject Default icon will appear on the display. The tape will begin to play when the icon appears. The cassette player has been pre-programmed to return to the radio after a tape has been ejected. This Press button (3, Figure 70-1) to change default may be changed to an “eject audio mute” from the radio to a cassette. TP SIDE 1 or TP mode. This mode will mute the radio after a cassette SIDE 2 will appear on the display depending on has been ejected. When this occurs, “NO TAPE” will which side of the cassette is currently being appear on the display and the radio will remain played. If a cassette is not loaded in the player, muted until BAND (2) is pressed. Pressing this button NO TAPE will appear on the display. will enable the radio. NOTE: A tape may be inserted when the receiver is Perform the following steps to change the eject off by pressing the eject button and inserting the tape default mode: within 25 seconds. 1. Press and hold DSP/TM SET (9, Figure 70-1) for at least 2 seconds until the hour digits flash. 2. Press button (3) to toggle between “P.PLAY” and “EJMUTE”. After five seconds of inactivity, the receiver will return to the default display.
Radio / Cassette Player - Section 70 OM7004 4/05 Page 70-6 Bad Tape Detect Cleaning The Cassette Player If the receiver detects a bad cassette, “BAD TAPE” After 35 hours of cassette play, the display will read will appear on the display and the tape will be TP CLEAN for five seconds. This indicates that it is ejected. If this occurs, remove the cassette from the time to clean the cassette player. player and do not re-insert. 1. Turn key switch to ON and turn off receiver. The bad tape detector must be turned off to use a 2. Disable BAD TAPE DETECT mode. Press and cleaning tape or a CD adapter in the cassette player. Perform the following steps to disable this mode: hold button (3, Figure 70-1) for five sec- onds. “BAD TAPE DETECT OFF” will appear 1. Turn off receiver and turn key switch to OFF. on the display. When this is displayed, the detector has been disabled. 2. Press and hold button (3) for five seconds. “BAD TAPE DETECT OFF” will appear on the 3. Turn the receiver on. display. When this is displayed, the detector 4. Insert a wet-type, non-abrasive, scrubbing cas- has been disabled. sette cleaner. Follow the instructions provided with the cleaner. Repeat this procedure to reactivate the bad tape detector. “BAD TAPE DETECT ON” will 5. Reset the clean tape timer. With the receiver appear on the display after the detector has on, press and hold the eject button for five sec- been activated. onds. TP CLEAN will appear on the display and the tape icon will flash after three seconds has elapsed. After five seconds CLN RST will appear on the display. When this occurs, the clean tape timer will be reset to zero hours. If the button was released before CLN RST was displayed, the timer will not be reset.