Operation & Maintenance CEAM011001

Manual

DUMP TRUCK

SERIAL SUFFIX A30212 and up

Unsafe use of this machine may cause serious injury or death. Operators and maintenance
personnel 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
disclosed 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
obligation 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.
NOTES
OM1032.1 02/03 Introduction - Section 1
Page 1-1

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 should read and understand the materials in this manual before operat-
ing the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings and
cautions should 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 G.V.W. (Gross Vehicle
Weight) rating.

The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 730E).
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 man-
ufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service
parts and/or warranty consideration.

The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other compo-
nents. The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle
Weight (GVW) GVW is TOTAL WEIGHT: the Empty Vehicle Weight + the fuel & 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 1 OM1032.1 02/03
Page 1-2

Alerts

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 WILL 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.
OM1032.1 02/03 Introduction - Section 1
Page 1-3

TABLE OF CONTENTS
SUBJECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION / PAGE
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 1
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
ALERTS Page - a description of the DANGER, WARNING, and CAUTION symbols used in this manual. . . 1-2
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Truck Model Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
STANDARD CHARTS and TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 2
Safety records of most organizations will show that the greatest percentage of accidents are caused by unsafe acts
of persons. The remainder are caused by unsafe mechanical or physical conditions. Report all unsafe conditions to
the proper authority. These safety rules are provided as a guide for the Komatsu truck operator. However, local
conditions and regulations may add many more to this list.
GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
PRECAUTIONS DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Before Starting Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Operating Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
PRECAUTIONS FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Before Carrying Out Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
During Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
ADDITIONAL JOB SITE RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
WHEN REPAIRS ARE NECESSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
WARNING, CAUTION, and Instruction Plates / Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3
This portion of the manual covers Identification, location, and operation of the controls, switches, and indicators in
the Operator's Cab and use / function of these controls, switches, and indicators.
OPERATING INSTRUCTIONS
Preparing For Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Safety Is Thinking Ahead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
At The Truck - Ground Level Walk-Around Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
ENGINE START-UP SAFETY PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
AFTER ENGINE HAS STARTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
MACHINE OPERATION SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
HAULING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
PASSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
DUMPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Introduction - Section 1 OM1032.1 02/03
Page 1-4

TABLE OF CONTENTS (Continued)

SUBJECT ....................................................................................................... SECTION / PAGE
OPERATION (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3
TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
SAFE PARKING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
DELAYED ENGINE SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
SUDDEN LOSS OF ENGINE POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
OPERATOR CAB and CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
STEERING WHEEL AND CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
SERVICE BRAKE PEDAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
DYNAMIC RETARDER PEDAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
THROTTLE PEDAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
HEATER / AIR CONDITIONER VENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
OVER HEAD PANEL AND DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
CENTER CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
INSTRUMENT PANEL AND INDICATOR LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23
Control Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23
INSTRUMENT PANEL (Figure 3-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
PANEL GAUGES, INDICATORS, AND CONTROLS (Discussion of items 1 - 28, Figure 3-6) . . . . . . . . . . . .3-24
OVERHEAD STATUS / WARNING INDICATOR LIGHT PANEL (Figure 3-7) . . . . . . . . . . . . . . . . . . . . . . . .3-30
INDICATOR LIGHT SYMBOLS - Refer to Figure 3-7 by rows (A-E) and columns (1 - 8). . . . . . . . . . . . . . . .3-31
Hazard Warning Lights (9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37
Lamp Test Switch / Centry™ Diagnostic Test Switch (10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37
CENTRY™ FUEL SYSTEM DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38
DETERMINING "FAULT" CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38
EXITING THE DIAGNOSTICS MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 4
This portion of the manual pertains mainly to the periodic Lubrication and Service required to keep the truck oper-
ating at its design potential. Routine lubrication and maintenance procedures are provided in this section. For
major repairs, refer to the appropriate section in the Truck Service Manual. Refer to the engine manufacturer's ser-
vice manual when servicing the engine.
Lubrication and Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Service Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Hydraulic Tank Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Coolant Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Radiator Filling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Cooling System Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
10 HOUR (SHIFT) Lubrication And Maintenance Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
50 HOUR Lubrication And Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
OM1032.1 02/03 Introduction - Section 1
Page 1-5

TABLE OF CONTENTS (Continued)

SUBJECT ....................................................................................................... SECTION / PAGE
MAINTENANCE (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 4
100 HOUR Lubrication And Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
250 HOUR Lubrication And Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
500 HOUR Lubrication And Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
1000 HOUR Lubrication And Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
5000 HOUR Lubrication And Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Lincoln Automatic Lubrication System (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
System Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
System Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Lubricant Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Filter and Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
System Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
24 VDC Solid State Timer Checkout & Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Pump Rebuild . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Preventative Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 5
This portion of the manual covers major component descriptions and truck specifications.
Major Component Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 6 & 7

This portion of the manual covers operation/maintenance of OPTIONAL EQUIPMENT.
PAYLOAD METER III (Refer to separate PAYLOAD METER III Index) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
RADIO, AM/FM STEREO CASSETTE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Introduction - Section 1 OM1032.1 02/03
Page 1-6

KOMATSU MODEL 730E DUMP TRUCK

OM1032.1 02/03 Introduction - Section 1
Page 1-7

About This Manual

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 should 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 should be understood and followed when operating or accomplishing repairs on the truck.
The front cover of this manual includes a Form Number. This Form No. should be referenced when ordering addi-
tional 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
FAX - (309) 672-7072

This 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.

When searching for a specific area of interest, go first to the Table of Contents to locate the Section in which the
subject 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 Num-
bers 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 No., 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 100 ft.lbs. (135 N.m) torque. All torque specifications have ±10% tolerance unless otherwise
specified.
Introduction - Section 1 OM1032.1 02/03
Page 1-8

NOTES
OM1032.2 Introduction - Section 1
Standard Charts and Tables Page 1-9

STANDARD CHARTS AND TABLES

This manual provides dual dimensioning for most spec- EFFECT OF SPECIAL LUBRICANTS
ifications. U.S. standard units are specified first, with On Fasteners and Standard Torque Values
metric (SI) units in parentheses. References through- KOMATSU engineering department does NOT recom-
out the manual to standard torques or other standard mend the use of special “friction-reducing” lubricants
values will be to one of the following Charts or Tables. such as, “Copper Coat”, “Never Seize”, and other simi-
For values not shown in any of the charts or tables, lar products on the threads of standard fasteners
standard conversion factors for most commonly used where “standard torque” values are applied.
measurements are provided in TABLE XIII, page 1-14.
The use of special “friction-reducing” lubricants will sig-
nificantly alter the clamping force being applied to fas-
INDEX OF TABLES
teners during the tightening process.
TABLE I . . . . . . . Standard Torque Chart (SAE) . . . 1-9
TABLE II . Standard Torque, 12-Point, Grade 9 . . 1-10 If special “friction-reducing” lubricants are used with the
TABLE III . . Standard Metric Assembly Torque . . 1-10 “Standard Torque” values listed below in Table I (and in
TABLE IV . . . . . . JIC Swivel Nuts Torque Chart . . 1-11 Komatsu shop manuals), excessive stress and possi-
TABLE V . . . . . . . . .Pipe Thread Torque Chart . . 1-11 ble breakage of the fasteners may result.
TABLE VI . . . . . . . . O-Ring Boss Torque Chart . . 1-11 Where Torque Tables specify “Lubricated Threads” for
TABLEVII . . . . O-Ring Face Seal Torque Chart . . 1-11 the Standard Torque values listed, these standard
TABLE VIII . Torque Conversions (ft.lbs. - N.m) . . 1-12 torque values are to be used with simple lithium
TABLE IX . . Torque Conversions (ft.lbs. - kg.m) . . 1-12 base chassis grease (multi-purpose EP NLGI) or a
TABLE X . . . Pressure Conversions (psi - kPa) . . 1-12 rust- preventive grease (see list, page 1-10) on the
TABLE XI . . Pressure Conversions (psi - MPa) . . 1-12 threads and seats, unless specified otherwise.
TABLE XII . . . . . . . .Temperature Conversions . . 1-13 NOTE: Always be sure threads of fasteners and tapped
TABLE XIII . . . Common Conversion Multipliers . . 1-14 holes are free of burrs and other imperfections before
assembling.
Standard torque values are not to be used when
“Turn-of-the-Nut” tightening procedures are rec-
ommended.

TABLE I. -STANDARD TORQUE CHART

SAE HEX HEAD CAPSCREW AND NUT ASSEMBLY
Grade 5 (LUBRICATED THREADS) Grade 8
TOLERANCES ±10%
Cap- TORQUE - TORQUE - Cap- TORQUE - TORQUE -
screw GRADE 5 GRADE 8 screw GRADE 5 GRADE 8
Thread Thread
Size ft. lbs. kg.m N.m ft. lbs. kg.m N.m Size 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
Introduction - Section 1 OM1032.2
Page 1-10 Standard Charts and Tables

Standard Assembly Torques For 12-Point, Grade 9, Standard Metric Assembly Torque For Class 10.9
Capscrews (SAE) Capscrews & 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), Capscrews. capscrews and Class 10 nuts.
• Capscrew threads and seats SHALL be lubricated • Capscrew threads and seats SHALL NOT be lubri-
when assembled. cated when assembled. These specifications are
Unless instructions specifically recommend otherwise, based on all capscrews, nuts, and hardened
washers being phosphate and oil coated.
these standard torque values are to be used with
simple lithium base chassis grease (multi-purpose EP NOTE: If zinc-plated hardware is used, each piece
NLGI) or a rust- preventive grease (see list, this page) must be lubricated with a Rust Preventive Grease or
on the threads. Lithium-base grease to achieve the same clamping
forces provided below.
• Torques are calculated to give a clamping force of
approximately 75% of proof load. • Torques are calculated to give a clamping force of
approximately 75% of proof load.
• The maximum torque tolerance shall be ±10% of
the torque value shown. • The maximum torque tolerance shall be within
±10% of the torque value shown.
TABLE II. - STANDARD ASSEMBLY TORQUE TABLE III. - STANDARD METRIC ASSEMBLY TORQUE
for 12-Point, Grade 9 Capscrews
CAPSCREW TORQUE TORQUE TORQUE
CAPSCREW TORQUE TORQUE TORQUE SIZE* N.m ft.lbs. kg.m
SIZE* ft. lbs. N.m kg.m
M6 x1 12 9 1.22
0.250 - 20 12 16 1.7
M8 x 1.25 30 22 3.06
0.312 - 18 24 33 3.3
M10 x 1.5 55 40 5.61
0.375 - 16 42 57 5.8
M12 x 1.75 95 70 9.69
0.438 -14 70 95 9.7
M14 x 2 155 114 15.81
0.500 -13 105 142 14.5
M16 x 2 240 177 24.48
0.562 - 12 150 203 20.7
M20 x 2.25 465 343 47.43
0.625 - 11 205 278 28.3
M24 x 3 800 590 81.6
0.750 - 10 360 488 49.7
M30 x 3.5 1600 1180 163.2
0.875 - 9 575 780 79.4
M36 x 4 2750 2028 280.5
1.000 - 8 860 1166 119
* Shank Diameter (mm) - Threads per millimeter
1.000 - 12 915 1240 126
This table represents standard values only. Do not use these val-
1.125 - 7 1230 1670 170 ues to replace torque values which are specified in assembly
1.125 - 12 1330 1800 184 instructions.

1.250 - 7 1715 2325 237

Suggested* Sources for Rust Preventive Grease:
1.250 - 12 1840 2495 254
1.375 - 6 2270 3080 313
• AMERICAN ANTI-RUST GREASE #3-X from
Standard Oil Company (also American Oil Co.)
1.375 - 12 2475 3355 342
1.500 - 6 2980 4040 411
• GULF NORUST #3 from Gulf Oil Company.
1.500 - 12 3225 4375 445 • MOBILARMA 355, Product No. 66705 from Mobil
* Shank Diameter (in.) - Threads per inch Oil Corporation.
This table represents standard values only. Do not use these val- • RUST BAN 326 from Humble Oil Company.
ues to replace torque values which are specified in assembly
instructions.
• 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.
OM1032.2 Introduction - Section 1
Standard Charts and Tables Page 1-11

TABLE IV. TABLE VI.

TORQUE CHART FOR JIC 37° SWIVEL NUTS TORQUE CHART FOR
WITH OR WITHOUT O-RING SEALS O-RING BOSS FITTINGS

SIZE TUBE SIZE THREADS TORQUE SIZE TUBE SIZE THREADS TORQUE
CODE (O.D.) UNF-2B FT. LBS. CODE (O.D.) UNF-2B FT. LBS.
–2 0.125 0.312 – 24 4 ±1 –2 0.125 0.312 – 24 4 ±2
–3 0.188 0.375 – 24 8 ±3 –3 0.188 0.375 – 24 5 ±2
–4 0.250 0.438 – 20 12 ±3 –4 0.250 0.438 – 20 8 ±3
–5 0.312 0.500 – 20 15 ±3 –5 0.312 0.500 – 20 10 ±3
–6 0.375 0.562 – 18 18 ±5 –6 0.375 0.562 – 18 13 ±3
–8 0.500 0.750 – 16 30 ±5 –8 0.500 0.750 – 16 24 ±5
– 10 0.625 0.875 – 14 40 ±5 – 10 0.625 0.875 – 14 32 ±5
– 12 0.750 1.062 – 12 55 ±5 – 12 0.750 1.062 – 12 48 ±5
– 14 0.875 1.188 – 12 65 ±5 – 14 0.875 1.188 – 12 54 ±5
– 16 1.000 1.312 – 12 80 ±5 – 16 1.000 1.312 – 12 72 ±5
– 20 1.250 1.625 – 12 100 ±10 – 20 1.250 1.625 – 12 80 ±5
– 24 1.500 1.875 – 12 120 ±10 – 24 1.500 1.875 – 12 80 ±5
– 32 2.000 2.500 – 12 230 ±20 – 32 2.000 2.500 – 12 96 ±10

TABLE V. TABLE VII.

TORQUE CHART FOR TORQUE CHART FOR
PIPE THREAD FITTINGS O-RING FACE SEAL FITTINGS

PIPE WITH WITHOUT SIZE TUBE SIZE THREADS TORQUE

SIZE THREAD SEALANT SEALANT CODE (O.D.) UNF-2B FT. LBS.
CODE SIZE FT. LBS. FT. LBS.
–4 0.250 0.438 – 20 11 ±1
–2 0.125 – 27 15 ±3 20 ±5
–6 0.375 0.562 – 18 18 ±2
–4 0.250 – 18 20 ±5 25 ±5 –8 0.500 0.750 – 16 35 ±4
–6 0.375 – 18 25 ±5 35 ±5
– 10 0.625 0.875 – 14 51 ±5
–8 0.500 – 14 35 ±5 45 ±5
– 12 0.750 1.062 – 12 71 ±7
– 12 0.750 – 14 45 ±5 55 ±5 – 16 1.000 1.312 – 12 98 ±6
– 16 1.000 – 11.50 55 ±5 65 ±5
– 20 1.250 1.625 – 12 132 ±7
– 20 1.250 – 11.50 70 ±5 80 ±5
– 24 1.500 1.875 – 12 165 ±15
– 24 1.500 – 11.50 80 ±5 95 ±10
– 32 2.000 – 11.50 95 ±10 120 ±10
Introduction - Section 1 OM1032.2
Page 1-12 Standard Charts and Tables

TABLE VIII. TORQUE CONVERSIONS

Foot Pounds – ft. lbs. To Newton-meters (N.m)

FT. LBS. 0 1 2 3 4 5 6 7 8 9
0 (N.m) 1.36 2.71 4.07 5.42 6.78 8.14 9.49 10.85 12.20
10 13.56 14.91 16.27 17.63 18.98 20.34 21.69 23.05 24.40 25.76
20 27.12 28.47 29.83 31.18 32.54 33.90 35.25 36.61 37.96 39.32
30 40.67 42.03 43.39 44.74 46.10 47.45 48.81 50.17 51.52 52.87
40 54.23 55.59 56.94 58.30 59.66 60.01 62.37 63.72 65.08 66.44
50 67.79 69.15 70.50 71.86 73.21 74.57 75.93 77.28 78.64 80.00
60 81.35 82.70 84.06 85.42 86.77 88.13 89.48 90.84 92.20 93.55
70 94.91 96.26 97.62 98.97 100.33 101.69 103.04 104.40 105.75 107.11
80 108.47 109.82 111.18 112.53 113.89 115.24 116.60 117.96 119.31 120.67
90 122.03 123.38 124.74 126.09 127.45 128.80 130.16 131.51 132.87 134.23
See NOTE on page 1 -13 regarding Table usage

TABLE IX. TORQUE CONVERSIONS

Foot Pounds – ft. lbs. To kilogram-meters (kg.m)

FT. LBS. 0 1 2 3 4 5 6 7 8 9
0 (kg.m) 0.138 0.277 0.415 0.553 0.692 0.830 0.968 1.106 1.245
10 1.38 1.52 1.66 1.80 1.94 2.07 2.21 2.35 2.49 2.63
20 2.77 2.90 3.04 3.18 3.32 3.46 3.60 3.73 3.87 4.01
30 4.15 4.29 4.43 4.56 4.70 4.84 4.98 5.12 5.26 5.39
40 5.53 5.67 5.81 5.95 6.09 6.22 6.36 6.50 6.64 6.78
50 6.92 7.05 7.19 7.33 7.47 7.61 7.74 7.88 8.02 8.16
60 8.30 8.44 8.57 8.71 8.85 8.99 9.13 9.27 9.40 9.54
70 9.68 9.82 9.96 10.10 10.23 10.37 10.51 10.65 10.79 10.93
80 11.06 11.20 11.34 11.48 11.62 11.76 11.89 12.03 12.17 12.30
90 12.45 12.59 12.72 12.86 13.00 13.14 13.28 13.42 13.55 13.69
See NOTE on page 1 -13 regarding Table usage

TABLE X. PRESSURE CONVERSIONS

Pounds/square inch (psi) To Kilopascals (kPa)
Formula: psi x 6.895 = kPa

PSI 0 1 2 3 4 5 6 7 8 9
0 (kPa) 6.895 13.79 20.68 27.58 34.47 41.37 48.26 55.16 62.05
10 68.95 75.84 82.74 89.63 96.53 103.42 110.32 117.21 124.1 131.0
20 137.9 144.8 151.7 158.6 165.5 172.4 179.3 186.2 193.1 200.0
30 206.8 213.7 220.6 227.5 234.4 241.3 248.2 255.1 262.0 268.9
40 275.8 282.7 289.6 296.5 303.4 310.3 317.2 324.1 331.0 337.9
50 344.7 351.6 358.5 365.4 372.3 379.2 386.1 393.0 399.9 406.8
60 413.7 420.6 427.5 434.4 441.3 448.2 455.1 462.0 468.9 475.8
70 482.6 489.5 496.4 503.3 510.2 517.1 524.0 530.9 537.8 544.7
80 551.6 558.5 565.4 572.3 579.2 586.1 593.0 599.9 606.8 613.7
90 620.5 627.4 634.3 641.2 648.1 655.0 661.9 668.8 675.7 682.6
See NOTE on page 1 -13 regarding Table usage
OM1032.2 Introduction - Section 1
Standard Charts and Tables Page 1-13

TABLE XI. PRESSURE CONVERSIONS

Pounds/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:
970 psi = 6688 kPa.
1. Select Table X.
4. Go to PSI row 0, column 5; read 34.475
2. Go to PSI row 90, column 7; read 668.8
psi = 34.47 kPa. Add to step 3.
97 psi = 668.8 kPa.
5. 970 + 5 psi = 6688 + 34 = 6722 kPa.

TABLE XII. TEMPERATURE CONVERSIONS

Formula: F° - 32 ÷ 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.
Introduction - Section 1 OM1032.2
Page 1-14 Standard Charts and Tables

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
2 2 929 2 2 0.001
sq. ft. – ft. sq. centimeters (cm ) sq. centimeters (cm ) sq. ft. – ft.
3 3 16.39 3 3 0.061
cu. in. – in. cu. centimeters (cm ) cu. centimeters (cm ) cu. in. – in.

cu. in. – in. 3 liters (l) 0.016 liters (l) cu. in. – in. 3 61.02
3 3 0.028 3 3 35.314
cu. ft. – ft. cu. meters (m ) cu. meters (m ) cu. ft. – ft.

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. (force) 0.7376
ft. lbs. (force) kilogram.meters (kg.m) 0.138 kilogram.meters (kg.m) ft. lbs. (force) 7.2329
kilogram.meters kilogram.meters (kg.m) Newton.meters (N.m) 9.807
Newton.meters (N.m) 9.807
(kg.m)
Kilopascals (kPa) psi (pressure) 0.1450
psi (pressure) kilopascals (kPa) 6.895 megapascals (MPa) psi (pressure) 145.038
psi (pressure) megapascals (MPa) 0.007
kilograms/cm2 (kg/cm2) psi (pressure) 14.2231
psi (pressure) 2
kilograms/cm (kg/cm ) 2 0.0704
kilograms/cm2 (kg/cm2) kilopascals (kPa) 98.068
ton (short) kilogram (kg) 907.2
kilogram (kg) ton (short) 0.0011
ton (short) metric ton 0.0907
metric ton ton (short) 1.1023
quart – qt. liters (l) 0.946
liters (l) quart – qt. 1.0567
gallon – gal. liters (l) 3.785
liters (l) gallon – gal. 0.2642
HP (horsepower) Watts 745.7
Watts HP (horsepower) 0.00134
HP (horsepower) kilowatts (kw) 0.745
kilowatts (kw) HP (horsepower) 1.3410
OM2026.1 Safety - Section 2
General Safety Page 2-1

GENERAL SAFETY
Safety records of most organizations will show that the greatest percentage of accidents are caused by unsafe acts
of persons. The remainder are caused by unsafe mechanical or physical conditions. Report all unsafe conditions to
the proper authority.
The following safety rules are provided as a guide for the operator. However, local conditions and regulations may
add many more to this list.

Read and follow all safety precautions.

Failure to do so may result in serious injury or death.

SAFETY RULES
• ONLY trained and authorized personnel can operate and maintain the machine.
• Follow all safety rules, precautions and instructions when operating or performing maintenance on the
machine.
• When working with another operator or a person on work site traffic duty, be sure all personnel understand all
hand signals that are to be used.

SAFETY FEATURES
• Be sure all guards and covers are in their proper position. Have guards and covers repaired if damaged.
(See Walk-Around Inspection, Operating Instructions - Section 3)
• Learn the proper use of safety features such as safety locks, safety pins, and seat belts, and use these safety
features properly.
• NEVER remove any safety features. ALWAYS keep them in good operating condition.
• Improper use of safety features could result in serious bodily injury or death.

CLOTHING AND PERSONAL PROTECTIVE ITEMS

• Avoid loose clothing, jewelry, and loose long hair. They can catch on controls or
in moving parts and cause serious injury or death. Also, do not wear oily clothes
because they are flammable.
• Wear a hard hat, safety glasses, safety shoes, mask or gloves when operating
or maintaining the machine. Always wear safety goggles, hard hat and heavy
gloves if your job involves scattering metal chips or minute materials-this is so
particularly when driving pins with a hammer and when cleaning the air cleaner
element with compressed air. Check also that there is no one near the machine.

UNAUTHORIZED MODIFICATION
• Any modification made without authorization from Komatsu can create hazards.
• Before making a modification, consult your Komatsu distributor. Komatsu will not be responsible for any injury
or damage caused by any unauthorized modification.
Safety - Section 2 OM2026.1
Page 2-2 General Safety

STANDING UP FROM THE SEAT

• To prevent any accident occurring if you should touch any control lever that is not locked, always carry out the
following before standing up from the operator's seat.
• Place the gear shift lever at neutral and set the parking lever to the PARKING position.
• Lower the dump body, set the dump lever to the FLOAT position.
• Stop the engine. When leaving the machine, always lock everything. Always remember to take the key with
you. If the machine should suddenly move or move in an unexpected way, this may result in serious bodily
injury or death.

MOUNTING AND DISMOUNTING

• NEVER jump on or off the machine. NEVER get on or off a moving machine.
• When getting on or off the machine, face the machine and use the handhold and steps.
• Never hold any control levers when getting on or off the machine.
• Always maintain three-point contact with the handholds and steps to ensure that you support yourself.
• When bringing tools to the operator's compartment, always pass them by hand or pull them up by rope.
• If there is any oil, grease, or mud on the handholds or steps, wipe it off immediately. Always keep these parts
clean. Repair any damage and tighten any loose bolts.
• Use the handrails and steps marked by arrows in the diagram below when getting on or off the machine.
A: For use when getting on or off the machine from the left door.
B: For use when getting on or off the machine from the engine hood or right door.

FIRE PREVENTION FOR FUEL AND OIL

Fuel, oil, and antifreeze can be ignited by a flame. Fuel is particularly FLAMMABLE and can be HAZARDOUS.
• Keep flame away from flammable fluids.
• Stop the engine and do not smoke when refueling.
• Tighten all fuel and oil tank caps securely.
• Refueling and oiling should be made in well ventilated areas.
• Keep oil and fuel in the determined place and do not allow unauthorized persons to enter.
OM2026.1 Safety - Section 2
General Safety Page 2-3
PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURES
• Immediately after operations, the engine cooling water, engine oil, and hydraulic oil are at high temperature
and are under pressure. If the cap is removed, or the oil or water is drained, or the filters are replaced, there is
danger of serious burns. Always wait for the temperature to cool down, and carry out the operation according
to the specified procedure.
• To prevent hot water from spurting out:
1) Stop the engine.
2) Wait for the water temperature to cool down.
3) Turn the cap slowly to release the pressure before removing the cap.
• To prevent hot engine oil from spurting out:
1) Stop the engine.
2) Wait for the oil temperature to cool down.
3) Turn the cap slowly to release the pressure before removing the cap.

ASBESTOS DUST HAZARD PREVENTION

Asbestos dust can be HAZARDOUS to your health if it is inhaled.If you handle
materials containing asbestos fibers, follow these guidelines as given below:
• NEVER use compressed air for cleaning.
• Use water for cleaning to keep down the dust.
• Operate the machine with the wind to your back, whenever possible.
• Use an approved respirator if necessary.

PREVENTION OF INJURY BY WORK EQUIPMENT

• Never enter or put your hand or arm or any other part of your body between movable parts such as the dump
body and chassis or cylinders. If the work equipment is operated, the clearance will change and this may lead
to serious bodily injury or death.

FIRE EXTINGUISHER AND FIRST AID KIT

• Be sure fire extinguishers have been provided and know how to use them.
• Provide a first aid kit at the storage point.
• Know what to do in the event of a fire.
• Be sure you know the phone numbers of persons you should contact in case of
an emergency.
Safety - Section 2 OM2026.1
Page 2-4 General Safety

PRECAUTIONS WHEN USING ROPS

• The ROPS is integrated into the cab design to protect the operator if the machine should roll over. It is designed
not only to support the load if the machine should roll over, but also to absorb the impact energy.
• The Komatsu ROPS fulfills all of the regulations and standards for all countries, but if it is rebuilt without
authorization or is damaged when the machine rolls over, the strength will drop and it will not be able to fulfill its
function properly. It can only display its performance if it is repaired or modified in the specified way.
• NEVER modify or repair the ROPS, unless authorized by the Komatsu distributor.
• The ROPS cannot provide its full protection if the operator does not fasten the seat belt properly. Always fasten
the seat belt when operating.

PRECAUTIONS FOR ATTACHMENTS

• When installing and using an optional attachment, 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 your 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.
OM2026.1 Safety - Section 2
General Safety Page 2-5

PRECAUTIONS DURING OPERATION

BEFORE STARTING ENGINE
SAFETY AT WORKSITE
• Before starting the engine, thoroughly check the area for any unusual conditions that could be dangerous.
• Examine the road surface in the job site and determine the best and safest method of operation.
• Choose an area where the ground is as horizontal and firm as possible before carrying out the operation.
• If you need to operate on a road, protect pedestrians and cars by designating a person for work site traffic duty
or by installing fences around the work site.
• Check the river bed condition, and depth and flow of water before crossing shallow parts of river. NEVER be in
water which is in excess of the permissible water depth.
• The operator must check personally the work position, roads to be used, and existence of obstacles before
starting operations.
• Always determine the travel roads in the work site and maintain them so that it is always safe for the machines
to travel.

FIRE PREVENTION
• Thoroughly remove wood chips, leaves, paper and other flammable things accumulated in the engine
compartment. They could cause a fire.
• Check fuel, lubrication, and hydraulic systems for leaks. Have any leaks repaired. Wipe up any excess oil, fuel
or other flammable fluids.
• Be sure a fire extinguisher is present and working.
• Do not operate the machine near any flame.

IN OPERATOR'S CAB
• Do not leave tools or spare parts lying around in the operator's compartment. They may
damage or break the control levers or switches. Always put them in the tool box on the
right side of the machine.
• Keep the cab floor, controls, steps and handrails free of oil, grease, snow, and excess
dirt.
• Check the seat belt, buckle and hardware for damage or wear. Replace any worn or
damaged parts. Always use seat belts when operating your machine.

VENTILATION FOR ENCLOSED AREAS

• If it is necessary to start the engine within an enclosed area, provide adequate
ventilation. Exhaust fumes from the engine can KILL.

KEEP MIRRORS, WINDOWS, AND LIGHTS CLEAN

• Remove any dirt from the surface of the windows or lights to ensure good visibility.
• Adjust the rear view mirror to a position where the operator can see best from the operator's seat, and keep the
surface of the mirror clean. If any glass should break, replace it with a new part.
• Check that the machine is equipped with the head lamps and working lamps needed for the operating
conditions. Check that all the lamps light up properly.
Safety - Section 2 OM2026.1
Page 2-6 General Safety

OPERATING MACHINE
WHEN STARTING ENGINE
• Walk around your machine again just before mounting it, checking for people and objects that might be in the
way.
• NEVER start the engine if a warning tag has been attached to the control.
• When starting the engine, sound the horn as an alert.
• Start and operate the machine only while seated.
• Do not allow any person other than the operator in the operator's compartment or any other place on the
machine.
• For machines equipped with a back-up alarm, check that the alarm works properly.

CHECK WHEN TRAVELING IN REVERSE

Before operating the machine or work equipment, do as follows:
• Sound the horn to warn people in the area.
• Check that there is no one near the machine. Be particularly careful to check
behind the machine.
• If necessary, designate a person to check the safety. This is particularly necessary when traveling in reverse.
• When operating in areas that may be hazardous or have poor visibility, designate a person to direct work site
traffic.
• Do not allow any one to enter the line of travel of the machine. This rule must be strictly observed even on
machines equipped with a backup alarm or rear view mirror.

TRAVELING
• When traveling on rough ground, travel at low speed. When changing direction, avoid turning suddenly.
• Lower the dump body and set the dump lever to the FLOAT position when traveling.
• If the engine should stop when the machine is traveling, the steering wheel will not work, and it will be
dangerous to drive the machine. Apply the brakes immediately and stop the machine.

TRAVELING ON SLOPES
• Traveling on slopes could result in the machine tipping over or slipping.
• Do not change direction on slopes. To ensure safety, go down to level ground before turning.
• 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. Take all possible steps to avoid traveling sideways, and always keep the travel
speed low.
• When traveling downhill, use the retarder to reduce speed. Do not turn the steering wheel suddenly. Do not use
the foot brake except in an emergency.
• If the engine should stop on a slope, apply the brakes fully and apply the parking brake, also, to stop the
machine.
OM2026.1 Safety - Section 2
General Safety Page 2-7
ENSURE GOOD VISIBILITY
• When working in dark places, install working lamps and head lamps, and set up lighting in the work area if
necessary.
• Stop operations if the visibility is poor, such as in mist, snow, or rain, and wait for the weather to improve to a
condition that allows the operation to be carried out safely.

OPERATE CAREFULLY ON SNOW

• When working on snowy or icy roads, there is danger that the machine may slip to the side on even the
slightest slope, so always travel slowly and avoid sudden starting, turning, or stopping.
• Be extremely careful when carrying out snow-clearing operations. The road shoulder and other objects are
buried in the snow and cannot be seen.
• When traveling on snow-covered roads, always install tire chains.

AVOID DAMAGE TO DUMP BODY

• When working in tunnels, on bridges, under electric cables, or when entering a parking place or any other place
where there are height limits, always drive extremely carefully and lower the dump body completely before
driving the machine.

DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES

• Going close to high-voltage cables can cause electric shock. Always maintain the safe distance given below
between the machine and the electric cable.

Voltage Minimum Safety Distance

6.6 kV 3m 10 ft.
33.0 kV 4m 14 ft.
66.0 kV 5m 17 ft.
154.0 kV 8m 27 ft.
275.0 kV 10 m 33 ft.

• The following actions are effective in preventing accidents:

1) Wear shoes with rubber or leather soles.
2) Use a signalman to give warning if the machine approaches too close to the electric cable.
• If the work equipment should touch the electric cable, the operator should not leave the operator's
compartment.
• When carrying out operations near high voltage cables, do not let anyone come close to the machine.
• Check with the electricity company about the voltage of the cables before starting operations.
Safety - Section 2 OM2026.1
Page 2-8 General Safety

WHEN DUMPING
• Before starting the dumping operation, check that there is no person or object behind the machine.
• Stop the machine in the correct position, and check again that there is no person or object 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 carrying out dumping operations on slopes, the machine stability will become poor and there is danger
that it may tip over. Always carry out such operations extremely carefully.
• Do not travel with the dump body raised.

WORKING ON LOOSE GROUND

• Avoid operating your machine too close to the edge of cliffs, overhangs, and deep ditches. If these areas
collapse, your machine could fall or tip over and result in serious injury or death. Remember that the soil after
heavy rain or blasting is weakened in these areas.
• Earth laid on the ground and the soil near ditches are loose. They can collapse under the weight or vibration of
your machine.
• When operating in places where there is danger of falling rocks or danger of the machine turning over, always
install ROPS and a seat belt.

WHEN LOADING
• Check that the surrounding area is safe, stop the machine in the correct loading position, then load the body
uniformly.
• Do not leave the operator's seat during the loading operation.

PARKING THE MACHINE

• Choose a horizontal road surface to park the machine. If the machine has to be parked on a slope, always put
blocks under all the wheels to prevent the machine from moving.
• When parking on public roads, provide fences and signs, such as flags or lights, on the machine to warn
pedestrians and other vehicles. Be sure that the machine, flags, or lights do not obstruct the traffic.
• Before leaving the machine, lower the dump body fully, set the parking lever to the PARKING position, stop the
engine, then lock everything. Always take the key with you.
OM2026.1 Safety - Section 2
General Safety Page 2-9

BATTERY
BATTERY HAZARD PREVENTION
• Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If you spill acid
on yourself, immediately flush the area with water.
• Battery acid could cause blindness if splashed into the eyes. If acid gets into the eyes, flush them immediately
with large quantities of water and see a doctor at once.
• If you accidentally drink acid, drink a large quantity of water or milk, beaten egg or vegetable oil. Call a doctor
or poison prevention center immediately.
• When working with batteries ALWAYS wear safety glasses or goggles.
• Batteries generate hydrogen gas. Hydrogen gas is very EXPLOSIVE, and is easily ignited with a small spark of
flame.
• Before working with batteries, stop the engine and turn the starting 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, check which is the positive (+) terminal and negative (-) terminal.
• Tighten the battery cap securely.
• Tighten the battery terminals securely. Loosened terminals can generate sparks and lead to an explosion.

STARTING WITH BOOSTER CABLES

• ALWAYS wear safety glasses or goggles when starting the machine with booster cables.
• When starting from another machine, do not allow the two machines to touch.
• Be sure to connect the positive (+) cable first when installing the booster cables. Disconnect the ground or
negative (-) cable first when removing them.
• If any tool touches between the positive (+) terminal and the chassis, it will cause sparks. This is dangerous, so
be sure to work carefully.
• Connect the batteries in parallel: positive to positive and negative to negative.
• When connecting the ground cable to the frame of the machine to be started, be sure to connect it as far as
possible from the battery.
Safety - Section 2 OM2026.1
Page 2-10 General Safety

TOWING
WHEN TOWING, FIX WIRE TO HOOK
• Towing in the wrong way may lead to serious personal injury or damage.
• When using another machine to tow this machine, use a wire rope with ample strength for the weight of this
machine.
• Never tow a machine on a slope.
• Do not use any towing rope that has kinks or is twisted.
• Do not stand astride the towing cable or wire rope.
• When connecting a machine that is to be towed, do not let any one come between the towing machine and the
machine that is being towed.
• Set the coupling of the machine being towed in a straight line with the towing portion of the machine, and
secure it in position.

(For towing method, see Section 3, "Operating Instructions", TOWING)

OM2026.1 Safety - Section 2
General Safety Page 2-11

PRECAUTIONS FOR MAINTENANCE

BEFORE CARRYING OUT MAINTENANCE

WARNING TAG
• If others start the engine or operate the controls while you are performing service or lubrication, you could
suffer serious injury or death.
• ALWAYS attach the WARNING TAG to the control lever in the operator's cab to alert others that you are
working on the machine. Attach additional warning tags around the machine, if necessary.
• These tags are available from your Komatsu distributor. (Part No. 09963-03000)

PROPER TOOLS
• Use only tools suited to the task. Using damaged, low quality, faulty, or
makeshift tools could cause personal injury.

PERIODIC REPLACEMENT OF CRITICAL PARTS

• Periodically replace parts used to insure safety or prevent accident.
• Replace these components periodically with new ones, regardless of whether or not they appear to be
defective. These components deteriorate over time.
• Replace or repair any such components if any defect is found, even though they have not reached the time
specified.

STOPPING THE ENGINE BEFORE SERVICE

• When carrying out inspection or maintenance, always stop the machine on firm flat ground, lower the dump
body, then stop the engine.
• If the engine must be run during service, such as when cleaning the radiator, always set the shift selector lever
to the neutral (N) position and the parking brake lever to the PARKING position. Always carry out the work with
two people. One person should sit in the operator's seat so that the engine can be stopped, if necessary.
NEVER move any controls not needed for operation.
• When servicing the machine, be careful not to touch any moving part or get clothing caught.
• Put blocks under the wheels.
• When carrying out service with the dump body raised, always place the dump lever at the HOLD position, and
insert the body-up safety pins (or safety cable, if equipped) securely.
Safety - Section 2 OM2026.1
Page 2-12 General Safety

DURING MAINTENANCE

PERSONNEL
• Only authorized personnel can service and repair the machine. Extra precaution should be used when
grinding, welding, and using a sledge-hammer.

ATTACHMENTS
• Place attachments that have been removed from the machine in a safe place so
that they do not fall. If they fall, serious injury could result.

WORK 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.

KEEP THE MACHINE CLEAN

• Spilled oil or grease, or scattered tools or broken pieces are dangerous
because they may cause you to slip or trip. Always keep your machine clean
and tidy.
• If water gets into the electrical system, there is danger that the machine may
not move or may move unexpectedly.Do not use water or steam to clean the
sensors, connectors, or the inside of the operator's compartment.

RULES TO FOLLOW WHEN ADDING FUEL OR OIL

• Spilled fuel and oil may cause a person to slip, always wipe it up immediately.
• Always tighten the cap of the fuel and oil fillers securely.
• Never use fuel for washing parts.
• Always add fuel and oil in a well-ventilated place.
OM2026.1 Safety - Section 2
General Safety Page 2-13
RADIATOR WATER LEVEL
• If it is necessary to add water to the radiator, stop the engine and allow the
engine and radiator to cool down before adding the water.
• Slowly loosen the cap to relieve pressure before removing the cap.

USE OF LIGHTING
When checking fuel, oil, coolant, or battery electrolyte, always use lighting
with anti-explosion specifications. If such lighting equipment is not used,
there is danger or explosion.

PRECAUTIONS WITH BATTERY

• When repairing the electrical system or when carrying out electrical
welding, remove the negative (-) terminal of the battery to stop the flow
of current.

HANDLING HIGH-PRESSURE HOSES

• Do not bend high-pressure hoses or hit them with hard objects. Do not use any bent or cracked piping, tubes or
hoses. They may burst during use.
• Always repair any loose or broken fuel hoses or oil hoses. If fuel or oil leaks, it may cause a fire.

PRECAUTIONS WITH HIGH PRESSURE OIL

• Do not forget that the work equipment circuits are always under pressure.
• Do not add oil, drain oil, or carry out maintenance or inspection before completely releasing the internal
pressure.
• If oil is leaking under high pressure from small holes, it is dangerous if the jet of high-pressure oil hits your skin
or enters your eyes. Always wear safety glasses and thick gloves, and 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.
Safety - Section 2 OM2026.1
Page 2-14 General Safety

PRECAUTIONS WHEN CARRYING OUT MAINTENANCE AT HIGH TEMPERATURE OR HIGH PRESSURE

• Immediately after stopping operations, the engine cooling water and oil at all
parts are at high temperature and under high pressure.In this condition, if
the cap is removed, or the oil or water are drained, or the filters are
replaced, it may result in burns or other injury. Wait for the temperature to go
down, then carry out the inspection and maintenance in accordance with the
procedures given in this manual.

ROTATING FAN AND BELT

• Keep away from rotating parts and be careful not to let anything get caught
in them.
• If your body or tools touch the fan blades or fan belt, they may be cut off or
sent flying, so never touch any rotating parts.

WASTE MATERIALS
• Never dump waste oil in a sewer system, rivers, etc.
• Always put oil drained from your machine in containers. Never drain oil
directly on the ground.
• Obey appropriate laws and regulations when disposing of harmful objects
such as oil, fuel, coolant, solvent, filters, batteries, and others.
OM2026.1 Safety - Section 2
General Safety Page 2-15

TIRES
HANDLING TIRES
If tires are not used under the specified conditions, they may overheat and burst or be cut and burst by sharp
stones on rough road surfaces. This may lead to serious injury or damage.
To maintain safety, always keep to the following conditions:
• Inflate the tires to the specified pressure. Abnormal heat is generated particularly when the inflation pressure is
too low.
• Use the specified tires.

The values given in this manual for the tire inflation pressure and permissible speed are general values. The actual
values may differ depending on the type of tire and the condition under which they are used. For details, please
contact your Komatsu distributor or tire maker.
If the tires become hot, a flammable gas is produced, and this may ignite. It is particularly
dangerous if the tires become overheated when the tires are under pressure. If the gas
generated inside the tire ignites, the internal pressure will suddenly rise, and the tire will
explode, and this may lead to serious personal injury. Explosions differ from punctures or
tire bursts, because the destructive force is extremely large. Therefore, the following oper-
ations are strictly prohibited when the tire is under high internal pressure:
• Welding the rim
• Building fires or carrying out welding near the wheel or tire.

If you do not understand the proper procedure for carrying out maintenance or replacement of the wheel or tire,
and you use the wrong method, the wheel or tire may burst and cause serious injury or damage. When carrying out
such maintenance, please consult your Komatsu distributor or tire maker.

STORING TIRES AFTER REMOVAL

• As a basic rule, store the tires in a warehouse which unauthorized persons cannot enter. If the tires are stored
outside, always erect a fence around the tires and put up "No Entry" and other warning signs that even young
children can understand.
• Stand the tire on level ground, and block it securely so that it cannot roll or fall over.
• If the tire should fall over, get out of the way quickly. The tires for construction equipment are extremely heavy,
so trying to hold the tire may lead to serious injury.
Safety - Section 2 OM2026.1
Page 2-16 General Safety

ADDITIONAL JOB SITE RULES

• Use this space to add any ADDITIONAL Job Site Rules not covered in any of the previous discussions.
• _______________________________________________________________________________________
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OM2026.1 Safety - Section 2
General Safety Page 2-17

WHEN REPAIRS ARE NECESSARY

1. Only qualified maintenance personnel who understand the systems being repaired should accomplish repairs.
2. Many components on the Komatsu Truck are large and heavy. Insure that lifting equipment - hoists, slings,
chains, lifting eyes - are of adequate capacity to handle the lift.
3. DO NOT WORK under a suspended load. Do 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 truck while engine is running, except when adjustments can only be made under such
conditions. Keep a safe distance from moving parts.
5. When servicing any air conditioning system with refrigerant, wear a face shield and cold resistant gloves for
protection against freezing. Be certain to follow all current regulations for handling and recycling refrigerants.
6. Follow package directions carefully when using cleaning solvents.
7. If an auxiliary battery assist is needed, first use one cable to connect the 24V positive (+) post of the disabled
truck batteries to the 24V positive (+) post of the auxiliary assist. Use second cable to connect the 24V nega-
tive (-) 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 welding on the
unit. Failure to do so may seriously damage the battery and electrical equipment. Disconnect battery charging
alternator lead wire and isolate electronic control components before making welding repairs. (It is not neces-
sary to disconnect or remove any control circuit cards on Komatsu Electric Drive Trucks or any of the "AID"
circuit control cards.)
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 voltage could be induced into the electrical harness and possi-
bly cause damage to components.
9. If truck is to be towed for any reason, use a rigid tow bar. Check truck cab for decal recommending special
towing precautions. (Also refer to Towing Procedure in OPERATING INSTRUCTIONS.)
10. Drain, clean and ventilate fuel tanks and/or hydraulic tanks before making any welding repairs.

Any operating fluid, such as hydraulic oil or brake fluid escaping 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.

11. Relieve pressure in lines or hoses before making any disconnects.

12. After adjustments or repairs, replace all shields, screens and clamps.
13. Tire Care:

Do not stand in front of rim and locking ring when inflating tire mounted on the machine. Observers should
not be permitted in the area and should be kept away from the side of such tires.
Do not weld or apply heat on the rim assembly with the tire mounted on the rim. Resulting gases inside the
tire may ignite, causing explosion of tire and rim.

14. Only a qualified operator or experienced maintenance personnel who are also qualified in operation should
move the truck under its own power in the repair facility or during road testing after repairs are complete.
Safety - Section 2 OM2026.1
Page 2-18 General Safety

NOTES
OM2026.2 02/03 Safety - Section 2
Warnings and Cautions Page 2-19

WARNINGS AND CAUTIONS

The following pages give an explanation of the Warning, Caution, and Service Instruction plates and decals
attached to the Komatsu 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 legible. If any decal or plate becomes unable to be read or dam-
aged, it should 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 plate is located on the left front post

of the operator's cab and provides the recommended
MAXIMUM speeds to be used when descending var-
ious 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 and Falling
Object Protective Structure meets various SAE per-
formance requirements.

Do not make modifications to this structure, or

attempt to repair damage without written
approval from the Manufacturer. Unauthorized
repairs will void certification.
Safety - Section 2 OM2026.2 02/03
Page 2-20 Warnings and Cautions

A warning instruction is applied below the Parking Brake and the Rear Wheel Brake Lock switches, which are
located to the right of the steering column on the instrument panel. Pushing the top of the rocker-style switch turns
the function ON, pushing the bottom, turns it OFF.

The Parking Brake is spring applied and hydraulically released. It is designed to hold a stationary truck
when the engine is shutdown and keyswitch is turned "Off". The truck must be completely stopped
before applying the parking brake, or damage may occur to parking brake.To apply the parking brake,
press the rocker switch toward the "On" symbol. To release the parking brake, press the rocker switch
toward the "Off"symbol. When the keyswitch is "On" and Parking Brake switch is applied, the Parking Brake indica-
tor light (A3, Overhead Panel) will be illuminated.
NOTE: Do not use the parking brake at shovel or dump. With keyswitch "on" and engine running, sudden shock
caused by loading or dumping could cause the system's motion sensor to RELEASE the park brake.
The Wheel Brake Lock switch is for holding the truck while parked at the shovel during loading, or
while dumping. It applies the rear service brakes only. If the brake treadle valve does not operate,
apply this brake to stop the truck. Do NOT use this brake as a parking brake when leaving the truck.
With engine shut down, the hydraulic system will eventually bleed down, releasing the service brakes.
Attached to the exterior of the battery compartment 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 connect the negative (-)
lead of the auxiliary power cable to a good frame ground. Do
not connect to the negative posts of the truck battery or
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, gog-
gles, rubber gloves and rubber apron when handling and servic-
ing batteries.

This plate is placed on both battery boxes and near the battery dis-
connect switches to indicate that the battery system (24VDC) is a
NEGATIVE (-) GROUND system.
These decals are placed above the battery disconnect switches on
the right side of the front bumper to indicate "Off" and "On" positions
of the switches.
OM2026.2 02/03 Safety - Section 2
Warnings and Cautions Page 2-21

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 radiator cap. Unless the pressure is first
released, removing the radiator cap after the engine
has been running for a time will result in the hot
coolant being expelled from the radiator. Serious
scalding and burning can result.

Warning plates are mounted on the frame in front of,

and to the rear, of the 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 body-up retention device (pins or cable) is in
position.

This Danger plate is attached to each

suspension and steering accumula-
tor(s). The plate contains instruc-
tions for releasing internal pressure
before disconnecting any hydraulic
lines or hardware.
Safety - Section 2 OM2026.2 02/03
Page 2-22 Warnings and Cautions

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 chances of
system contamination. Service the tank with clean
Type C-4 hydraulic oil. All oil being put into the
hydraulic tank should be filtered through 3 micron fil-
ters.

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 filling instructions, if oil level is below top of sight
glass.

A warning plate is attached to the frame above the

hydraulic system (APU) quick disconnect fittings to
alert technicians that high pressure hydraulic oil is
present during operation. Care must be taken when it
is necessary to open the hydraulic system. There is
always a chance of residual pressure being present.
Open fittings slowly to allow any 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 warning plate is located above the hydraulic sys-

tem (APU) quick disconnect fittings in front of the
hydraulic tank which provides instructions to the
operator or technician for towing a disabled truck.
This plate specifies the requirements for an auxiliary
source of supply for hydraulic oil and the proper
hookup.
TEST BOTH STEERING AND BRAKE SYSTEM
OPERATION BEFORE TOWING.
OM2026.2 02/03 Safety - Section 2
Warnings and Cautions Page 2-23
High Voltage Danger Plates and Caution Plates are
attached to the doors of the Electrical Control Cabi-
net. The High Voltage Plate is also attached to the
blown grid housing, extended range housing, rectifier
housing, inlet duct structure and rear hatch cover.
Before doing any welding on the truck, always dis-
connect the positive and negative battery cables of
the vehicle. Failure to do so may seriously damage
the battery and electrical equipment. Disconnect bat-
tery charging alternator lead wire and isolate elec-
tronic control components before making welding
repairs. (It is not necessary to disconnect or remove
any control circuit cards on electric drive HAULPAK®
Trucks or any of the "AID" circuit control cards.)
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 voltage could be induced into the electrical
harness and possibly cause damage to components.

This plate is mounted on the top side of the blown

grid housings. Stepping or standing here may result
in serious personal injury.

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 is located on the frame near the left

hoist cylinder which provides the operator or techni-
cian with the hook-up procedure for dumping a
loaded, disabled truck, by using a functional truck for
hydraulic power.
Refer to the Service manual for additional instruc-
tions for using this procedure.
Safety - Section 2 OM2026.2 02/03
Page 2-24 Warnings and Cautions

Warning and Danger plates are located inside the

door of the brake system cabinet behind the cab.

This plate alerts technicians to read the warning

labels attached to the accumulators prior to releasing
internal nitrogen pressure or disconnecting any
hydraulic lines or hardware.

This plate warns the technician to stop the engine,

turn off the key switch, and open the drain valves on
all three accumulators to bleed the hydraulic pres-
sure before loosening or disconnecting a brake line.

This plate is placed near the four jacking points on

the truck. Two are placed at the front of the truck next
to the right and left frame upright supports. Two are
placed at the rear of the truck under the right and left
suspension supports.

This plate is placed on the left front battery box sup-

port.
It identifies the Emergency Engine Shutdown Switch.
This switch is spring-loaded to the OFF position. It
must be held in ON position until the engine stops.
OM2026.2 02/03 Safety - Section 2
Warnings and Cautions Page 2-25

A Product Identification plate is located on the

frame in front of the right side front wheel and
shows the Truck Model Number, Maximum
G.V.W. and Product Identification Number (Truck
Serial Number). The Product Identification Num-
ber contains information which will identify the
original manufacturing bill of material for this unit.
This complete number will be necessary for
proper ordering of many service parts and/or war-
ranty consideration.

The Lubrication Chart is located on the right hand side of the radiator grille and is for reference. Refer to the "Lubri-
cation Section" in this manual for more complete lubrication instructions.
Safety - Section 2 OM2026.2 02/03
Page 2-26 Warnings and Cautions

NOTES
OM3035.1 02/03 Operation - Section 3
Operating Instructions Page 3-1

OPERATING INSTRUCTIONS
Preparing for Operation
The safest trucks are those which have been properly prepared for operation. At the beginning of each shift, a
careful check of the truck should be made by the operator before attempting to start the engine.

Safety is Thinking Ahead

Prevention is the best safety program. Prevent a potential accident by knowing the employer's safety require-
ments, all necessary job site regulations, as well as use and care of the safety equipment on the Komatsu Truck.
Only qualified operators or technicians should attempt to operate or maintain the Komatsu Truck.

Safe practices start before the operator gets to the equipment!

• Wear the proper clothing. Loose fitting clothing, unbuttoned sleeves and jackets, jewelry, etc., can catch on a
protrusion and cause a potential hazard.
• Always use the personal safety equipment provided for the operator such as hard hat, safety shoes, safety
glasses or goggles. There are some conditions when protective hearing devices should also be worn for
operator safety.
• When walking to and from the truck, maintain a safe distance from all machines even if the operator is visible.

At The Truck - Ground Level Walk Around Inspection

At the beginning of each shift, a careful walk around inspection of the truck should be made before the operator
attempts engine start-up. A walk around inspection is a systematic ground level inspection of the truck and its com-
ponents to insure that the truck is safe to operate before entering the operator's cab.
Start at the left front corner of the truck (see illustration, next page), and move in a counter-clockwise direction,
front-to-rear, across the rear, and continuing forward up the opposite side of the truck to the original starting point.
If these steps are taken in sequence, and are repeated from the same point and in the same direction before every
shift, many potential problems may be avoided, or scheduled for maintenance. UNSCHEDULED downtime and
loss of production can be reduced.
Local work practices may prevent an operator from performing all tasks suggested here, but to the extent permit-
ted, the operator should follow this or similar routine.
1. Start at left front of truck. While performing the walk around inspection, visually inspect all lights and safety
equipment for external damage from rocks or misuse. Make sure lenses are clean and unbroken.
Empty the dust pans on the left side air cleaner assemblies. Be sure battery box covers are in place and
secure.
2. Move behind the front of the left front tire, inspect the hub and brake assemblies for leaks and any abnormal
conditions. Check front wheel hub oil sight gauge for oil level.
Check that all suspension attaching hardware is secure and inspect mounting key area for evidence of wear.
Check that the suspension extension (exposed piston rod) is correct, and that there are no leaks.
3. With engine stopped, check engine oil level. If dark, turn on service light.
4. Inspect fan and air conditioner belts for correct tension, obvious wear, and tracking. Inspect fan guard for
security and condition. When leaving this point, be sure to turn off service light, if used.
5. Inspect anchor end of steering cylinder for proper greasing and for security.
6. Move outboard of the front wheel, and inspect attaching lugs/wedges to be sure all are tight and complete.
Check tires for cuts, damage or "bubbles" and that inflation appears to be correct.
Operation - Section 3 OM3035.1 02/03
Page 3-2 Operating Instructions
OM3035.1 02/03 Operation - Section 3
Operating Instructions Page 3-3
7. Move behind the rear of the front wheel, inspect for leaks at hub or brakes or any unusual conditions. Inspect
suspension hardware to be sure it is all in place. Inspect live end of steering cylinder for proper greasing, and
for security of all parts. Inspect for any hydraulic leaks.
8. Inspect sight glass on hydraulic tank. With engine stopped and body down, hydraulic fluid should be visible in
upper sight glass.
9. Move on around the hydraulic tank and in front of the rear dual tires, inspect the hoist cylinder for any damage
and leaks, also that lower guard is in place. Inspect both upper and lower hoist cylinder pins for security, and
for proper greasing.
10. Before leaving this position, look under the lower edge of the chassis to be sure the flexible duct that carries
the air from the main blower to the final drive housing is in good condition with no holes or breakage. Also look
up at the main hydraulic pumps to see that there is no leakage or any other unusual condition with pumps or
pump drive shafts.
11. Move on around the dual tires, check to see that all lugs/wedges are in place and tight. Inspect wheel cover for
cracks or damage, and check latches to be sure they are properly latched. Inspect wheel for any leakage that
may be coming from inside the wheel cover that would indicate brake leakage, or wheel motor leakage.
Check dual tires for cuts, damage or "bubbles" and that inflation appears to be correct. If truck has been run
on a "flat", the tire must be cooled before parking truck inside. Inspect for any rocks that might be lodged
between dual tires, and that rock ejector is in good condition and straight so that it can not damage a tire.
12. Inspect left rear suspension for damage and for proper inflation, and that there are no leaks. Inspect also for
proper greasing, and that covers over the chromed piston rod are in good condition.
13. Open rear hatch cover, turn on work light, if necessary. Inspect for leaks around wheel motor mounting to rear
housing and brake hoses and fittings. Be sure that covers on wheel motor sump are in place, and that there
are no rags or tools left behind. Inspect condition of hatch cover gasket, report any bad gasket to mainte-
nance. Turn off work light if used, close and latch rear hatch cover.
14. While standing in front of rear hatch, look up to see that rear lights are in good condition, along with dual back
up horns. Look up at panhard rod to see that it is getting proper greasing. Also look at both body hinge pins
for greasing and any abnormal condition.
15. Perform the same inspection on the right rear suspension as done on the left.
16. Move on around the right dual tires, inspect between the tires for rocks, and for condition of the rock ejector,
inspect the tires for cuts or damage, and for correct inflation.
17. Perform the same inspection for wheel lugs/wedges, wheel cover latches, and for leaks that was done on the
left hand dual wheels.
18. Move in front of right dual tires, and inspect the hoist cylinder the same as was done on the left side. Check
security and condition of body-up limit switch. Remove any mud/dirt accumulation from switch.
19. Move on around the fuel tank, inspect the fuel quantity gauge, (this should agree with what will show on the
gauge in the cab). Inspect the attaching hardware for the fuel tank at the upper saddles, and then at the lower
back of the tank for the security and condition of the mounts.
20. Move in behind the right front wheel, and inspect the steering cylinder, suspension attaching hardware and
suspension extension, as well as greasing and attaching hardware for the steering cylinder. Inspect the hub
and brakes for leaks and any unusual condition. Be sure the suspension protective boot is in good condition.
21. Move out and around the right front wheel, inspect that all lugs/wedges are in place and tight.
22. Move in behind the front of the right front wheel, check hub and brakes for leaks and any unusual condition.
Inspect steering cylinder for security and for proper greasing. Inspect the engine compartment for any leaks
and unusual condition. Inspect the fan guard, and belts also for any rags or debris behind radiator. Turn work
light off, if used, and secure the ladder up and latched. Inspect auto lube system. See Maintenance Section 4
for specific details concerning auto lube system.
23. Move on around to the right front of the truck, drop the air cleaner pans to remove dirt, latch up and secure.
Inspect battery box cover for damage and be sure it is in place and secure.
Operation - Section 3 OM3035.1 02/03
Page 3-4 Operating Instructions

24. As you move in front of the radiator, inspect for any debris that might be stuck in front of the radiator and
remove it. Check for any coolant leaks. Inspect all head and fog lights.
25. Before climbing ladder to first level, be sure ground level engine shutdown switch is "ON". Inspect fire control
actuator to be sure safety pin is in place and plastic tie that prevents accidental actuation is in place and in
good condition. Be sure battery disconnect switches are "ON".
26. Climb ladder to main deck. Always use grab rails and ladder when mounting or dismounting from the truck.
Clean ladder and hand rails of any foreign material, such as ice, snow, oil or mud.

Always mount and dismount ladders facing the truck. Never attempt to
mount or dismount while the truck is in motion.

27. When checking coolant in radiator, use coolant level sight gauge (if equipped) or observe coolant level through
opening in end of hood. If it is necessary to remove radiator cap, shut down engine (if running), and relieve
coolant pressure SLOWLY before removing radiator cap.

If engine has been running, allow coolant to cool, before removing the fill
cap or draining radiator. Serious burns may result if coolant is not allowed
to cool.
28. Inspect covers over braking grids to be sure latches are in place and secure. Inspect main air inlet to be sure it
is clear. Be sure all cabinet door latches are secure.
29. Move on around the cab to the back, open the doors to the brake cabinet, inspect for leaks. Before latching
doors, turn work lights off, if used.
30. Clean cab windows and mirrors; clean out cab floor as necessary. Insure steering wheel, controls and pedals
are free of any oil, grease or mud.
31. Stow personal gear in cab so that it does not interfere with any operation of the truck. Dirt or trash buildup,
specifically in the operator's cab, should be cleared. Do not carry tools or supplies in cab of truck or on the
deck.
32. Adjust seat and steering wheel so that it is comfortable for use.
33. Read and understand the OPERATOR CONTROLS AND INSTRUMENT PANEL discussion in this section. Be
familiar with all control locations and functions BEFORE operating truck.

ENGINE START-UP SAFETY PRACTICES

1. Insure all personnel are clear of truck before starting engine. Always sound the horn as a warning before actu-
ating any operational controls. If the truck is in an enclosure, insure adequate ventilation before start-up.
Exhaust fumes are dangerous!
2. Be sure parking brake switch is in "On" position. Check and insure Selector Switch is in "Neutral" before start-
ing.
3. If truck is equipped with auxiliary cold weather heater system(s), do not attempt to start engine while heaters
are in operation. Damage to coolant heaters will result.
OM3035.1 02/03 Operation - Section 3
Operating Instructions Page 3-5
4. The keyswitch is a three position (Off, Run, Start)
switch. When switch is rotated one position clockwise,
it is in the "Run" position and all electrical circuits
(except "Start") are activated. With Selector Switch in
"Neutral", rotate keyswitch fully clockwise to "Start"
position and hold this position until engine starts.
"Start" position is spring loaded to return to "Run"
when key is released.
NOTE: If truck is equipped with the Engine Prelube
System, a noticeable time delay will occur (while engine
lube oil passages are being filled) before starter
engagement and engine cranking will begin. The colder the
engine oil temperature, the longer the time delay will be. In
addition, if truck is also equipped with Engine Starting Aid
for cold weather starting, the Engine Prelube System
should be engaged FIRST for 5-10 seconds, or until starter
is engaged, BEFORE activating the Engine Starting Aid.

Starting fluid is extremely volatile and flammable! Use with extreme care.

If truck is equipped with optional Engine Starting Aid and ambient temperature is below 50oF (10oC), turn the key-
switch to the "Start" position, and while cranking engine, move the Engine Starting Aid switch to the "On" position
for three (3) seconds MAXIMUM; then release Engine Starting Aid. If engine does not start, wait at least fifteen (15)
seconds before repeating the procedure.
Do not crank an electric starter for more than 30 seconds. Allow two minutes for cooling before attempting to
start engine again. Severe damage to starter motor can result from overheating.

AFTER ENGINE HAS STARTED

1. Become thoroughly familiar with steering and emergency controls. After engine has started and low pressure
and warning systems are normal, test the truck steering in extreme right and left directions. If the steering
system is not operating properly, shut engine down immediately. Determine the steering system problem and
have repairs made before resuming operation.
2. Operate each of the truck's brake circuits at least twice prior to operating and moving the truck. These circuits
include individual activation from the operator's cab of the service brake, parking brake, and brake lock (also
emergency brake, if equipped). With the engine running and with the hydraulic circuit fully charged, activate
each circuit individually. If any application or release of any brake circuit appears sluggish or improper, or if
warning alarms are activated on application or release, shut the engine down and notify maintenance person-
nel. Do not operate truck until brake circuit in question is fully operational.
3. Check gauges, warning lights and instruments before moving the truck to insure proper system operation and
proper instrument functioning. Give special attention to braking and steering circuit hydraulic warning lights. If
warning lights come on, shut down the engine immediately and determine the cause.
4. Insure headlights, work lights and taillights are in proper working order. Good visibility may prevent an acci-
dent. Check operation of windshield wiper.
5. When truck body is in dump position, do not allow anyone beneath it unless body-up retaining pin or cable is in
place.
6. Do not use the fire extinguisher for any purpose other than putting out a fire! If extinguisher is discharged,
report the occurrence so the used unit can be refilled or replaced.
7. Do not allow unauthorized personnel to ride in the truck. Do not allow anyone to ride on the ladder of the truck.
8. Do not leave truck unattended while engine is running. Shut down engine and apply park brake before getting
out of cab.
Operation - Section 3 OM3035.1 02/03
Page 3-6 Operating Instructions

MACHINE OPERATION SAFETY PRECAUTIONS

After the truck engine is started and all systems are functioning properly, the operator must follow all local safety
rules to insure safe machine operation.
If any of the red warning lights come "On" or if any gauge reads in the red
area during truck operation, a malfunction is indicated. Stop truck as soon
as safety permits, shut down engine if problem indicates and have problem
corrected before resuming truck operation.
Operating truck with stalled or free spinning wheel motors may cause seri-
ous damage to wheel motors! If truck does not begin to move within 10
seconds after depressing throttle pedal (Selector Switch in a drive posi-
tion), release throttle pedal and allow wheels to regain traction before
accelerating engine again.
1. Always look to the rear before backing the truck. Watch for and obey ground spotter's hand signals before
making any reverse movements. Sound the warning horn (3 blasts). Spotter should have a clear view of the
total area at the rear of the truck.
2. Operate the truck only while properly seated with seat belt fastened. Keep hands and feet inside the cab com-
partment while truck is in operation.
3. Check gauges and instruments frequently during operation for proper readings.
4. Observe all regulations pertaining to the job site's traffic pattern. Be alert to any unusual traffic pattern. Obey
the spotter's signals.
5. Match the truck speed to haul road conditions and slow the truck in any congested area. Keep a firm grip on
steering wheel at all times.
6. Do not allow engine to run at "Idle" for extended periods of time.
7. Check parking brake periodically during shift. Use parking brake ONLY for parking. Do not use park brake for
loading / dumping.
Do not attempt to apply parking brake while truck is moving!
Do not use "Brake Lock" or "Emergency Brake" (if equipped) for park-
ing.With engine stopped, hydraulic pressure will bleed down, allowing
brakes to release!

8. Check brake lock performance periodically for safe loading and dump operation.
9. Proceed slowly on rough terrain to avoid deep ruts or large obstacles. Avoid traveling close to soft edges and
the edge of fill area.
10. Truck operation requires concentrated effort by the driver. Avoid distractions of any kind while operating the
truck.
LOADING
1. Pull into the loading area with caution. Remain at a safe distance while truck ahead is being loaded.
2. Do not drive over unprotected power cables.
3. When approaching or leaving a loading area, watch out for other vehicles and for personnel working in the
area.
4. When pulling in under a loader or shovel, follow "Spotter" or "Shovel Operator" signals. The truck operator
may speed up loading operations by observing the location and loading cycle of the truck being loaded
ahead, then follow a similar pattern.
5. When being loaded, operator should stay in truck cab with engine running. Place Selector Switch in "Neutral"
and apply Wheel Brake Lock.
6. When loaded, pull away from shovel as quickly as possible but with extreme caution.
7.
8.
OM3035.1 02/03 Operation - Section 3
Operating Instructions Page 3-7

HAULING
1. Always stay alert! If unfamiliar with the road, drive with extreme caution. Cab doors should remain closed at all
times if truck is in motion or unattended.
2. Obey all road signs. Operate truck so it is under control at all times. Govern truck speed by the road condi-
tions, weather and visibility. Report haul road conditions immediately. Muddy or icy roads, pot holes or other
obstructions can present hazards.
3. When backing the truck, give back-up signal (three blasts on the horn); when starting forward, two blasts on
the horn. These signals must be given each time the truck is moved forward or backward.
4. Use extreme caution when approaching a haul road intersection. Maintain a safe distance from oncoming
vehicles.
5. Maintain a safe distance when following another vehicle. Never approach another vehicle from the rear, in the
same lane, closer than 50 ft. (15 m). When driving on a down grade, this distance should not be less than 100
ft. (30 m).
6. Do not stop or park on a haul road unless unavoidable. If you must stop, move truck to a safe place, apply
parking brake, and shut down engine before leaving cab. Block wheels securely and notify maintenance per-
sonnel for assistance.
7. Before starting up or down a grade, maintain a speed that will insure safe driving and provide effective retard-
ing under all conditions. Refer to Grade/Speed decal in operator's cab.
8. When operating truck in darkness, or when visibility is poor, do not move truck unless all headlights, clearance
lights, and tail lights are on. Do not back truck if back-up horn or lights are inoperative. Always dim headlights
when meeting oncoming vehicles.
9. If the "Emergency Steering" light and/or "Low Brake Pressure Warning" light (if equipped) illuminate during
operation, steer the truck immediately to a safe stopping area, away from other traffic if possible. Refer to
item 6 above.
10. The Statex III w/Fuel Enhancement system monitors wheel motor, ambient, and static exciter temperatures. If
any one of these values is outside the limits established, the Statex III controls will cause the engine to
increase to 1650 RPM. (Normal engine RPM for haul road/retarding operation is 1250 RPM.)
11. When maximum truck speed is reached, haul trucks equipped with Statex III w/Fuel Enhancement (Fuel
Saver) system will experience a DECREASE in engine RPM.
NOTE: This is different from trucks equipped with Statex II or Statex III without Fuel Enhancement, which increase
RPM upon reaching speed limit.

12. Check tires for proper inflation periodically during shift. If truck has been run on a "flat", or under-inflated tire, it
must not be parked in a building until the tire cools.

PASSING
1. Do not pass another truck on a hill or blind curve!
2. Before passing, make sure the road ahead is clear. If a disabled truck is blocking your lane, slow down and
pass with extreme caution.
3. Use only the areas designated for passing.
Operation - Section 3 OM3035.1 02/03
Page 3-8 Operating Instructions

DUMPING
1. Pull into dump area with extreme caution. Make sure area is clear of persons and obstructions, including over-
head utility lines. Obey signals directed by the spotter, if present.
Avoid unstable areas. Stay a safe distance from edge of dump area. Position truck on a solid, level surface
before dumping.
As body raises, the truck Center of Gravity (CG) will move. Truck must be
on level surface to prevent tipping / rolling!

2. Carefully maneuver truck into dump position. When backing truck into dump position, use only the foot-oper-
ated brake pedal to stop and hold truck; DO NOT rely on Wheel Brake Lock to stop truck; this control is
unmodulated and applies REAR SERVICE BRAKES ONLY.
3. When truck is stopped and in dump position, apply Wheel Brake Lock and move the Selector Switch to the
"Neutral" position.

To Raise dump body:

The dumping of very large rocks (10% of payload, or greater) or sticky mate-
rial (loads that do not flow freely from the body) may allow the material to
move too fast and cause the body to move RAPIDLY and SUDDENLY. This
sudden movement may jolt the truck violently and cause possible injury to
the operator, and/or damage to the hoist cylinders, frame, and/or body hinge pins. If it is necessary to
dump this kind of material, refer to the CAUTION in the following procedure:
4. Pull the lever to the rear to actuate hoist circuit. (Releasing the lever anywhere during "hoist up" will place the
body in "hold" at that position.)
5. Raise engine RPM to accelerate hoist speed. Refer to the CAUTION below.
If dumping very large rocks or sticky mate-
rial as described in WARNING above, slowly
accelerate engine RPM to raise body. When
the material starts to move, release hoist
lever to "HOLD" position. If material does not continue moving and clear
body, repeat this procedure until material has cleared body.
6. Reduce engine RPM as last stage of hoist cylinder begins to extend and let
engine go to low idle as last stage reaches half-extension.
7. Release hoist lever as last stage of hoist cylinder reaches full extension.

To Lower Body:
(When dumping over a berm or into a crusher):

8. 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.
NOTE: If dumped material builds up at the rear of the body and the body cannot be lowered, perform steps "a" &
"b" below:
a. Move hoist lever back to the "hoist" position to fully raise the dump body. Then release the hoist lever so it
returns to the "hold" position.
NOTE: DO NOT drive forward if the tail of body will not clear the crusher wall in the fully raised position.
b. Shift Selector Switch to "Forward", release Brake Lock, depress Override button and drive forward to clear
the material. Stop, shift Selector Switch to "Neutral", apply Brake Lock and lower body again.
OM3035.1 02/03 Operation - Section 3
Operating Instructions Page 3-9
NOTE: Failure to "hoist" the body after making an unsuccessful attempt at lowering the body may result in the
dump body suddenly lowering after the truck has pulled ahead of the material that was previously preventing the
body from lowering.
The truck is not to be moved with the dump body
raised except for emergency moves only. Failure to
lower body before moving truck may cause damage to
hoist cylinders, frame and/or body hinge pins.

To Lower Body
(When dumping on flat ground):
It is very likely when dumping on flat ground that the dumped material will build up enough to prevent the body from
lowering. In this case, the truck will have to be driven forward a short distance (just enough to clear the material)
before the body can be lowered.
a. Shift Selector Switch to "Forward", release Brake Lock, depress Override button and drive just far enough
forward for body to clear material. Stop, shift Selector Switch to "Neutral", apply Brake Lock.
b. 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.
NOTE: If dumped material builds up at the rear of the body and the body cannot be lowered, then perform steps "c"
and "d" below:
c. Move hoist lever back to the "hoist" position to fully raise the dump body. Then release the hoist lever so it
returns to the "hold" position.
d. Shift Selector Switch to "Forward", release Brake Lock, depress Override button and drive forward to clear
the material. Stop, shift Selector Switch to "Neutral", apply Brake Lock and lower body again.
NOTE: Failure to "hoist" the body after making an unsuccessful attempt at lowering the body may result in the
dump body suddenly lowering after the truck has pulled ahead of the material that was previously preventing the
body from lowering.
CAUTION! The truck is not to be moved with the dump
body raised except for emergency moves only. Failure
to lower body before moving truck may cause damage
to hoist cylinders, frame and/or body hinge pins.

9. With body returned to frame, move Selector Switch to "Forward", release Brake Lock, and leave dump area
carefully.
Operation - Section 3 OM3035.1 02/03
Page 3-10 Operating Instructions

TOWING
Prior to towing a truck, many factors must be carefully considered. Serious personal injury and/or significant prop-
erty damage may result if important safety practices, procedures and preparation for moving heavy equipment are
not observed.
Do not tow the truck any faster than 5 MPH (8 kph).

A disabled machine may be towed after the following MINIMUM precautions have been taken.
1. Shut down engine.
2. If truck is equipped, install hydraulic connections for steering and dumping between towing and towed vehi-
cles. Check towed vehicle for braking system.
3. Inspect tow bar for adequacy (approximately 1.5 times the gross vehicle weight of truck being towed).
4. Determine that towing vehicle has adequate capacity to both move and stop the towed truck under all condi-
tions.
5. Protect both operators in the event of tow bar failure.
6. Block disabled truck to prevent movement while attaching tow bar.
7. Release disabled truck brakes and remove blocking.
8. Sudden movement may cause tow bar failure. Smooth and gradual truck movement is preferred.
9. Minimize tow angle at all times - NEVER EXCEED 30o. The towed truck must be steered in the direction of the
tow bar.

SAFE PARKING PROCEDURES

The operator must continue the use of safety precautions when preparing for parking and engine shutdown.
In the event that the equipment is being worked in consecutive shifts, any questionable truck performance the
operator may have noticed must be checked by maintenance personnel before the truck is released to another
operator.
1. The truck should be parked on level ground, if at all possible. If parking must be done on a grade, the truck
should be positioned at right angles to the grade.
2. The parking brake must be applied and/or chocks placed fore/aft of wheels so that the truck cannot roll. Each
truck should be parked at a reasonable distance from another.
3. Haul roads are not safe parking areas. In an emergency, pick the safest spot most visible to other machines in
the area. If the truck becomes disabled where traffic is heavy, mark the truck with warning flags in daylight or
flares at night.
OM3035.1 02/03 Operation - Section 3
Operating Instructions Page 3-11

ENGINE SHUTDOWN PROCEDURE

The following procedure (1. - 4.) should be followed at each engine shutdown.
1. Stop truck. Reduce engine RPM to low idle. Place Selector Switch in "Neutral" and apply Parking Brake
switch.If the Engine Shutdown with Timer Delay is preferred, refer to the DELAYED ENGINE SHUTDOWN
PROCEDURE below.
2. Allow engine to cool gradually by running at low idle for 3 to 5 minutes.
3. With truck stopped and engine cooled down, turn keyswitch counterclockwise to "Off" for normal shutdown of
engines. If engine does not shutdown with keyswitch, use Engine Shutdown Switch on center console (see
"Operator Controls" section) and hold this switch down until engine stops.
4. With keyswitch "Off", and engine stopped, wait at least 90 seconds. Insure steering circuit is completely bled
down by turning steering wheel back and forth several times. No front wheel movement will occur when
hydraulic pressure is relieved.
5. Close and lock all windows, remove key from keyswitch and lock cab to prevent possible unauthorized truck
operation. Dismount truck properly.
DELAYED ENGINE SHUTDOWN PROCEDURE
1. Stop the truck out of the way of other traffic on a level surface and free of overhead power
lines or other obstructions (in case dump body should need to be raised).
a. Reduce engine speed to low idle.
b. Place the directional Selector Switch (2, Figure 3-4) in "Neutral".
c. Apply the Parking Brake switch (13, Figure 3-6). Be sure the "Parking Brake Applied"
indicator light in the overhead display panel (A3, Figure 3-7) is illuminated.
2. Refer to "Instrument Panel And Indicator Lights" Section for the location on the instrument
panel of Engine Shutdown Switch with 5 Minute Idle Timer Delay (2, Figure 3-6). This
is a 3-position rocker-type switch (Off-On-Momentary).
a. Press top of switch to the "On" (center position), then press firmly to the "Momentary"
(upper position) and hold this position briefly to activate the 5 Minute Idle Timer (switch
is spring-loaded to return to "On" position when released).
b. When the Engine Shutdown Timer has been activated, the Timer Delay indicator light
in the overhead display panel (C4, Figure 3-7) will illuminate to indicate that the shut-
down timing sequence has been started. The engine will continue to run at Idle RPM
for approximately 5 minutes to allow for proper engine cool-down before stopping.

c. The Engine Shutdown Timer switch DOES NOT turn off 24 VDC electric power. Turn
Keyswitch counterclockwide to the “Off” position to cause the engine to shutdown when timing sequence is
complete. When the engine stops after the 5 minute idle period, the hydraulic bleeddown timer will be acti-
vated and turn off the 24 VDC electric circuits controlled by the keyswitch.
Engine WILL NOT SHUT DOWN, if keyswitch is not
turned to the “Off” position.

NOTE : To cancel the 5 Minute Idle Timer sequence, press Timer Delay Shutdown switch to the "Off"
(lower) position.
•If keyswitch is in "Off" position, engine will stop.
•If keyswitch is in "On" position, engine will continue to run.
If engine does not shutdown with keyswitch, use Engine Shutdown Switch (8, Figure 3-4) on operator cab
center console, and hold this switch down until engine stops. The Ground Level Shutdown Switch will also
stop the engine during this time-out.
3. After engine has stopped, perform steps 4 and 5, as described in "ENGINE SHUTDOWN PROCEDURE"
above.
Operation - Section 3 OM3035.1 02/03
Page 3-12 Operating Instructions

SUDDEN LOSS OF POWER

Bring the truck to a safe stop as quickly as possible by using the foot pedal to apply the service brakes.

Dynamic retarding will not be available!

Do not use the service brakes for continuous retarding purposes.

If possible, steer the truck to the side of the road while bringing it to a complete stop. Apply the parking brake as
soon as the truck has stopped moving. Turn key switch "Off" and notify maintenance personnel immediately.
If the truck becomes disabled where traffic is heavy, mark the truck with warning flags in daylight or flares at night.
If the engine suddenly stops, there is enough hydraulic pressure stored in the brake and steering accumulators to
allow the operation of the steering and brake functions. However, this oil supply is limited so it is important to stop
the truck as quickly and safely as possible after the loss of engine power. If the brake supply pressure drops to a
pre-determined level, the "Low Brake Pressure" warning light will illuminate and a buzzer will sound. If the brake
pressure continues to decrease, the "Auto-Apply" feature will activate and the service brakes will apply automati-
cally to stop the truck. Apply parking brake as soon as the truck comes to a complete stop.
OM3035.2 02/03 Operation - Section 3
Operator Cab and Controls Page 3-13

FIGURE 3-1. CAB INTERIOR - OPERATOR VIEW

1. Steering Wheel 6. Heater / Air Conditioner Controls 11. Radio, AM/FM Stereo, Cassette
2. Service Brake Pedal 7. Instrument Panel 12. Warning Lights Dimmer Control
3. Retarder Pedal 8. Grade / Speed Chart 13. Warning / Status Indicator Lights
4. Throttle / Accelerator 9. Radio Speakers 14. Air Cleaner Vacuum Gauges
5. Heater / Air Conditioner Vents 10. Warning Alarm Buzzer 15. Windshield Wipers
Operation - Section 3 OM3035.2 02/03
Page 3-14 Operator Cab and Controls

OPERATOR CAB AND CONTROLS

STEERING WHEEL AND CONTROLS
The steering wheel (1, Figure 3-2) will telescope "in"
and "out" and adjust through a tilt angle to provide a
comfortable wheel position for most operators.

HORN BUTTON
The horn (2, Figure 3-2) is actuated by pushing the
button in the center of the steering wheel. Operation
of the horn should be verified before moving the
truck. Observe all local safety rules regarding the use
of the horn as a warning signal device before starting
engine and moving the vehicle.

TELESCOPE LOCK RING

The Telescope Lock Ring (3, Figure 3-2) around the
horn button locks/unlocks the telescoping function of
the steering column. Rotating the ring 90° - 180°
counterclockwise (L.H. rotation), releases the column
to move "in" or "out". Rotating the ring clockwise
(R.H. rotation), locks the column in the adjusted posi-
tion.
FIGURE 3-2. STEERING WHEEL AND CONTROLS
TILT WHEEL LEVER
Adjust the tilt of the steering wheel by pulling the tilt
adjustment lever (4, Figure 3-2) toward the steering
wheel and moving the wheel to the desired angle.
Releasing the lever will lock the wheel in the desired
location.

TURN SIGNAL / HEADLIGHT DIMMER

The Turn Signal Lever (5, Figure 3-2) is used to acti-
vate turn signal lights and to select either high or low
headlight beams.

• Move the lever upward to signal a

turn to the right.

• An indicator in the top, center of the instrument

panel will illuminate to indicate turn direction
selected. Refer to INSTRUMENT PANEL &
INDICATOR LIGHTS.

• Move the lever downward to signal a

turn to the left.

• Moving the lever toward the steering

wheel changes Headlight beam. When
high beams are selected, the indicator
in the top, center of the instrument
panel will illuminate.
OM3035.2 02/03 Operation - Section 3
Operator Cab and Controls Page 3-15

SERVICE BRAKE PEDAL THROTTLE PEDAL

The Service Brake Pedal (2, Figure 3-1) is a foot- The Throttle Pedal (4, Figure 3-1) is a foot-operated
operated pedal which applies the service brakes. pedal which allows the operator to control engine
RPM, depending on pedal depression.
NOTE: In some OPTIONAL installations, this pedal
may not be present, because it is incorporated into a
single pedal function with the Retarder Pedal (3).

DYNAMIC RETARDER PEDAL

The Dynamic Retarder Pedal (3, Figure 3-1) is a foot-
operated pedal which allows the operator to slow the
truck and maintain a safe productive speed without
the use of the service brakes. For normal truck oper-
ation, only dynamic retarding should be used to slow
and control the speed of the truck. The Grade/Speed
Chart (8, Figure 3-1) should always be followed to
determine MAXIMUM safe truck speeds for descend-
ing various grades with a loaded truck. Service
brakes should be applied only when dynamic retard-
ing requires additional braking force to slow the truck
speed quickly and to bring the truck to a complete
stop.
When dynamic retarding is in operation, the engine
RPM will automatically go to an advance RPM retard
speed setting (usually 1250 RPM)*. Dynamic retard-
ing will be applied automatically, if the speed of the
truck reaches the predetermined overspeed retard
setting. Dynamic Retarding is available in "Forward/
Reverse" at all truck speeds above 0 mph/kph, but is Reference: Figure 3-1
available in "Neutral" only when truck speed is above
3 mph (4.8 kph).
* NOTE: The exact engine speed in retarding may
vary (1250 - 1650 RPM) due to the temperature of
certain components; this is controlled by the Statex
III control system.

OPTIONAL - DUAL FUNCTION / SINGLE PEDAL HEATER / AIR CONDITIONER VENTS

The Dynamic Retarding/Brake Pedal is a single foot- The operator has complete control of the air flow in
operated pedal which controls both retarding and the cab. The heater/air conditioner vents (5, Figure 3-
service brake functions. Thus, the operator must first 1) are a flapper type which may be individually
apply, and maintain, full dynamic retarding in order to opened or closed and may be rotated 360° for opti-
apply the service brakes. mum air flow. There are four (three not shown)
across the top of the panel, two in front of the opera-
When the pedal is partially depressed, the dynamic tor (one each in right and left panel modules), and
retarding is actuated (actuation is modulated). As the four below the panel.
pedal is further depressed, dynamic retarding is fully
applied; then, while maintaining full retarding, the
service brakes are actuated (a slight increase in
pedal resistance will be felt) through a hydraulic
valve, which modulates pressure to the service
brakes. Completely depressing the pedal causes
full application of both dynamic retarding AND
the service brakes.
Operation - Section 3 OM3035.2 02/03
Page 3-16 Operator Cab and Controls

HEATER / AIR CONDITIONER HEATER/AIR CONDITIONER SELECTOR SWITCH

COMPARTMENT AND CONTROLS The selector switch (6, Figure 3-3) allows the opera-
The heater/air conditioner compartment contains the tor to select heat or air conditioning, or neither. The
heater/air conditioner controls (6, Figure 3-1) and the left position of the switch activates the air condition-
heater/air conditioner components, such as the ing and the right side of the switch activates the
blower motor assembly and heater coils. Optimum heater. Neither the heat nor the air conditioning can
cab air climate can be selected by using the following be activated in this position.
controls in various combinations.
HEATER/AIR CONDITIONER VENTS
These heater/air conditioner vents (7, Figure 3-3)
DEFROSTER VENT CONTROL SWITCH may be rotated 360°. Air flow through the vents is
controlled by manually opening/closing or turning the
The defroster control switch (1, Figure 3-3) directs louvers.
heated air for windshield defrosting. "Down" position
of the toggle switch is Off. "Up" position of the toggle
switch is On.

OUTSIDE/INSIDE AIR CONTROL SWITCH

The outside/inside air control switch (2, Figure 3-3)
allows either outside or inside air to be circulated
through the cab heater assembly.
Moving the switch "Up" directs outside air to be circu-
lated through the heater assembly and through the
cab.
Moving the switch "Down" directs inside air to be
recirculated through the heater assembly.

HEAT VENT CONTROL SWITCH

The heater control (3, Figure 3-3) directs heated air
to the cab floor for heating of the cab. "Down" posi-
tion of the toggle switch is Off. "Up" position of the
toggle switch is On.

TEMPERATURE CONTROL KNOB

The Temperature control knob (4, Figure 3-3) is pro-
vided for the operator to select a comfortable temper-
ature.
Rotating the knob counter-clockwise (blue arrow) will
select cooler temperatures. Full counter-clockwise
position is the coldest air setting.
Rotating the knob clockwise (red arrow) will select
warmer temperatures. Full clockwise position is the
warmest heater setting.

FAN CONTROL KNOB

The fan control knob (5, Figure 3-3) is provided to
control the cab air fan motor. The fan motor is a 3-
speed motor (low, medium and high). Speeds are FIGURE 3-3. A/C HEATER CONTROLS
selected by rotating the control knob clockwise to the
desired position. "Off" is full counter-clockwise posi-
tion.
OM3035.2 02/03 Operation - Section 3
Operator Cab and Controls Page 3-17

INSTRUMENT PANEL WARNING ALARM BUZZER

The Instrument Panel (7, Figure 3-1) includes a wide This alarm (10, Figure 3-1) will sound when activated
variety of switches, gauges, and indicators. Refer to by any one of several truck functions. Refer to
INSTRUMENT PANEL AND INDICATOR LIGHTS, INSTRUMENT PANEL AND INDICATOR LIGHTS,
for a detailed description of function and location of for a detailed description of functions and indicators
these components. that will activate this alarm.

GRADE/SPEED WARNING CHART CAB RADIO

The Grade/Speed WARNING chart (8, Figure 3-1) This panel will normally contain an AM/FM Stereo
provides the recommended MAXIMUM truck speeds radio (11, Figure 3-1). Refer to Section 7, for a more
for descending various grades with a loaded truck. complete description of the radio and its functions.
Individual customers may use this area for other pur-
poses, such as a two-way communications radio.

WARNING LIGHTS DIMMER CONTROL

This control knob (12, Figure 3-1) permits the opera-
tor to adjust the brightness of the Warning Indicator
Lights. This Control may not be on all Model trucks.

WARNING INDICATOR LIGHT PANEL

This panel (13, Figure 3-1) contains an array of indi-
cator lights to provide the operator with important sta-
tus messages concerning selected truck functions.
Refer to INSTRUMENT PANEL AND INDICATOR
LIGHTS, for a detailed description of these indica-
tors.

AIR CLEANER VACUUM GAUGES

The air cleaner vacuum gauges
(14, Figure 3-1) provide a con-
tinuous reading of maximum air
cleaner restriction reached dur-
ing operation. The air cleaner(s)
should be serviced when the
The operator should reference this chart before gauge(s) display the following
descending any grade with a loaded truck. Proper MAXIMUM recommended
use of Dynamic Retarding will maintain a safe speed. restriction:
DO NOT exceed these recommended MAXIMUM Komatsu Engine: . . . . . . 25 inches of H2O vacuum.
speeds when descending grades with a loaded truck.
NOTE: After service, push the reset button on face of
This decal may change with OPTIONAL truck equip- gauge to allow the gauge to return to zero.
ment such as: wheel motor drive train ratios, retarder
grids, tire sizes, etc. WINDSHIELD WIPERS
ALWAYS refer to this decal in the operator's cab, The windshield wipers (15, Figure 3-1) are powered
and follow these recommendations for truck opera- by an electric motor. Refer to INSTRUMENT PANEL
tion. AND INDICATOR LIGHTS, for a location and
description of the windshield wiper and washer con-
trols.
RADIO SPEAKERS
Radio Speakers (9, Figure 3-1) for the AM/FM Stereo
radio are located at the far left and right of the over-
head panel.
Operation - Section 3 OM3035.2 02/03
Page 3-18 Operator Cab and Controls

CENTER CONSOLE

The center console (1, Figure 3-4)

contains:

1. Center Console
2. F-N-R Selector Switch
3. Hoist Control Lever
4. Ash Tray
5. Cigarette Lighter
6. L.H. Window Control Switch
7. R.H. Window Control Switch
8. Engine Shutdown Switch
9. Override Switch
10. BLANK - NOT USED on this
truck
11. RSC “On/Off” Switch
12. Retarder Speed Control Dial
13. Statex III Download Port
14. Engine Diagnostic Port
(CENSE)
15. Modular Mining Port
(Optional)
16. Passenger Seat (mounted on
top of the right hand portion of
the console structure)
17. Engine Diagnostic Port
(QUANTUM/CENTRY)
(Optional)
18. Engine Diagnostics
19. Data Storage Button
FIGURE 3-4. CENTER CONSOLE

F-N-R SELECTOR SWITCH

The Selector Switch (2, Figure 3-4) is mounted on a
console to the right of the operator's seat. It is a
three position switch which controls the Forward-
Neutral-Reverse motion of the truck. When the
Selector Switch handle is in the center "N" position, it
is in "Neutral". The handle must be in Neutral to
start the engine.

The operator can select Forward drive by

moving the handle forward.

Reverse drive can be selected by moving

the handle to the rear.

The truck should be stopped before the selector

handle is moved to a drive position.
OM3035.2 02/03 Operation - Section 3
Operator Cab and Controls Page 3-19
HOIST CONTROL LEVER ASH TRAY
The hoist control (3, Figure 3-4) is a four position The Ash Tray (4, Figure 3-4) is used for extinguishing
hand-operated lever located between the operator and depositing smoking materials. DO NOT use for
seat and the Center Console. flammable materials, such as paper wrappers.
To Raise dump body: Be certain that all fire ash is extinguished!
1. Pull the lever to the rear to actuate hoist circuit.
(Releasing the lever anywhere during "hoist up"
will place the body in "hold" at that position.) LIGHTER
2. Raise engine RPM to increase hoist speed. Lighter (5, Figure 3-4) may be used for lighting
3. Reduce engine RPM as the last stage of the cigars/cigarettes.
hoist cylinders begin to extend and then let the
Always use CAUTION with smoking materials!
engine go to low idle as the last stage reaches
half-extension. This socket may also be used for a 12 VDC power
4. Release hoist lever as the last stage reaches full supply.
extension.
5. After material being dumped clears the body,
lower the body to frame. L.H. WINDOW CONTROL SWITCH

Refer to "OPERATING INSTRUCTIONS, DUMPING" This switch (6, Figure 3-4) is spring-loaded to the
for more complete details concerning this control. "OFF" position. Pushing the front of the switch raises
the left side cab window. Pushing the rear of the
switch lowers the window.

R.H. WINDOW CONTROL SWITCH

This switch (7, Figure 3-4) is spring-loaded to the
"OFF" position. Pushing the front of the switch raises
the right side cab window. Pushing the rear of the
switch lowers the window.

ENGINE SHUTDOWN SWITCH

This switch (8, Figure 3-4) is used for
engine shutdown by depressing this but-
ton and holding it until engine stops.
Use this switch to shutdown engine if
To lower body: engine does not shutdown by turning off keyswitch,
Move hoist lever forward to "down" position and or to shutdown engine without turning off 24 VDC
release. Releasing the lever places hoist control electric circuits.
valve in the "float" position allowing the body to There is also a ground level engine shutdown switch
return to frame. on the left front frame rail behind the ladder.
Operation - Section 3 OM3035.2 02/03
Page 3-20 Operator Cab and Controls

OVERRIDE SWITCH RETARD SPEED CONTROL (RSC) ADJUST DIAL

This push-but- The RSC Adjust Dial (12, Figure 3-4) allows the
ton switch (9, operator to vary the downhill truck speed that the
Figure 3-4) is Retard Speed Control system will maintain when
spring-loaded to descending a grade.
the "OFF" posi-
When the dial is rotated counterclockwise
tion. When
toward this symbol, the truck will descend
pushed in and held, this switch may be used for sev-
a grade at lower speeds.
eral functions.
When the dial is rotated clockwise toward
1. The override switch permits the operator to
this symbol, the truck speed will increase.
move the truck forward when the Selector
Switch is in Forward, the dump body is raised,
Throttle pedal position will override RSC setting. If
and the brakes are released.
operator depresses throttle pedal to increase truck
! Use of the override switch for this purpose is
speed, Dynamic Retarding will not come on unless
intended for emergency situations only!
truck overspeed setting is reached or foot operated
2. If the operator stops the truck on an uphill retard pedal is used. When throttle pedal is released
incline, the override switch can be used to set and RSC switch is "On", Dynamic Retarding will
up forward propulsion while the brakes are come on at, or above, the RSC dialed speed and will
applied. As soon as forward propulsion is felt, adjust truck speed to, and maintain, the dialed
release the brakes and as the truck begins to speed.
move forward, release the override switch.
To adjust RSC control, pull switch (11) "On" and start
3. The push button deactivates the retard pedal
with dial (12) rotated toward fastest speed while driv-
function when speed of truck is below 3 mph
ing truck at desired maximum speed. Relax throttle
(4.8 kph).
pedal to let truck coast and turn RSC Adjusting Dial
4. The override switch is also used to reset an slowly counterclockwise until Dynamic Retarding is
electric system fault when indicated by the red activated. Dynamic Retarding will now be activated
warning light (Refer to "Instrument Panel And automatically anytime the "set" speed is reached, the
Indicator Lights", Overhead Warning / Status RSC switch is "On", and throttle pedal is released.
panel).
With RSC switch "On" and dial adjusted, the system
will function as follows: As truck speed increases to
10, FIGURE 3-4 - BLANK the "set" speed and throttle pedal released, Dynamic
This position is not used for the Retarding will apply. As truck speed tries to increase,
730E. the amount of retarding effort will automatically adjust
to keep the selected speed. When truck speed
decreases, the retarding effort is reduced to maintain
In some other truck models, this posi- the selected speed. If truck speed continues to
tion is used for an Engine Idle Switch. decrease to approximately 3 mph (4.8 kph) below
"set" speed, Dynamic Retarding will turn off automat-
ically. If truck speed must be reduced further, the
operator can turn the Adjust Dial to a new setting or
depress the foot operated retard pedal.
RETARD SPEED CONTROL (RSC)
"OFF/ON" SWITCH
The Retard Speed Control “IN” “OFF”
Switch (11, Figure 3-4) turns
the system "OFF" or "ON".
Push the knob "IN" to turn
"OFF" and pull the knob "OUT"
to turn the system "ON".
“OUT” “ON”
OM3035.2 02/03 Operation - Section 3
Operator Cab and Controls Page 3-21
The RSC Adjust Dial (12, Figure 3-4) Continued PAYLOAD METER
If the operator depresses the foot operated retard The Payload Meter (1, Figure 3-5) and Download
pedal and the retard effort called for is greater than Connector (2) are used to provide management with
that from the automatic system, the foot pedal retard operational data such as tonnage hauled and cycle
will override RSC. times.

STATEX III DOWNLOAD PORT Refer to Section 6, Optional Equipment, for a more
complete description of the payload meter and its
This connector (13, Figure 3-4) is for use by qualified functions.
personnel to access G.E. STATEX III electric propul-
sion diagnostic information and data.

KOMATSU ENGINE CENSE CONNECTOR Payload Meter Download Connector

This 3-pin connector (14, Figure 3-5) is for use by This connector (2, Figure 3-5) is used with a special
qualified personnel to access engine diagnostic infor- cable to allow the Payload Meter (1) to communicate
mation for the CENSE system. Refer to engine man- with a Portable Computer.
ufacturer’s service publications for troubleshooting
information.

MODULAR MINING PORT

This connector (15, Figure 3-5) location is used if the

optional Modular Mining System is installed on the
truck.

PASSENGER SEAT
The Passenger Seat (16, Figure 3-4) is mounted on
top of the right hand portion of the Center Console
structure.
The area beneath the passenger seat provides a
cabinet for various 24 VDC electrical components.
Consult the Service Manual for service involving any
of these components.

Centry™ Fuel Control

DIAGNOSTICS DOWNLOAD PORT
This connector (17, Figure 3-4) is for use by qualified
personnel to access the Engine Centry™ Fuel Con- FIGURE 3-5. PAYLOAD METER
trol system diagnostic information.
1. Payload Meter 2. Download Connector
ENGINE DIAGNOSTICS PORT
This connector (18, Figure 3-4) is used by qualified
personnel to access engine diagnostic information.

DATA STORAGE BUTTON

This button (19, Figure 3-5) is for use by qualified
maintenance personnel to record in memory a “snap-
shot” of the Statex III drive system.
Operation - Section 3 OM3035.2 02/03
Page 3-22 Operator Cab and Controls

OPERATOR SEAT
The operator's seat provides a fully adjustable cush-
ioned ride for the driver's comfort and ease of opera-
tion.

Adjustment
The following adjustments must be made while sit-
ting in the seat.
1. Headrest: Move up, down, fore, or aft by mov-
ing headrest (1, Figure 3-6) to desired position.
2. Armrests: Rotate adjusting knob until armrest
is in desired position.
3. Backrest: Lift handle (3) to release and select
backrest angle; release control handle to set.
4. Seat Belt: Operator should always have seat
belt (4) buckled in place and properly adjusted
whenever vehicle is in motion.
5. Seat Slope: Lift lever (5) and hold to adjust the
slope of seat. Release lever to lock adjust-
ment.
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
rocker switch and hold for desired support, then
release. To deflate, press on bottom of rocker
switch and hold for desired support, then
release. Adjust each pillow for desired support.
8. Seat Suspension: Move rocker switch (8) up to
increase ride stiffness and down to decrease FIGURE 3-6. OPERATOR SEAT
ride stiffness. ADJUSTMENT CONTROLS
1. Headrest
9. Horizontal Adjustment: Lift control lever (9)
2. Armrest Adjustment
and hold. Bend knees to move seat to a com-
3. Backrest Adjustment
fortable position; release control lever to lock
4. Seat Belt
adjustment
5. Seat Slope Adjustment
10. Seat Height: Lift lever (12) and hold to adjust 6. Upper Air Pillow Lumbar Support
the height of the seat. Release lever to lock 7. Lower Air Pillow Lumbar Support
adjustment. 8. Suspension Adjustment
9. Horizontal Adjustment
Seat Removal 10. Mounting Capscrews and Hardware
1. Remove capscrews (10, Figure 3-6) and hard- 11. Seat Tether Capscrew
ware that secures the seat base to the riser. 12. Seat Height Adjustment
Remove capscrews (11) that secures tether to
floor. Seat Installation
2. Remove seat assembly from cab to clean work 1. Mount seat assembly to seat riser. Install cap-
area for disassembly. screws (10, Figure 3-6), lockwashers, flatwash-
ers and nuts. Tighten capscrews to standard
torque.
2. Fasten tether straps to floor with capscrews
(11), flatwashers and lockwashers. Tighten
capscrews to standard torque.
OM3035.3 02/03 Operation - Section 3
Instrument Panel & Indicator Lights Page 3-23

INSTRUMENT PANEL AND INDICATOR LIGHTS

CONTROL SYMBOLS
Many control functions are identified with "International" symbols that the operator should learn to recognize imme-
diately. The operator must understand the function and operation of each instrument and control. This knowledge
is essential for proper and safe operation of the machine.
The following symbols are general indicators and may appear in multiple locations and combinations on the instru-
ment panel.

This symbol may be used alone This symbol when it appears on

or with another symbol. This an indicator or control identifies
symbol identifies the “Off” posi- that this indicator or control is
tion of a switch or control. NOT used.

This symbol may be used alone This symbol identifies a rotary

or with another symbol. This sym- control or switch. Rotate the knob
bol identifies the “On” position of clockwise or counterclockwise for
a switch or control. functions.

This symbol identifies the This symbol identifies a switch

“Pushed-In” position of a push- used to test or check a function.
pull switch or control. Press the switch on the side near
the symbol to perform the test.

This symbol identifies the “Pulled-

Out” position of a push-pull switch
or control.

INSTRUMENT PANEL (Figure 3-6)

The operator must understand the function and oper- Items that are marked OPTIONAL do not apply to
ation of each instrument and control. Control func- every truck.
tions are identified with “International” symbols that
the operator should learn to recognize immediately.
This knowledge is essential for proper and safe oper-
ation.
Operation - Section 3 OM3035.3 02/03
Page 3-24 Instrument Panel & Indicator Lights

FIGURE 3-6. PANEL, GAUGES, INDICATORS, AND CONTROLS

1. Keyswitch 16. High Beam Headlight Indicator Light
2. Engine Shutdown Switch with Timer Delay 17. Left Turn Signal Indicator Light
3. Fog Light Switch (N./O.) (Optional) 18. Digital Speedometer / Payload Meter Displa
4. Ladder Light Switch 19. Voltmeter Gauge
5. Backup Light Switch (N./O.) 20. Engine Oil Pressure Gauge
6. Panel Illumination Light(s) 21. Engine Water Temperature Gauge
7. Vent(s) - Cab Air Conditioner / Heater 22. Fuel Gauge
8. Engine Starting Aid Switch (N./O.) (Optional) 23. Blank - Not Used In This Application
9. Rotating Beacon Light Switch (N./O.) (Optional) 24. Engine Hourmeter
10. Heated Mirror Switch (N./O.) (Optional) 25. Blank - Not Used In This Application
11. Leakage Test Switch (Trolley Option) 26. Blank - Not Used In This Application
12. Wheel Brake Lock Switch (N./O.) 27. Headlights Switch (N./O.)
13. Parking Brake Switch (N./O.) 28. Wiper / Washer Switch
14. Digital Tachometer 29. Panel Illumination Lights Dimmer Rheostat
15. Right Turn Signal Indicator Light 30. Payload Meter Switch

PANEL GAUGES, INDICATORS, AND CONTROLS (Figure 3-6)

(1, Figure 3-6) KEY SWITCH
The keyswitch is a 3-position (Off, Run, Start) switch.
When switch is rotated one position clockwise, it is in
the "Run" position and all electrical circuits (except
"Start") are activated. With Selector Switch in "Neu-
tral", rotate keyswitch fully clockwise to "Start" posi-
tion and hold this position until engine starts. "Start"
position is spring loaded to return to "Run" when key
is released. With truck stopped, turn keyswitch coun-
terclockwise to "Off" for normal engine shutdown.
Use Engine Shutdown switch on center console if
engine does not shutdown with keyswitch.
NOTE: A ground level shutdown switch is located on
lower front left side of truck.
OM3035.3 02/03 Operation - Section 3
Instrument Panel & Indicator Lights Page 3-25

(2, Figure 3-6) ENGINE SHUTDOWN SWITCH with TIMER DELAY

This is a 3-position rocker-type switch (Off-On-Momentary). Refer to "Operating Instructions" section, "DELAYED
ENGINE SHUTDOWN PROCEDURE", for a complete detailed operation of this switch.
1. Press top of switch to the “On” (center position), then press firmly to the “Momentary”
(upper position) and hold this position briefly to activate the 5 Minute Idle Timer (switch is
spring-loaded to return to “On” position when released).
2. When the Engine Shutdown Timer has been activated, the Timer Delay indicator light in
the overhead display panel (C4, Figure 3-7) will illuminate to indicate that the shutdown
timing sequence has been started. The engine will continue to run at Idle RPM for approx-
imately 5 minutes to allow for proper engine cool-down before stopping.
3. The Engine Shutdown Timer switch DOES NOT turn off 24 VDC electric power. Turn Key-
switch counterclockwise to the “Off” position to cause the engine to shutdown when timing
sequence is complete. When the engine stops after the 5 minute idle period, the hydrau-
lic bleeddown timer will be activated and turn off the 24 VDC electric circuits controlled by
the keyswitch.

Engine WILL NOT SHUT DOWN, if keyswitch is not turned to

the “Off “ position.

NOTE: To cancel the 5 Minute Idle Timer sequence, press Timer Delay Shutdown switch to the “Off” (lower)
position.
• If keyswitch is in “Off” position, engine will stop.
• If keyswitch is in “On” position, engine will continue to run.
If engine does not shutdown with keyswitch, use Engine Shutdown Switch on operator cab center console,
and hold this switch down until engine stops. The Ground Level Shutdown Switch will also stop the engine
during this time-out.

(3, Figure 3-6) FOG LIGHTS (OPTIONAL)

Fog Lights are optional equipment that are useful in foggy conditions and heavy rain. Pressing
the top of the rocker switch turns the lights "On". Pressing the bottom of the switch turns the
lights "Off".

(4, Figure 3-6) LADDER LIGHT SWITCH

The switch turns the ladder lights "On" or "Off" after or before using ladder. Pressing the top of
the rocker switch turns the lights "On". Pressing the bottom of the switch turns the lights "Off".
Another switch is mounted at the front left of truck near the base of ladder.
Operation - Section 3 OM3035.3 02/03
Page 3-26 Instrument Panel & Indicator Lights

(5, Figure 3-6) MANUAL BACKUP SWITCH

The Manual Backup Switch allows backup lights to be turned "On" providing added visibility
and safety when the Selector Switch (see OPERATOR CONTROLS) is not in "REV" position.
When the SWITCH is pressed toward the "on" position, the MANUAL BACK UP LIGHT indica-
tor (B4, Overhead Panel) will be illuminated.

(6, Figure 3-6) PANEL ILLUMINATION LIGHTS

These lights provide illumination for the instrument panel. Brightness is controlled by the panel light dimmer switch
(28).

(7, Figure 3-6) CAB AIR CONDITIONER / HEATER VENTS

These Vents are spherically mounted and may be directed by the operator to provide the most comfortable cabin
air flow.

(8, Figure 3-6) ENGINE COLD WEATHER STARTING AID (OPTIONAL)

The OPTIONAL Engine Starting Aid switch is spring-loaded to the "Off" position. Use only
when ambient temperature is below 50° F (10° C). When switch is held in the "On" position,
ether is injected into the engine intake manifold to aid engine starting in cold weather. Move
the Engine Starting Aid switch to the "On" position while cranking engine, for three (3) sec-
onds maximum, and then release Engine Starting Aid. If engine does not start, wait at least
fifteen (15) seconds before repeating the procedure. Refer to "Operating Instructions", for
more specific operating details.

(9, Figure 3-6) ROTATING BEACON LIGHT SWITCH (OPTIONAL)

If truck is equipped with the OPTIONAL Rotating Beacon Light, it will be activated by this
rocker-type switch when it is pressed toward the "on" position.

(10, Figure 3-6) HEATED MIRROR SWITCH (OPTIONAL)

If truck is equipped with the OPTIONAL Heated Mirror, it will be activated by this rocker-type
switch when it is pressed toward the "on" position.

(11, Figure 3-6) LEAKAGE TEST SWITCH (Trolley Option Only)

Refer to TROLLEY OPERATION for this switch, if truck is equipped with Trolley.
OM3035.3 02/03 Operation - Section 3
Instrument Panel & Indicator Lights Page 3-27

(12, Figure 3-6) WHEEL BRAKE LOCK CONTROL

The Wheel Brake Lock should be used with engine running for dumping and loading operations only.
The brake lock switch actuates the hydraulic brake system which locks the rear wheel service brakes
only. When pulling into shovel or dump area, stop the truck using the foot-operated service brake
pedal. When truck is completely stopped and in loading position, apply the brake lock by pressing the
rocker switch toward the "On" symbol. To release, press the rocker switch toward the "Off"symbol.
Use at shovel and dump only to hold truck in position.
Do not use this switch to stop truck, unless foot-operated treadle valve is inoperative. Use of this switch
applies rear service brakes at full, unmodulated pressure!
Do not use brake lock for parking. With engine stopped, hydraulic pressure will bleed down, allowing
brakes to release!

(13, Figure 3-6) PARKING BRAKE CONTROL

The Parking Brake is spring applied and hydraulically released. It is designed to hold a stationary truck
when the engine is shutdown and keyswitch is turned "Off". The truck must be completely stopped
before applying the parking brake, or damage may occur to parking brake.To apply the parking brake,
press the rocker switch toward the "On" symbol. To release the parking brake, press the rocker switch
toward the "Off"symbol. When the keyswitch is "On" and Parking Brake switch is applied, the Parking Brake indica-
tor light (A3, Overhead Panel) will be illuminated.
NOTE: Do not use the parking brake at shovel or dump. With keyswitch "on" and engine running, sudden shock
caused by loading or dumping could cause the system's motion sensor to RELEASE the park brake.

(14, Figure 3-5) TACHOMETER

The tachometer registers engine crankshaft speed in hundreds of revolutions per minute (RPM).

Governed RPM (Komatsu Engine):

Low Idle - 700 RPM
High Idle, No load - 2150 RPM Maximum
High Idle, Full Load - 1900 RPM
Operation - Section 3 OM3035.3 02/03
Page 3-28 Instrument Panel & Indicator Lights

(15, Figure 3-6) RIGHT TURN SIGNAL INDICATOR

This light illuminates to indicate the right turn signals are operating when the turn signal lever
on the steering column is moved upward. Moving the lever to its center position will turn indica-
tor "Off".

(16, Figure 3-6) HIGH BEAM INDICATOR

The high beam indicator when lit, indicates that the truck headlights are on "High" beam. To
switch headlights to "High" beam, push the turn indicator lever away from steering wheel. For
"Low" beam, pull lever toward the steering wheel.

(17, Figure 3-6) LEFT TURN SIGNAL INDICATOR

This light illuminates to indicate the left turn signals are operating when the turn signal lever on
the steering column is moved downward. Moving the lever to its center position will turn indica-
tor "Off".

(18, Figure 3-6) SPEEDOMETER / PAYLOAD METER DISPLAY

The speedometer indicates the truck speed in miles per hour (MPH), or with OPTIONAL
speedometer, it may indicate truck speed in kilometers per hour (KPH). The display also shows
Payload Meter information. For more information, see Payload Meter in Index.

(19, Figure 3-6) VOLTMETER

The voltmeter indicates the voltage of the 24V battery system. Normal indicated voltage at high
RPM is 27 to 28 volts with batteries in fully charged condition. When keyswitch (10) is "On" and
engine is NOT running, voltmeter indicates battery charge condition.

(20, Figure 3-6) ENGINE OIL PRESSURE GAUGE

The engine oil pressure gauge indicates pressure in the engine lubrication system in pounds
per square inch (psi). Normal operating pressure after engine warm up should be:
Idle - 20 to 35 psi (138 - 250 kPa)

(21, Figure 3-6) WATER TEMPERATURE GAUGE

The water temperature gauge indicates the temperature of the coolant in the engine cooling
system. The temperature range after engine warm-up and truck operating under normal condi-
tions should be: 165° - 195°F (74° - 91°C)

(22, Figure 3-6) FUEL GAUGE

The fuel gauge indicates how much diesel fuel is in the fuel tank.
Fuel tank capacity is 850 gallons (3217 liters).
OM3035.3 02/03 Operation - Section 3
Instrument Panel & Indicator Lights Page 3-29

(23, Figure 3-6) (Not Used)

BLANK. Not used in this truck application.

(24, Figure 3-6) HOURMETER

The hourmeter registers the total number of hours the engine has been in operation.

(25, Figure 3-6) (Not Used)

BLANK. Not used in this truck application.

(26, Figure 3-6) (Not Used)

BLANK. Not used in this truck application.

(27, Figure 3-6) LIGHT SWITCH

The instrument panel lights, clearance lights, and the headlights are controlled by this three
position rocker type switch. "Off" is selected by pressing the bottom of the switch. Press the top
of the switch until it reaches the first detent to select the panel, clearance, and tail lights only.
Press the top of the switch again, until it reaches the second detent to select headlights, as
well as panel, clearance, and tail lights.

(28, Figure 3-6) WINDSHIELD WIPER and WASHER

The windshield wiper control switch is a four position rotary switch with intermittent wiper
delay and wash feature. "Off" position is the detented position when the knob is rotated fully
counterclockwise against the stop.The intermittent wiper position is located between "Off"
and the first detent position, when rotating the knob clockwise. Rotating the knob closer to
the first detent position decreases the time interval between wiper strokes. Rotate the knob
clockwise to the first detent position for slow speed. Rotate the knob to the second detent
position for fast speed.

To use the windshield washer, press and hold the knob "in" to activate the windshield washer
system.

(29, Figure 3-6) PANEL LIGHT DIMMER

The panel light dimmer control is a rheostat which allows the operator to vary the brightness of
the instruments and panel lights. Rotating knob to the full counterclockwise position turns
panel lights "On" to brightest condition. Rotating knob clockwise continually dims lights until
"Off" position is reached at full clockwise rotation.

(30, Figure 3-6) PAYLOAD METER SWITCH

The Payload Meter Switch is a two-way, momentary switch. The top position is the Select
position. The Select position is used to step through the different displays. The lower position
is the SET position. The SET position is used to set the Operator ID or clear the load and total
ton counters. Refer to Section 6, Optional Equipment, for a more complete description of the
Payload Meter System and its functions.
Operation - Section 3 OM3035.3 02/03
Page 3-30 Instrument Panel & Indicator Lights

OVERHEAD STATUS / WARNING INDICATOR LIGHT PANEL

Row / Indicator Indicator Color Row / Indicator Indicator Color

Column Description Wire Index Column Description Wire Index
A1 Hydraulic Oil Temp. Red - 12F/34TL A5 Service Engine (Aem) Blue - 12M/528A
B1 Steering Pressure Red - 12F/33A B5 Wheel Motor Temp. Red - 12F/722L
C1 Low Accumulator Press. Red - 12F/33K C5 Blower OFF Red - 12F/32B
D1 Electric Sys. Fault Red - 12F/79V D5 Blank - For Future Use Yellow - 12F/SP4
E1 Low Brake Pressure Red - 12F/33L E5 Blank - For Future Use Yellow - 12F/SP5
A2 Hydraulic Tank Level Red - 12F/34LL A6 Blank - For Future Use Yellow - 12M/SP6
B2 Low Automatic Red-12FD8/68LLP B6 Blank - For Future Use Red - 12M/SP7
Lubrication Pressure
C6 Blank - For Future Use Yellow - 12M/SP8
C2 Circuit Breaker Tripped Yellow - 12F/31CB
D6 Service Engine (Cen) Yellow - 528/12M
D2 Hydraulic Oil Filter Yellow - 12F/39
E6 Blank - For Future Use Red - 12M/SP9
E2 Low Fuel Yellow - 12F/38
A7 * Diesel Power Yellow - 71/719DP
A3 Park Brake Yellow - 12M/52A
B7 * Trolley Ready Yellow - 71/76Z
B3 Service Brake Yellow - 12M/44L
C7 * On Trolley Green - 71/719SB
C3 Body Up Yellow - 12M/63L
D7 * Trolley Fault Red - 71/78CA
D3 Dynamic Retarding Yellow - 12M/44DL
E7 * Left Limit Yellow - 71/719P
E3 Stop Engine - (DDC) Red - 12M/509MA
A8 * Max. Speed Green - 71/721L
A4 Blank - For Future Use Yellow - 12M/SP2
B8 * High Speed Green - 71/721K
B4 Back-Up Lights Yellow - 12M/47L
C8 * Med Speed Green - 71/721J
C4 5 Min. Idle Timer Yellow - 12M/23L1
D8 * Low Speed Green - 71/721H
D4 Retard Speed Control Yellow - 12M/31R
E8 * Right Limit Yellow - 71/719M
E4 Check Engine (DDC) Yellow - 12M/419

9. HAZARD LIGHTS SWITCH, N/O - Wires 11L/45L/45R * USED FOR TROLLEY OPTION ONLY

10. LAMP CHECK SWITCH, N/O (Mom.) -

Wires 712/52B/33H/710
OM3035.3 02/03 Operation - Section 3
Instrument Panel & Indicator Lights Page 3-31

INDICATOR LIGHT SYMBOLS

Indicator Lights which are AMBER (Yellow)in color alert the operator that the indicated truck function requires some
precaution when lighted.
Indicator Lights which are RED in color alert the operator that the indicated truck function requires immediate
action by the operator. Safely stop the truck and shut down the engine.
DO NOT OPERATE THE TRUCK WITH A RED WARNING LIGHT ILLUMINATED.
Refer to Figure 3-7 and the descriptions below for explanations of the symbols. Location of the symbols is
described by rows (A-E) and columns (1 - 8).

A1. High Hydraulic Oil Temperature (optional)

This warning light indicates high oil temperature in the hydraulic tank. Continued operation
could damage components in the hydraulic system. Notify maintenance personnel immedi-
ately. The light turns on at 225° F (107° C).

B1. Low Steering Pressure

When the keyswitch is turned “ON”, the low steering pressure warning light will illuminate until
the steering system hydraulic pressure reaches 2100 psi (14.7 MPa). The warning horn will
also turn on, and both will remain on, until the accumulator has been charged.
During truck operation, the low steering pressure warning light and warning horn will turn
sound if steering system hydraulic pressure drops below 2100 psi (14.7 MPa).
• If the light illuminates momentarily ("flickers") while turning the steering wheel at low truck
speed and low engine RPM, this may be considered "normal", and truck operation may
continue.
• If the indicator light illuminates at higher truck speed and high engine RPM, DO NOT OPERATE TRUCK.
If the low steering warning light continues to illuminate and the alarm con-
tinues to sound, low steering pressure is indicated. The remaining pressure
in the accumulators allows the operator to control the truck to a stop. Do
not attempt further operation until the malfunction is located and corrected.

C1. Low Accumulator Precharge Pressure

The low accumulator precharge warning light, if illuminated, indicates low nitrogen precharge
for the steering accumulator(s). To check for proper accumulator nitrogen precharge, engine
must be stopped and hydraulic system completely bled down; then turn keyswitch to "Run"
position. Warning light will NOT illuminate if system is properly charged. The warning light will
flash if the nitrogen precharge within the accumulator(s) is below 1100 ± 45 psi (7585 ± 310
kPa).

If low accumulator precharge warning light flashes, notify maintenance per-

sonnel. Do not attempt further operation until the accumulators have been
recharged with nitrogen to 1400 psi (9653 kPa). Sufficient energy for emer-
gency steering may not be available, if system is not properly charged.
Operation - Section 3 OM3035.3 02/03
Page 3-32 Instrument Panel & Indicator Lights

D1. Electric System Fault

The Electric System fault warning light will flash on and off when a malfunction occurs in the
electrical system. The warning horn will also sound intermittently. When light comes "On", pro-
pulsion will be dropped automatically. Reset by pushing override button. If fault repeats
again, stop truck and report problem to maintenance personnel.
NOTE: STATEX III records the number of "faults/events". When a predetermined number
of "faults/events" are recorded within a given time frame, the operator will not be able to
reset the fault/event by using the override switch. If this occurs, notify maintenance per-
sonnel immediately.

E1. Low Brake Pressure

This red indicator light indicates a malfunction within the hydraulic brake circuit. If this light
comes on and buzzer sounds, shut down truck operation and notify maintenance person-
nel.
NOTE: Adequate hydraulic fluid is stored to allow the operator to safely stop the truck.

A2. Low Hydraulic Tank Level (optional)

This warning light indicates the oil level in the hydraulic tank is below recommended level.
Damage to hydraulic pumps may occur if operation continues. Shut truck down and notify
maintenance personnel immediately.

B2. Low Automatic Lubrication System Pressure

This amber light will illuminate if the Automatic Lubrication System fails to reach 2,200 PSI (at
the junction block located on the rear axle housing) within one minute after the Lube Timer
indicates a cycle of grease. To turn the light off, turn key switch off, then back on again. Notify
maintenance personnel at earliest opportunity after light comes on.

C2. Circuit Breaker Tripped

This 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 control cabinet.
NOTE: Additional circuit breakers are in the operator cab behind the center console, however
tripping of these circuit breakers should not activate this light.

D2. Hydraulic Oil Filter Monitor

This light indicates a restriction in the high pressure filter assembly for either the steering or
hoist circuit. This light will come on before filters start to bypass. Notify maintenance personnel
at earliest opportunity after light comes on.
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.

E2. Low Fuel (Optional)

This amber low fuel indicator will illuminate when the usable fuel remaining in the tank is
approximately 25 gallons (95 liters). A warning buzzer will also sound.
OM3035.3 02/03 Operation - Section 3
Instrument Panel & Indicator Lights Page 3-33
A3. Parking Brake
This amber parking brake indicator will illuminate when the parking brake is applied. Do not
attempt to drive truck with parking brake applied.

B3. Service Brake

This amber service brake indicator light will illuminate when the service brake pedal is applied
or when wheel brake lock or emergency brake is applied. Do not attempt to drive truck from
stopped position with service brakes applied.

C3. Body Up
This amber Body Up indicator, when illuminated, shows that the body is not completely down
on the frame. The truck should not be driven until body is down and light is off.

D3. Dynamic Retarding

This amber dynamic retarding indicator light illuminates when the retarder pedal is operated,
RSC (Retarder Speed Control) is activated, or the automatic overspeed retarding circuit is
energized, indicating the dynamic retarding function of the truck is operating.

E3. Stop Engine

This RED engine monitor warning light will illuminate if a serious engine malfunction is
detected in the electronic engine control system. Electric propulsion to the wheel motors will
be discontinued and the maximum engine speed will be reduced to 1250 RPM. Dynamic
Retarding will still be available if needed to slow or stop the truck.

Stop the truck as quickly as possible in a safe area and apply parking brake.
SHUT DOWN THE ENGINE IMMEDIATELY. Additional engine damage is
likely to occur if operation is continued.
Operation - Section 3 OM3035.3 02/03
Page 3-34 Instrument Panel & Indicator Lights

A4. NOT USED

Reserved for future use or options.

B4. Manual Backup Lights

This amber indicator will illuminate when the manually operated Manual Backup switch (3, Fig-
ure 3-6, Instrument Panel) is turned "on".

C4. Engine Shutdown Timer - 5 Minute Idle

When the Engine Shutdown Timer switch has been activated (2, Figure 3-6, Instrument
Panel), this indicator light will illuminate to indicate that the shutdown timing sequence has
started. Refer to Instrument panel for operation of this switch.

D4. Retard Speed Control Indicator

This amber light is illuminated when the RSC switch mounted on the console is pulled out to
the "On" position.

E4. Check Engine Monitor (DDC)

This indicator light used for trucks equipped with DDEC engines only.
OM3035.3 02/03 Operation - Section 3
Instrument Panel & Indicator Lights Page 3-35
A5. Service Engine
This amber indicator light will illuminate when the Advanced Engine Monitor (AEM) system
detects a fault. A warning buzzer will also sound.

B5. High Wheel Motor Temperature (Optional)

When this indicator is illuminated and alarm sounds, high wheel motor temperature is indi-
cated. Stop truck, place Selector Switch in "Neutral" and raise engine RPM to high idle for
several minutes to cool wheel motors. If indicator does not turn off, notify maintenance per-
sonnel.

C5. Motor Blower OFF

The motor blower warning light will flash on and off and an alarm will sound if a malfunction
occurs in the cooling air circuit for the alternator and motorized wheels. Stop the truck immedi-
ately and notify maintenance personnel if warning light glows. Damage to electrical compo-
nents may result without proper ventilation of rotating equipment.

D5. NOT USED

Not currently used. Reserved for future use or options.

E5. NOT USED

Not currently used. Reserved for future use or options.
Operation - Section 3 OM3035.3 02/03
Page 3-36 Instrument Panel & Indicator Lights

A6. NOT USED

Not currently used. Reserved for future use or options.

B6. NOT USED

Not currently used. Reserved for future use or options.

C6. NOT USED

Not currently used. Reserved for future use or options.

D6. Service Engine (Cummins)

When the keyswitch is turned "On" (before starting engine), this amber "Service Engine" indi-
cator light will illuminate for about 2 seconds and then turn off, if no "faults" are detected in
the system. If this indicator remains "On" (or flashes when equipped with Centry™ Fuel Con-
trol system), alert maintenance personnel as soon as possible.

Komatsu Engines w/Centry™ Fuel Control -

This indicator monitors the Centry™ fuel system. During engine operation, if a "fault" is detected in the system, the
light will turn ON and stay on for "Warning" faults, or it will turn ON and FLASH for more "Severe" faults that can
affect engine operation and require immediate attention.
• "Warning" faults (light ON) are ones that require attention in the near future, but in most conditions will not
greatly affect governing performance.
• "Severe" faults (light FLASHING) are ones that require immediate attention, because Centry™ governor
performance could be significantly affected, resulting in a backup mode of operation.
Active fault conditions MUST be corrected as soon as possible.
Refer to "Lamp Test/Diagnostic Test Switch" for additional description of this light's function.

E6. NOT USED

Not currently used. Reserved for future use or options.
OM3035.3 02/03 Operation - Section 3
Instrument Panel & Indicator Lights Page 3-37

TROLLEY INDICATOR LIGHTS ( Figure 3-7, Columns 7 & 8)

The indicator lights shown in Figure 3-7, Columns 7 & 8, are used ONLY when the truck is equipped with the
TROLLEY OPTION.
If truck is equipped with Trolley, refer to TROLLEY OPERATION Section for a description of these indicator lights.

(9) HAZARD WARNING LIGHTS

The hazard warning light switch flashes all the turn signal lights. Pressing the bottom side of
the rocker switch (toward the triangle) activates these lights. Pressing the top side of the
rocker switch (toward the "OFF" symbol) turns these lights off.

(10) LAMP TEST SWITCH / Centry™ Diagnostic Test Switch

This switch may be used for Lamp Test, or for Centry™ diagnostic tests of a Komatsu
engine equipped with Centry™ Fuel Control.
The lamp test switch is provided to allow the operator to test the indicator lamps prior to
starting the engine. To test the lamps, and the warning horn, turn the key switch (1, Figure 3-
6) to the "Run" position and press the bottom side of the rocker switch for the “Check” posi-
tion. All lamps should illuminate, except those which are for optional equipment that is not
installed. The warning 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.
For diagnostic tests of a Komatsu engine equipped with Centry™ Fuel Control, refer to "Centry™ Diagnostics" at
the end of this section.
Operation - Section 3 OM3035.3 02/03
Page 3-38 Instrument Panel & Indicator Lights

CENTRY™ FUEL SYSTEM DIAGNOSTICS

If the truck is equipped with a Komatsu engine and
Centry™ Fuel Control system, the SERVICE
ENGINE Indicator Light (D6, Figure 3-7) monitors the
Centry™ fuel system. When the keyswitch is turned
"On", this light should illuminate for about 2 seconds
and then turn "Off", if no "faults" are detected in the
system. If the light stays ON, or FLASHES, then
active "faults" have been detected by the system and
the engine should not be started.
Refer to DETERMINING "FAULT" CODES below.

During engine operation, if a "fault" is detected in the

system, the light will turn ON and stay on for "Warn-
ing faults", or it will turn "ON and FLASH" for more
severe faults that can affect engine operation and
require immediate attention.
• "Warning" faults (light ON) are ones that require
attention in the near future, but in most conditions
will not greatly affect governing performance.
• "Severe" faults (light FLASHING) are ones that
require immediate attention, because Centry™
governor performance could be significantly
affected, resulting in a backup mode of operation.
Active fault conditions MUST be corrected as
soon as possible.
The Lamp Test/Diagnostic Test Switch (10, Figure 3-
7) may be used to activate the Centry™ Fuel System
diagnostic codes. When the Centry™ fuel system
detects a "fault" and the SERVICE ENGINE indicator
light (D6, Figure 3-7) illuminates as described above,
this switch will permit determination of the kind of
"fault(s)" detected.

DETERMINING "FAULT" CODES

Centry™ fault codes consist of three numerical dig-
its. Each digit is indicated with up to five light flashes
(SERVICE ENGINE indicator light) per each digit.
There is a short pause between each digit of the fault
code. Once all three digits are flashed, there is a
longer pause, followed by a repeating of the same
fault code sequence.
1. To determine an active Centry™ "fault", turn the
keyswitch to the OFF position. Be sure engine
completely stops, if it was running.
OM3035.3 02/03 Operation - Section 3
Instrument Panel & Indicator Lights Page 3-39

2. Turn keyswitch to ON position (engine not run-

ning) and press Lamp Test switch to the bottom
(" √" position) for 1 - 2 seconds, then release
(switch is spring-loaded to the top, "OFF" posi-
tion).
NOTE: Since this is the Lamp Test switch, all red
warning lights and amber indicator lights should light
up except those that are "BLANK". The warning horn
will also sound.

3. If there is an active fault after releasing the

switch, there will be a short pause, followed by
the first fault code.

4. Pressing the Lamp Test switch to the bottom

("√") again will advance to the next fault code (if
more than one code is present). Once all active
fault codes have been displayed, the fault code
display sequence will be repeated, starting from
the first fault code.

EXITING THE DIAGNOSTICS MODE

Starting the engine or turning the keyswitch to the
OFF position will EXIT the diagnostics fault flash
mode.

If active fault codes have been determined as

described previously, refer to the Cummins Centry™
System "Troubleshooting and Repair Manual", Bulle-
tin No. 3666070, or contact an Authorized Repair
Location.
Operation - Section 3 OM3035.3 02/03
Page 3-40 Instrument Panel & Indicator Lights

NOTES
OM4035.1 Maintenance - Section 4
Lubrication and Service Page 4-1

LUBRICATION AND SERVICE

Recommended Preventive Maintenance will contribute HYDRAULIC TANK SERVICE
to the long life and dependability of the truck and its
components. The use of proper lubricants and the per- There are two sight gauges on the side of the hydraulic
formance of checks and adjustments at recommended tank. With engine stopped, keyswitch "off", hydraulic
intervals is most important. system bled down and body down, oil should be visible
in the top sight gauge. If hydraulic oil is not visible in
Lubrication requirements are referenced to the lube the top sight gauge, follow "Adding Oil" instructions
key found in the Truck Lubrication Specifications Chart below.
(page 4-2). For detailed service requirements for spe-
cific components, refer to the Shop Manual Section for Adding Oil
that component (i.e. Section “H” for Suspensions, Sec-
tion "L" for Hydraulic System, etc.). Keep the system open to the atmosphere only as long
as absolutely necessary to lessen chances of system
Refer to manufacturer's service manual when servicing contamination.
any components of the General Electric System.
Service the tank with clean Type C-4 hydraulic oil only.
Refer to engine manufacturer's service manual when All oil being put into the hydraulic tank should be fil-
servicing the engine or any of its components. tered through 3 micron filters.
5. With engine stopped, keyswitch "off", hydraulic
system bled down and body down, check to see
730E SERVICE CAPACITIES that hydraulic oil is visible in the top or lower sight
Crankcase: Liters U.S. gauge.

(including lube oil filters). Gal- 6. If hydraulic oil is not visible in the top sight gauge,
lons remove the tank fill cap and add clean, filtered C-
Komatsu SSA16V159 Engine
214 56.6 4 hydraulic oil (Lubrication Chart, Lube Key "D")
until oil is visible in the top sight gauge.
Cooling System: 409 108
7. Replace fill cap.
Komatsu SSA16V159 Engine
8. Start engine. Raise and lower the dump body
Hydraulic System: 731 193
three times.
Refer to "Hydraulic Tank Ser-
vice". 9. Repeat steps 1 through 4 until oil is maintained in
the top sight gauge with engine stopped, body
Wheel Motor Gear Box 39.7 10.5 down, and hydraulic system bled down
(each side)
Fuel Tank (Diesel Fuel Only) 3217 850

The service intervals presented here are in hours of

operation. These intervals are recommended in lieu of
an oil analysis program which may determine different
intervals. However, if truck is being operated under
extreme conditions, some or all, of the intervals may
need to be shortened and the service performed more
frequently.

Many Komatsu trucks are equipped with an Automatic

Lubrication System option. The initial setup for this sys-
tem provides for nominal amounts of lubricant to be
delivered to each serviced point. The lubrication injec-
tors can be adjusted to vary the amount of lubricant
delivered. In addition, the timer for lubrication intervals
is normally adjustable. Consult the "Options and
Accessories", Section "M", of the truck service manual
for adjustments to these devices.
Maintenance - Section 4 OM4035.1
Page 4-2 Lubrication and Service

COOLANT LEVEL CHECK Engine coolant must always be visible in the sight
gauge before truck operation.
Inspect the coolant sight gauge. If coolant cannot be
seen in the sight gauge, it is necessary to add coolant
to the cooling system before truck operation. Refer to
COOLING SYSTEM ANTI - FREEZE
the procedure below for the proper filling procedure.
RECOMMENDATIONS
(Ethlyene Glycol Permanent Type Anti-Freeze)
RADIATOR FILLING PROCEDURE
Percentage of Protection To
Cooling System is pressurized due to thermal expan- Anti-Freeze
sion of coolant. DO NOT remove radiator cap while
10 +23°F - 5°C
engine and coolant are hot. Severe burns may result.
20 +16°F - 9°C
1. With engine and coolant at ambient temperature,
25 +11°F - 11°C
remove radiator cap.
30 +4°F - 16°C
Note: If coolant is added using the Wiggins quick 35 - 3°F - 19°C
fill system, the radiator cap MUST be removed prior
to adding coolant. 40 - 12°F - 24°C
45 - 23°F - 30°C
2. Fill radiator with proper coolant mixture (as specified
50 - 34°F - 36°C
by the engine manufacturer) until coolant is visible
in the sight gauge. 55 - 48°F - 44°C
60 - 62°F - 52°C
3. Install radiator cap.
Use only anti-freeze that is compatible with engine
4. Run engine for 5 minutes, check coolant level. as specified by engine manufacturer.

5. If coolant is not visible in the sight gauge, repeat

steps 1 through 4. Any excess coolant will be dis-
charged through the vent hose after the engine
reaches normal operating temperature.
OM4035.1 Maintenance - Section 4
Lubrication and Service Page 4-3

Lubrication Chart
Maintenance - Section 4 OM4035.1
Page 4-4 Lubrication and Service

10 HOUR (DAILY) INSPECTION

Prior to each operating shift, a “walk around” inspection Truck Serial Number __________________________
should be performed. Check the truck for general con- Site Unit Number _____________________________
dition. Look for evidence of hydraulic leaks; check all Date: __________ Hour Meter __________________
lights and mirrors for clean and unbroken lenses; check Name of Service Person _______________________
operator's cab for clean and unbroken glass; check
frame, sheet metal and body for cracks. Notify the NOTE:“Lube Key” references are to the Lubrication
proper maintenance authority if any discrepancies are Specification Chart.
found. Give particular attention to the following:

COMMENTS CHECKED INITIALS

1. FAN DRIVE AND TURBOCHARGERS - Check for
leaks, vibration or unusual noise. Check alternator and
fan belts for proper tension, condition and for align-
ment.

2. RADIATOR - Check coolant level and fill with proper

mixture as shown in Cooling System Recommendation
Chart. Refer to Engine Manual for proper DCA levels.

3. ENGINE - Check oil level. Refer to engine manufac-

turer's manuals for oil recommendations. Lube Key "A".

4. FUEL FILTER - Drain water from bottom of filter

housing.

5. FUEL STRAINER - Drain water and sediment at

drain cock.

6. MOTORIZED WHEELS - Refer to G.E. Motorized

Wheel Service & Maintenance Manual for lubrication
specifications and service intervals.

7. HYDRAULIC TANK - Check oil level in tank, add if

necessary. Refer to "Hydraulic Tank Service". Oil
should be visible in sight glass. - DO NOT OVERFILL.
Lube Key "B".

8. AIR CLEANERS (NOT SHOWN) - Check air cleaner

vacuum gauges in operator cab. The air cleaner(s)
should be serviced, if the gauge(s) shows the following
maximum restriction: Komatsu Engine: 25 in. of H2O
vacuum*.

NOTE: After service, push the reset button on face

of gauge to allow the gauge to return to zero.
OM4035.1 Maintenance - Section 4
Lubrication and Service Page 4-5

10 HOUR (DAILY INSPECTION (continued)

COMMENTS CHECKED INITIALS

9. AIR CLEANERS

See Section "C" of the service manual for servicing air

cleaner elements. Empty air cleaner dust caps.

After service, push the reset button on face of gauge (if

equipped) to allow the needle to return to zero.

10. WHEELS AND TIRES -

a. Inspect tires for proper inflation and wear.

b. Inspect for debris embedded in cuts or tread.

After each wheel mounting operation, recheck wheel

mounting capscrew tightness after approximately five
hours of operation, again at the end of the shift and
then periodically until all capscrews hold at the pre-
scribed 450 ft.lbs. (610 N.m) torque. This requirement
is prescribed for both front and rear wheels.

11. BODY UP SWITCH (NOT SHOWN) - Clean sens-

ing area of any dirt accumulation.

12. FUEL TANK - Fill as required.

13. HOIST LIMIT SWITCH (NOT SHOWN) - Clean

sensing area of any dirt accumulation.

14. CAB AIR FILTER (NOT SHOWN) - Under normal

operating conditions, clean every 250 hours. In
extremely dusty conditions, service as frequently as
required. Clean filter element with mild soap and water,
rinse completely clean and air dry with maximum of 40
psi (275 kPa). Reinstall filter.
Maintenance - Section 4 OM4035.1
Page 4-6 Lubrication and Service

50 HOUR LUBRICATION AND MAINTENANCE CHECKS

Maintenance for every 10 hours/shift checks should Truck Serial Number __________________________
also be carried out at this time. Site Unit Number _____________________________
Date: __________ Hour Meter __________________
Name of Service Person _______________________

COMMENTS CHECKED INITIALS

1. FAN - After the first 50 hours of operation (new truck
or new fan installation), check the torque for the fan
mounting capscrews -90 ft.lbs. (122 N.m).

2. FINAL DRIVE PIVOT PIN - (If not equipped with

automatic lube system) - Add one or two applications
of grease at grease fitting. Lube Key "D".
OM4035.1 Maintenance - Section 4
Lubrication and Service Page 4-7

100 HOUR LUBRICATION AND MAINTENANCE CHECKS

Maintenance for every 10 & 50 hour Lubrication and Truck Serial Number __________________________
Maintenance Checks should also be carried out at this Site Unit Number _____________________________
time. Date: __________ Hour Meter __________________
Name of Service Person _______________________

COMMENTS CHECKED INITIALS

1.REAR HYDRAIR® SUSPENSION PIN JOINTS - (If

not equipped with automatic lube system) - Add one or
two applications of grease to each grease fitting for the
upper and lower suspension mount pins. Use Lube Key
"D".

2. BODY HINGE PINS - (If not equipped with automatic

lube system) - Add one or two applications of grease to
each grease fitting. Lube Key "D" for the body hinge
pins.

3. HOIST CYLINDER - (If not equipped with automatic

lube system) - Add one or two applications of grease to
each grease fitting for bearing and pivots. Use Lube
Key "D".

4. ANTI-SWAY BAR - (If not equipped with automatic

lube system) - Add one or two applications of grease to
each grease fitting for pin and bearings. Use Lube Key
"D".

5. HYDRAULIC OIL FILTERS - Change filter elements

after the initial 100 hours of operation; then at 250
hours; and then each 500 hours of operation thereafter.
Maintenance - Section 4 OM4035.1
Page 4-8 Lubrication and Service

250 HOUR LUBRICATION AND MAINTENANCE CHECKS

Maintenance for every 10 & 50 hour Lubrication and
Maintenance Checks should also be carried out at this Truck Serial Number __________________________
time. Site Unit Number _____________________________
Date: __________ Hour Meter __________________
NOTE: "Lube Key" references are to the Lubrica- Name of Service Person _______________________
tion Specification Chart.

1. ENGINE - Refer to the engine Operation & Mainte- COMMENTS CHECKED INITIALS
nance manual for complete specifications regarding
engine lube oil specifications.

NOTE: If 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 the engine Operation & Maintenance
manual for specific oil & filter change intervals.

a. Change engine oil. Lube Key “A”.

b. Replace lube 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 truck is equipped with a Reserve Engine Oil Tank,

change the reserve tank oil filter.

d. Check the fan belt tension.Refer to the engine Oper-

ation & Maintenance manual for specific fan belt
adjustment instructions.

2. HYDRAULIC SYSTEM FILTERS - Change filter ele-

ments after the initial 250 hours; then each 500 hours
of operation thereafter.

3. FUEL FILTER AND STRAINER - Change filter and

strainer element.

4. MOTORIZED WHEEL GEAR CASE - Refer to the

G.E. planned maintenance manual and specific motor-
ized wheel service manual.

5. STEERING LINKAGE - (If not equipped with auto-

matic lube system) - Add one or two applications of
grease to each grease fitting for pin and bearing.
Check torque on steering pin nuts 525 ft. lbs. (712 N.m)
torque. Use Lube Key "E".

∗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.
OM4035.1 Maintenance - Section 4
Lubrication and Service Page 4-9

250 HOUR LUBRICATION AND MAINTENANCE CHECKS (continued)

COMMENTS CHECKED INITIALS

6. COOLING SYSTEM DCA WATER FILTER - Change
spin-off filter. Check cooling system for proper coolant
mixuture. Add water mixture as required.

7. HYDRAULIC PUMP & U-JOINT - Add one or two

applications of grease to each grease fitting on the
cross and bearing assemblies and splines. Use Lube
Key "D".

8. FRONT WHEEL BEARINGS - Check oil level.

9. FUEL TANK - Drain H2O and sediment.

10. AXLE BLOWER MOTOR (If equipped with trolley

system) - Add only one application of grease to each
ball bearing on the blower shaft. Use lube Key "D".

11. GE PREFILTER BLOWER - Add one or two appli-

cations of grease to the grease fitting. Use Lube Key
"D".

12. CHASSIS LUBE LEVEL - Check the level of grease

in the supply canister. Add more grease to ensure the
supply will not run out before the next scheduled ser-
vice. Use Lube Key "D".

13. BATTERIES (NOT SHOWN) - Check electrolyte

level and add water if necessary.
Maintenance - Section 4 OM4035.1
Page 4-10 Lubrication and Service

500 HOUR LUBRICATION AND MAINTENANCE CHECKS

Maintenance for every 10, 50, 100 & 250 hour Lubrica- Truck Serial Number __________________________
tion and Maintenance Checks should also be carried Site Unit Number _____________________________
out at this time. Date: __________ Hour Meter __________________
Name of Service Person _______________________
NOTE: "Lube Key" references are to the Lubrica-
tion Specification Chart.
COMMENTS CHECKED INITIALS

1. FINAL DRIVE CASE BREATHERS - Remove

breather elements for motorized wheels and clean or
replace elements.

2. HYDRAULIC SYSTEM FILTERS - Replace filter ele-

ments. Check oil level. Add oil as necessary. Lube Key
"B".

3. HYDRAIR® SUSPENSION - Check for proper piston

extension (front and rear).

4. THROTTLE AND BRAKE PEDAL (NOT SHOWN) -

Lubricate treadle roller and hinge pins with lubricating
oil. Lift boot from mounting plate and apply a few drops
of oil between mounting plate and plunger. Lube Key
"B".

5. HYDRAULIC TANK BREATHER - Replace breather.

6. FRONT WHEELS - Check front wheel bearing pre-

load 500 hours after truck commissioning (and at 500
hours after each rebuild) as per Section G (in the ser-
vice manual for Disassembly and Assembly proce-
dures) and every 5,000 hours there after.
OM4035.1 Maintenance - Section 4
Lubrication and Service Page 4-11

1000 HOUR LUBRICATION AND MAINTENANCE CHECKS

Maintenance for every 10, 50, 100, 250 & 500 hour Truck Serial Number __________________________
Lubrication and Maintenance Checks should also be Site Unit Number _____________________________
carried out at this time. Date: __________ Hour Meter __________________
Name of Service Person _______________________
NOTE: "Lube Key" references are to the Lubrica-
tion Specification Chart.
COMMENTS CHECKED INITIALS

1. HYDRAULIC TANK - Drain hydraulic oil and clean

inlet strainer. Refill tank with new oil, approximate
capacity 134 gal. (507 l). Use Lube Key "B".

2. RADIATOR - Clean cooling system with a quality

cleaning compound. Flush with water. Refill system
with DCA or anti-freeze and water solution. Check
Cooling System Recommendation Chart for correct
mixture.

3. FUEL TANK - Remove breather and clean in sol-

vent. Dry with air pressure and reinstall.

4. ENGINE - Remove, clean and dry crankcase

breather elements.

5. OPERATOR'S SEAT - Apply grease to slide rails.

Use Lube Key "D".
Maintenance - Section 4 OM4035.1
Page 4-12 Lubrication and Service

5000 HOUR LUBRICATION AND MAINTENANCE CHECKS

Maintenance for every 10, 50, 100, 250, 500 & 1000 Truck Serial Number __________________________
hour Lubrication and Maintenance Checks should also Site Unit Number _____________________________
be carried out at this time. Date: __________ Hour Meter __________________
Name of Service Person _______________________
NOTE: "Lube Key" references are to the Lubrica-
tion Specification Chart.
COMMENTS CHECKED INITIALS

1.FRONT WHEELS - Drain oil and completely disas-

semble and check all parts for wear or damage. Refer
to Section "G" of the service manual for Disassembly
and Assembly procedures. Refill with oil. Check the oil
level at oil level plug on wheel hub. Lube Key "C".
Check wheel bearing preload at the first 500 hours
after each rebuild.

2. 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 tubes. Refer to
Section "C" of the service manual.

NOTE: Do not use a hot pressure washer or high pres-

sure air to clean tubes, high pressure causes pre-
cleaner tubes to distort.
OM4035.2 02/03 Maintenance - Section 4
Automatic Lube System Page 4- 13

AUTOMATIC LUBRICATION SYSTEM

Simultaneously, grease is discharged through the outlet
GENERAL DESCRIPTION
(9) of the pump. The volume of grease during intake is
The Lincoln Automatic Lubrication System is a pressur- twice the amount of grease output during one cycle.
ized lubricant delivery system which delivers a controlled During the upstroke, the inlet check valve closes, and
amount of lubricant to designated lube points. The sys- one half the grease taken in during the previous stroke
tem is controlled by an electric timer which signals a is transferred through the outlet check and discharged
solenoid valve to operate a hydraulic motor powered to the outlet port.
grease pump. Hydraulic oil for pump operation is sup-
plied by the truck steering circuit.
Grease output is proportional to the hydraulic motor
input flow. A pump control manifold (4, Figure 3-1),
mounted on top of the hydraulic motor (2), controls input
flow and pressure. A 24VDC Solenoid (5) mounted on
the manifold turns the pump on and off. Over-pressurizing of the system, modifying parts,
using incompatible chemicals and fluids, or using
The pump is driven by the rotary motion of the hydraulic
worn or damaged parts, may result in equipment
motor, which is then converted to reciprocating motion
damage and/or serious personal injury.
through an eccentric crank mechanism. The reciprocat-
ing action causes the pump cylinder to move up and * DO NOT exceed the stated maximum working
down. The pump is a positive displacement, double- pressure of the pump, or of the lowest rated
acting type as grease output occurs on both the up and component in the system.
the down stroke.
* Do not alter or modify any part of this system
During the down stroke, the pump cylinder is extended unless approved by factory authorization.
into the grease. Through the combination of shovel
* Do not attempt to repair or disassemble the
action and vacuum generated in the pump cylinder
equipment while the system is pressurized.
chamber, the grease is forced into the pump cylinder.
* Make sure all fluid connections are securely
tightened before using this equipment.
* Always read and follow the fluid manufacturer's
recommendations regarding fluid compatibili-
ty, and the use of protective clothing and equip-
ment.
* Check all equipment regularly and repair, or
replace, worn or damaged parts immediately.
This equipment generates very high grease pres-
sure. Extreme caution should be used when operat-
ing 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 recommended to prevent splashing of
material onto the skin or into the eyes.
If any fluid appears to penetrate the skin, get emer-
gency medical care immediately! Do not treat as a
FIGURE 3-1. PUMP COMPONENTS simple cut. Tell attending physician exactly what
fluid was injected.
1. Orifice Fitting 6. Pressure Guage
2. Hydraulic Motor 7. Pump Assembly
3. Pressure Reducing Valve 8. Flow Control Valve
4. Manifold 9. Grease Outlet
5. Solenoid Valve 10. Grease Pickup Tube
11. Manual Override
Maintenance - Section 4 OM4035.2 02/03
Page 4- 14 Automatic Lube System

FIGURE 3-2. AUTO LUBE SYSTEM INSTALLATION

1. Reservoir (Torque Tube) 8. Hyd. Oil Supply 15. R.H. Body Pivot Pin 22. L.H. Top Hoist Cyl.
2. Grease Supply From Filter 9. Hyd. Oil Return 16. R.H. Top Hoist Cyl. 23. L.H. Body Pivot Pin
3. Grease Pump/Motor 10. Reservoir Vent Line 17. R.H. Bottom Hoist Cyl 24. L.H. Top Susp.
4. Relay Box 11. Lube Injectors (each side)18. Rear Axle Pivot Pin 25. L.H. Lower Susp.
5. Pressure Gauge 12. Rear Lube Injectors 19. R.H. Anti-Sway Bar 26. Grease Supply
6. Vent Valve Assy. 13. R.H. Lower Suspension 20. L.H. Bottom Hoist Cyl. 27. Pressure Switch
7. Reservoir Fill Hose (To Filter) 14. R.H. Top Suspension 21. L.H. Anti-Sway Bar
OM4035.2 02/03 Maintenance - Section 4
Automatic Lube System Page 4- 15

SYSTEM COMPONENTS Flow Control Valve (8, Figure 3-1)

The flow control valve mounted on the manifold, controls
Filter (2, Figure 3-6) the amount of oil flow to the hydraulic motor.
A filter assembly mounted on the right front upright filters The flow control valve has been factory adjusted and
the grease prior to refilling the reservoir from the shop the setting should not be disturbed.
supply. A bypass indicator alerts service personnel
when the filter requires replacement. Solenoid Valve (5, Figure 3-1)
The solenoid valve, when energized, allows oil to flow to
Hydraulic Motor and Pump (2 & 7, Figure 3-1) the hydraulic motor.
Note: The pump crankcase oil level must be maintained
to the level of the pipe plug port. If necessary, refill with Vent Valve (6, Figure 3-2)
10W-30 motor oil. With the vent valve closed, the pump continues to oper-
Specifications are as follows: ate until maximum grease pressure is achieved. As this
occurs, the vent valve opens and allows the grease
•Max. hydraulic oil inlet pressure: pressure to drop to 0, so the injectors can recharge for
.............................................. 3,000 psi (20 685 kPa) their next output cycle.
•Hydraulic oil operating pressure:
..................................325-350 psi (2 240-2 415 kPa) 24 VDC Lubrication Cycle Timer (Not Shown)
•Hydraulic inlet flow The lube cycle timer provides a 24 VDC timed-interval
............................................ up to 7 GPM (28 L/min.) signal to operate the solenoid valve (5, Figure 3-1),
causing the grease pump motor to operate. This timer is
•Pump ratio: approx. 9:1 mounted in the cab (in the housing under the passenger
...@300 to 350 psi (2 068 to 2 415 kPa) oil pressure seat) to insure temperature stability.
............................ @less than 2 GPM (7 L/min.) flow
•Operating temperature Pressure Switch (N.O. 2500 psi [17 237 kPa])
....................................-20 to +150 °F (-10 to +65°C) (Not Shown)
The pressure switch, mounted on the front pump outlet
port, energizes the normally closed pump solenoid relay
when the grease line pressure reaches the switch pres-
sure setting, turning off the motor and pump.

Unloader Valve (Not Shown)

Hydraulic oil supply inlet pressure must not exceed The unloader valve is mounted on a “tee” fitting with the
3000 psi (20 685 kPa). Exceeding the rated pressure pressure switch described above. This valve will relieve
may result in damage to the system components grease pressure in the pump if pressure exceeds 4000
and personal injury. psi (27.6 MPa). This valve has been factory adjusted
and is not repairable.
Grease Reservoir (1, Figure 3-2)
The reservoir has an approximate capacity of 214 lbs. Pressure Gauge (6, Figure 3-1)
(97 kg) of grease. When the grease supply is replen- The pressure gauge monitors hydraulic oil pressure to
ished by filling the system at the service center, the the inlet of the hydraulic motor.
grease is passed through the filter to remove contami-
nants before it flows into the reservoir. Manual Override (11, Figure 3-1)
Pressure Reducing Valve (3, Figure 3-1) The manual override is used to actuate the hydraulic
motor to manually activate a lubrication cycle.
The pressure reducing valve, located on the manifold
reduces the hydraulic supply pressure (from the truck Relay Box (4, Figure 3-2)
steering circuit) to a suitable operating pressure, [325-
350 psi (2 240-2 415 kPa)] for the hydraulic motor used The relay box houses the 24V relay used to control the
to drive the lubricant pump. solenoid valve controlling the hydraulic motor.
Maintenance - Section 4 OM4035.2 02/03
Page 4- 16 Automatic Lube System

Injectors (11, Figure 3-2) 4. With oil flowing into the hydraulic motor, the grease
pump will operate, pumping grease from the reser-
Each injector delivers a controlled amount of pressur-
voir to the injectors (13), and to the vent valve (11)
ized lubricant to a designated lube point. Refer to Figure
and the normally open pressure switch (9).
3-2 for locations.
5. During this period, the injectors will meter the ap-
Pressure Switch (27, Figure 3-2) propriate amount of grease to each lubrication
point.
This pressure switch will activate a Lube System Low
Pressure Warning lamp on the overhead display if ade- 6. When grease pressure reaches the pressure switch
quate grease pressure (2000 psi (13790 kPa)) is not setting, the switch contacts will close and energize
attained within 1 minute. (Note: Warning system is the relay (3, Figure 3-4), removing power from the
optional on early model trucks.) hydraulic motor/pump solenoid and the the pump
will stop. The relay will remain energized until
SYSTEM OPERATION grease pressure drops and the pressure switch
opens again or until the timer turns off.
Refer to Figure 3-3 & 3-4:
7. After the pump solenoid valve (3) is de-energized,
1. During truck operation, with the pump and timer
hydraulic pressure in the manifold drops and the
systems in a rest state, a preset time interval oc-
vent valve will open, releasing grease pressure in
curs.
the lines to the injector banks. When this occurs,
2. The lubrication cycle timer (1, Figure 3-4) provides the injectors are then able to recharge for the next
a 24 VDC signal through the normally closed relay lubrication cycle.
(3) used to energize the pump solenoid valve (4),
8. The unloader valve (10) prevents excessive grease
allowing hydraulic oil provided by the truck steering
pressure if the pressure switch fails to close and
pump circuit to flow to the pump motor and initiate
shut off the hydraulic supply to the pump. The
a pumping cycle.
unloader will open at approximately 4000 psi (27.6
3. The hydraulic oil pressure from the steering circuit MPa).
is reduced to 325 to 350 psi (2 240 to 2 413 kPa)
by the pressure reducing valve (4, Figure 3-3)
before entering the motor. In addition, the amount
of oil supplied to the pump is limited by the flow
control valve (6). Pump pressure can be read using
the gauge (5) mounted on the manifold.

FIGURE 3-3. HYDRAULIC SCHEMATIC

1. Hydraulic Oil Return 6. Flow Control Valve 10. Unloader Valve
2. Hydraulic Oil Supply 7. Hydraulic Motor 11. Vent Valve
3. Pump Solenoid Valve 8. Grease Pump 12. Orifice
4. Pressure Reducing Valve 9. Pressure Switch (N.O.) 13. Injector Bank
5. Motor Pressure Gauge
OM4035.2 02/03 Maintenance - Section 4
Automatic Lube System Page 4- 17

Pressure Failure Detection Circuits 4. Once RB6-K6 is energized, it will latch and remain
1. When the lubrication cycle is initiated, 24VDC latched as long as the key switch in ON. Also,
flows through relay RB6-K4 (8, Figure 3-4) N.C. RB6-K2 will remain energized and the Low Lube
contacts to a 1 minute delay timer (7). Pressure Warning light will remain on to notify the
operator a problem exists and the system
2. If the system is operating normally, grease pres-
requires service.
sure at the rear axle injector bank will rise to pres-
sure switch (9) setting of 2000 psi (13.8 MPa), 5. The warning circuits are reset when the key switch
closing the switch contacts and energizing relay is turned OFF.
RB6-K4 (8), removing 24 volts from the delay
timer. The timer is then reset and no current will
flow from the timer output terminal.
3. If a problem occurs and the system is not able to
attain 2000 psi (13.8 MPa), then delay timer (7)
will energize relay RB6-K2 after 60 seconds, turn-
ing on the “Low Lube System Pressure” warning
lamp on the overhead display. After RB6-K2
energizes, it will ground the coil of RB6-K6 and
allow it to energize.

FIGURE 3-4. ELECTRICAL SCHEMATIC

1. Solid State Timer 7. Time Delay Module
2. Circuit Breaker 33 (Power Distribution Module in 8. Relay Board 6, Relay K4
Cab) 9. Pressure Switch (rear Axle Injector Bank)
3. Circuit Breaker 35 (Power Distribution Module in 10.Relay Board 6, Relay K2
Cab) 11.Auto Lube Low Pressure Warning Lamp
4. Pressure Switch (On Grease Pump) 12.Relay Board 6, relay K1
5. Pump Solenoid Valve 13.Manual Override
6. Relay Board 6, Relay K6
Maintenance - Section 4 OM4035.2 02/03
Page 4- 18 Automatic Lube System

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 lu-
bricant (6), the slide valve (5) is about to
open the passage (4) leading to the mea-
suring chamber (1) above the injector pis-
ton (2).

STAGE 2.
When the slide valve (5) uncovers the pas-
sage (4), lubricant (6) is admitted to the
measuring chamber (1) above the injector
piston (2) which forces lubricant 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 passage (4) and mea-
suring chamber (1). The injector piston (2)
and slide valve (5) remain in this position
until lubricant pressure in the supply line (6)
is vented.

STAGE 4.
After venting, the injector spring expands,
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 pas-
sage (4) and valve port (8) to refill the
discharge chamber (3).

Injector is now ready for the next cycle.

OM4035.2 02/03 Maintenance - Section 4
Automatic Lube System Page 4- 19

GENERAL INSTRUCTIONS

LUBRICANT REQUIRED FOR SYSTEM Pump Pressure Control

Grease requirements will depend on ambient tempera- High pressure hydraulic fluid from the truck steering
tures encountered during truck operation: system is reduced to 325 to 350 psi (2 240 to 2 413 kPa)
by the pressure reducing valve located on the manifold
•Above 90°F (32°C) - Use NLGI No.2 multipurpose
on top of the pump motor. This pressure can be read on
grease (MPG).
the gauge installed on the manifold and should be
•-25° to 90°F (-32° to 32°C) - Use NLGI No. 1 multipur- checked occasionally to verify pressure is within the
pose grease (MPG). above limits.
•Below -25°F (-32°C) - Refer to local supplier for ex-
Pressure Control Valve Adjustment
treme cold weather lubricant requirements.
1. With the truck engine running, install a jumper wire
SYSTEM PRIMING across the “LUBE SW.” and “SOL.” terminals on the
lube timer under the passenger seat.
The system must be full of grease and free of air pockets
to function properly. After maintenance, if the primary or 2. Loosen the locknut on the pressure control (1,
secondary lubrication lines were replaced, it will be Figure 3-5) by turning the nut counterclockwise.
necessary to reprime the system to eject all entrapped
3. Turn the valve stem counterclockwise until it no
air.
longer turns. (The valve stem will unscrew until it
1. Fill lube reservoir with lubricant, if necessary. reaches the stop - it will not come off.)
2. To purge air from the main supply line, remove the Note: This is the minimum pressure setting, which is
main supply line at the pump outlet port (6, Figure about 170 psi (1 172 kPa).
3-5) and connect an external grease supply to the
4. With the pump stalled against pressure, turn the
line.
pressure control valve stem clockwise until 325 to
3. Remove plugs from each injector group in sequence 350 psi (2 240 to 2 413 kPa) is attained on the
(right front, left front, and rear axle). manifold pressure gauge (3).
4. Using the external grease source, pump grease 5. Tighten the locknut to lock the stem in position.
until grease appears at the group of injectors and
Note: The flow control valve (5) is factory adjusted to 2.5
re-install the pipe plug. Repeat for remaining injec-
GPM (9.5 L/min.). Do not change this setting.
tor 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 the joint being greased.

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 3-5) and fill housing to bottom of plug hole.
FIGURE 3-5. PUMP CONTROLS

1. Pump Pressure Control 4. Oil Level Plug

2. Manifold 5. Flow Control Valve
3. Pressure Gauge 6. Outlet Port
7. Manual Override
Maintenance - Section 4 OM4035.2 02/03
Page 4- 20 Automatic Lube System

FILTER AND RESERVOIR Filter Assembly

A filter assembly (2, Figure 3-6) is mounted on the right The filter assembly element (5, Figure 3-7) should be
upright (1) and filters the grease when the grease supply replaced if the bypass indicator (2) shows excessive
is refilled through the “quick fill” fittings. element restriction.
Grease is pumped into the filter through a hose (4)
routed from the Service Center and then flows out the
filter through a hose (3) to the reservoir (5). A vent hose
(7) purges air from the reservoir as it is being filled and
prevents a vacuum as grease is pumped out.
A cap (6) allows the reservoir to be drained if desired
and a plate secured on the end of the reservoir (frame
torque tube) can be removed if the reservoir requires
cleaning.

FIGURE 3-7. FILTER ASSEMBLY

1. Housing 6. Spring
2. Bypass Indicator 7. Bowl
3. O-Ring 8. O-Ring
4. Backup Ring 9. Plug
5. Element

FIGURE 3-6. FILTER AND RESERVOIR

1. R.H. Upright 5. Grease Reservoir

2. Filter Assembly 6. Cap
3. Filter Outlet Hose 7. Vent Hose
4. Filter Inlet Hose 8. Pump Access Door
OM4035.2 02/03 Maintenance - Section 4
Automatic Lube System Page 4- 21

INJECTORS (SL-1 Series “H”)

Injector Specifications
• Each lube injector services only one grease point. In
case of pump malfunction, each injector is equipped
with a covered grease fitting to allow the use of exter-
nal lubricating equipment.
• Injector output is adjustable:
Maximum output = 0.08 in3 (1.31 cc).
Minimum output = 0.008 in3 (0.13 cc).
• Operating Pressure:
Minimum - 1850 psi (12 755 kPa)
Maximum - 3500 psi (24 133 kPa)
Recommended - 2500 psi (17 238 kPa)
Maximum Vent Pressure - (Recharge)
600 psi (4 137 kPa)

Injector Adjustment FIGURE 3-8. TYPE SL-1 INJECTOR

The injectors may be adjusted to supply from 0.008 in3 1. Adjusting Screw 12. Plunger
to 0.08 in3 (0.13 cc to 1.31 cc) of lubricant per injection 2. Locknut 13. Viton Packing
cycle. The injector piston travel distance determines the 3. Piston Stop Plug 14. Inlet Disc
amount of lubricant supplied. This travel is in turn con- 4. Gasket 15. Viton Packing
trolled by an adjusting screw in the top of the injector 5. Washer 16. Washer
housing. 6. Viton O-Ring 17. Gasket
7. Injector Body Assy. 18. Adapter Bolt
Turn the adjusting screw (1, Figure 3-8) counterclock- 8. Piston Assembly 19. Adapter
wise to increase lubricant amount delivered and clock- 9. Fitting Assembly 20. Viton Packing
wise to decrease the lubricant amount. 10. Plunger Spring
11. Spring Seat
When the injector is not pressurized, maximum injector
delivery volume is attained by turning the adjusting
screw (1) fully counterclockwise until the indicating pin NOTE: The Piston Assembly (8) has a visible indicator
(8) just touches the adjusting screw. At the maximum pin at the top of the assembly to verify the injector oper-
delivery point, about 0.38 inch (9.7 mm) adjusting screw ation.
threads should be showing. Decrease the delivered
lubricant amount by turning the adjusting screw clock-
wise to limit injector piston travel. If only half the lubricant
is needed, turn the adjusting screw to the point where
about 0.19 inch (4.8 mm) threads are showing. The
injector will be set at minimum delivery point with about
0.009 inch (0.22 mm) 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.
Maintenance - Section 4 OM4035.2 02/03
Page 4- 22 Automatic Lube System

SYSTEM CHECKOUT
To check system operation (not including timer), pro-
ceed as follows:
1. Turn keyswitch "ON" and start the engine.
2. Actuate the manual override (11, Figure 3-1) on
the end of the solenoid valve.
3. The pump should operate and the system should
build grease pressure.
4. When the pump stalls, release the manual over-
ride knob and motor should turn Off. The vent
valve should open to vent grease pressure from
the injector bank feeder lines.

FIGURE 3-9. TIMER (TOP COVER REMOVED)

24 VDC TIMER CHECK 1. Timer Enclosure
2. Red LED (Light Emitting Diode)
To check the timer operation without waiting for the 3. Time Selector
normal timer setting, proceed as follows:
1. Remove timer dust cover.
NOTE: The timer incorporates a liquid and dust
tight cover which must be in place and secured at
all times during truck operation.
2. Adjust timer selector (3, Figure 3-9) to 5 minute Lubrication Cycle Timer Adjustment
interval setting. The timer is factory set for a nominal 2.5 minute (off time)
3. The timer should cycle in five minutes if the truck is interval. Dwell time is approximately 1 minute, 15 sec-
operating. onds. A longer interval (off time) is obtained by turning
the Selector knob (3, Figure 3-9) to the desired position .
NOTE: If the timer check is being made on a cold start,
the first cycle will be approximately double the nominal NOTE: Set timer by turning the Selector knob (3) to the
setting. All subsequent cycles should be within the se- 2.5 minute setting point. Then, turn the Selector clock-
lected time tolerance. wise, one detent at a time, to the desired setting, or until
the maximum limit of eighty minutes is reached.
4. Voltage checks at the timer should be accomplished
if the above checks do not identify the problem. The timer is a sealed unit, do not attempt disassem-
bly.
a. Insure timer ground connection is clean and tight.
b. Using a Volt-Ohm meter, read the voltage be-
tween positive and negative posts on the solid
state timer with the truck keyswitch “ON”.
Normal reading should be 18-26 VDC, depend-
ing upon whether or not the engine is running.
OM4035.2 02/03 Maintenance - Section 4
Automatic Lube System Page 4- 23

PUMP REBUILD 14. Remove the pump plunger (20) from the plunger link
rod (17). (A spanner wrench, which uses the holes
in the the pump plunger, is required.)
15. Unscrew the plunger link rod (17) from the plunger
tube (11) and slide off the cup seal (16) backup
washer (15) and wrist pin anchor (14).
Be certain to bleed steering accumulators to relieve 16. Unscrew the plunger tube (11) from the outlet pin (9).
hydraulic pressure and to relieve pump outlet
grease pressure before removing any hoses or fit- 17. To dismantle the crankrod assembly (1 through 8),
tings. remove flat head screws (1) and the inner and outer
weights (2 & 3).
Disassembly 18. Remove the small retaining rings (6) and press the
1. Remove the four socket head screws (33, Figure 3- crank eccentric (7) out of the ball bearing (8). Be
10) and separate the manifold (37) from the hydrau- sure to support the ball bearing on the inner race.
lic motor (42).
2. Remove pipe plug (45) and drain the crankcase oil
from pump housing (46). Cleaning and Inspection
3. Remove the six screws (29) and remove the hous- 1. Discard all seals and gaskets. Repair kits are avail-
ing cover (30) and cover gasket (31). able containing all the necessary seals and gaskets
4. Remove retaining ring (57) and pull the shovel plug for reassembly. Refer to the appropriate truck parts
(56) from the housing tube (55). book.
5. Remove two socket head screws (44) and separate 2. Clean and inspect the following parts. Replace if
hydraulic motor (42) from the pump housing (46). excessive wear is evident:
6. Remove two outlet pin nuts (50) from pump housing.
•Ball bearing (8)
7. Remove the pump subassembly (1 through 28) from •Crank eccentric (7)
the pump housing. Pushing the subassembly up
with a .75 in. (19 mm) diameter wooden or plastic •Crankrod (5)
rod against the check seat housing (28) is helpful. •Wrist pin bushings (13)
8. Remove the housing tube (55) from the pump •Plunger tube (11)
housing by inserting a .75 in. (19 mm) diameter rod •Pump plunger & upper check parts (20, 19 & 18)
through the inlet holes at the bottom of the housing •Pump cylinder (24)
tube and unscrewing it. •Check seat housing/lower check ball (28, 26)
9. Remove the bronze bearing (51), O-ring (52), back- •Upper bronze bushing (51)
up washer (53), and O-ring (54) from the housing •Housing tube (55)
tube.
•Shovel plug (56)
10. Remove the crankrod assembly (1 through 8) from •Reciprocating tube (21)
the pump by unscrewing the button head screws
(12) and then pulling out the wrist pin bushings (13).
11. Remove the check seat housing (28) from the recip-
rocating tube (21).
Note: There is a 3/8 in. allen head socket in the throat of
the check seat housing to facilitate removal.
12. Unscrew the wrist pin anchor (14) from the recipro-
cating tube (21) and pull the plunger assembly (9
through 20) from the tube.
13. Using a .50 in. (13 mm) diameter wooden or plastic
rod, push the cup seal (22) and the pump cylinder
(24) from the reciprocating tube.
Maintenance - Section 4 OM4035.2 02/03
Page 4- 24 Automatic Lube System

FIGURE 3-10. LUBE PUMP ASSEMBLY

1. Screw 17. Plunger Rod 33. Screw 49. O-Ring
2. Outer Weight 18. Spring 34. Valve Cartridge 50. Nut
3. Inner Weight 19. Steel Ball 35. Solenoid Valve 51. Bronze Bearing
4. Retaining Ring 20. Plunger 36. Connector 52. O-Ring
5. Crankrod 21. Reciprocating Tube 37. manifold 53. Backup Washer
6. Retaining Ring 22. Cup Seal 38. Press. Reducing Valve 54. O-Ring
7. Eccentric Crank 23. O-Ring 39. Flow Control Valve 55. Housing Tube
8. Ball Bearing 24. Cylinder 40. O-Ring 56. Shovel Plug
9. Outlet Pin 25. Ball Cage 41. Gasket 57. Retaining Ring
10. O-Ring 26. Steel Ball 42. Hydraulic Motor 58. Orifice Fitting
11. Plunger Tube 27. O-Ring 43. Washer
12. Screw 28. Check Seat 44. Screw
13. Wrist Pin Bushing 29. Screw 45. Pipe Plug
14. Wrist Pin Anchor 30. Housing Cover 46. Pump Housing
15. Backup Washer 31. Cover Gasket 47. Backup Ring
16. Cup Seal 32. Guage 48. O-Ring
OM4035.2 02/03 Maintenance - Section 4
Automatic Lube System Page 4- 25

Assembly 8. Assemble crank rod assembly, to pump with bush-

ings (13) and button head screws (12). Tighten
Note: Use Loctite® 242 (or equivalent) thread locker on
screws to 100 - 110 in. lbs. (11.3 - 12.4 N.m)
all torqued, threaded connections. Use extreme care to
torque.
prevent thread locker from flowing into adjacent areas
such as clearance fits and ball check. Allow a minimum 9. Place pump subassembly (parts 1 through 28) into
of 30 minutes cure time before operating pump. pump housing (46).
10. Install new O-ring (54), backup washer (53) and O-
ring (52) and bronze bushing (51) into housing tube
1. Support ball bearing (8, Figure 3-10) inner race and
(55).
press eccentric (7) into bore. Install small retaining
rings (6). 11. Install housing tube assembly onto pump housing
(46). Be certain reciprocating tube (21) is inserted
2. Assemble crankrod assembly parts; large retaining
through both bushings. Using a .75 in. (19 mm)
rings (4), inner weights (3), outer weights (2) and
diameter rod through the inlet holes at bottom of
install flat head screws (1). Tighten to 100 - 110 in.
tube, tighten to 20 - 25 ft. lbs. (27.1 - 33.9 N.m)
lbs. (11.3 - 12.4 N.m) torque.
torque.
3. Using a new O-ring (10), install install plunger tube
12. Install shovel plug (56) and retainer (57).
(11) on outlet pin (9). Tighten to 100 - 110 in. lbs.
(11.3 - 12.4 N.m) torque. 13. Install new backup rings (47), O-rings (48 & 49), and
outlet pin nuts (50). Tighten to 30 - 35 ft. lbs. (40.7
4. Assemble the wrist pin anchor (14), backup washer
- 47.5 N.m) torque.
(15), cup seal (16) and plunger link rod (17) onto
plunger tube (11). Tighten to 100 - 110 in. lbs. (11.3 14. Install gasket (41) and motor (42) on pump housing
- 12.4 N.m) torque. (46). Install washers (43) and socket head screws
(44).
5. Assemble spring (18), ball (19), and plunger (20) on
plunger link rod (17). Tighten plunger to 100 - 110 15. Install shovel plug (56) in housing tube (55). Install
in. lbs. (11.3 - 12.4 N.m) torque. retaining ring (57).
6. Install reciprocating tube (21) onto wrist pin anchor 16. Install gasket (31), cover (30) and six self-tapping
(14). Tighten to 20 - 25 ft. lbs. (27.1 - 33.9 N.m) screws (29), on pump housing.
torque.
17. Using new O-rings (40), install manifold (37) on
7. Install cup seal (22), O-ring (23), cylinder (24), ball motor (42). Install socket head screws (33).
cage (25), ball (26), O-ring (27) and check seat (28)
18. With the pump assembly in its normal operating
into reciprocating tube (21). Tighten check seat
position, add SAE 10W-30 motor oil to pump hous-
housing to 20 - 25 ft. lbs. (27.1 - 33.9 N.m) torque.
ing until oil is level with bottom of pipe plug (45) hole.
Install pipe plug.
Maintenance - Section 4 OM4035.2 02/03
Page 4- 26 Automatic Lube System

SYSTEM TROUBLESHOOTING CHART

If the following procedures do not correct the problem, contact a factory authorized service center.

POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION

TROUBLE: Pump Does Not Operate

Lube system not grounded. Correct grounding connections to pump assembly and
truck chassis.

Electrical power loss. Locate cause of power loss and repair. 24VDC power
required. Be sure keyswitch is “ON”.

Timer malfunction. Replace timer assembly.

Solenoid valve malfunctioning. Replace the solenoid valve assembly.

Relay malfunctioning Replace relay.

Motor or pump malfunction. Replace motor and/or pump assembly.

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.

TROUBLE: Pump Will Not Prime

Low lubricant supply. Dirt in reservoir, pump inlet clogged, filter clogged.

TROUBLE: Pump Will Not Build Pressure

Air trapped in lubricant supply line. Prime system to remove trapped air.

Lubricant supply line leaking. Check lines and connections to repair leakage.

Vent valve leaking. Clean or replace vent valve.

Pump worn or scored. Repair or replace pump assembly.

TROUBLE: Injector Indicator Stem Does Not Operate

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 indicated by the pump Replace individual injector assembly.
building pressure and then venting.

All injectors inoperative - pump build up not sufficient Service and/or replace pump assembly.
to cycle injectors.
OM4035.2 02/03 Maintenance - Section 4
Automatic Lube System Page 4- 27

SYSTEM TROUBLESHOOTING CHART

If the following procedures do not correct the problem, contact a factory authorized service center.
POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION

TROUBLE: Pressure Gauge Does Not Register Pressure

No system pressure to the pump motor. Check hydraulic hose from steering system.

No 24 VDC signal at pump solenoid. Determine problem in 24 VDC electric system.

Pressure reducing valve set too low. Refer to “Pressure Control Valve Adjustment”.

24V Relay may be defective. Replace relay.

TROUBLE: Pump Pressure Builds Very Slowly Or Not At All

No signal at 24V relay. Check Timer.

Pressure switch may be defective Replace pressure switch.

Pressure reducing valve may be set too low. Refer to “Pressure Control Valve Adjustment”.

Grease viscosity may be too high for temperature at Replace grease with a lower viscosity lubricant.
which pump is operating.

Pump inlet check or outlet check may have foreign Remove, inspect and clean, if necessary.
matter trapped causing leakage. Inspect sealing surfaces between checks. Replace if
rough or pitted.

Lubricant supply line leaks or is broken. Repair lubricant supply line

Insufficient hydraulic oil supply. Check oil pressure and flow to motor.

TROUBLE: 24VDC Timer Not Operating

Timer BAT (-) connection is not on grounded member. Connect to good ground.

Timer BAT (+) connection not on circuit continuously Establish direct connection between Timer BAT (+)
connected to BAT (+) terminal during operation of connection and 24 V BAT (+) terminal.
vehicle.

Loose wire connections at any of the timer terminals. Secure wire connections.

TROUBLE: Timer Stays Timed Out

Commutation failure in timer caused by damaged Replace Timer.

component.

Output relay contacts welded shut caused by Replace Timer

extended short to ground.

Solenoid valve connected to LUBE SW terminal of Correct wiring hook-up.

timer instead of terminal marked SOL.
Maintenance - Section 4 OM4035.2 02/03
Page 4- 28 Automatic Lube System

POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION

TROUBLE: Timer Turns On At Intervals Two (2) To Ten (10) Times More Often Than Set Time Interval

Electrical noise is being introduced into the power sup- IMPORTANT: In some instances, electrical noise
ply to the timer overcoming suppressor capacitor may be generated into vehicle electrical system
causing uncontrolled turn-on of its output relay. which may cause timer to turn on at random inter-
vals, independent of timer setting.
If this occurs, a 250 to 1,000 MFD capacitor rated
150 to 350 VDC should be added across BAT (+) and
BAT (-) terminals to suppress this noise and im-
prove timer performance.

TROUBLE: Timer Turns On At Intervals Faster Than Allowable Tolerances Of Settings

Timer out of adjustment or damaged component. Refer to “Timer Adjustment and re-adjust timer or
replace timer.
OM4035.2 02/03 Maintenance - Section 4
Automatic Lube System Page 4- 29

PREVENTATIVE MAINTENANCE PROCEDURE

The following maintenance procedures should be used This will indicate if there are any frozen or plugged
to insure proper system operation. bearings, and will help flush the bearings of con-
taminants.
Daily Lubrication System Inspection
5. System Checkout
1. Check grease reservoir level. a. Remove all SL-1 injector cover caps to allow
Inspect grease level height after each shift of oper- visual inspection of the injector cycle indicator
ation. Grease usage should be consistent from day- pins during system operation.
to-day operations. b. Start truck engine.
•Lack of lubricant usage would indicate an inopera- c. Lift the passenger seat and connect a jumper
tive system. Excessive usage would indicate a bro- wire between “SOL” and “LUBE SW” on the lube
ken supply line. cycle timer or activate test switch if installed.
The hydraulic grease pump should operate.
2. Check filter bypass indicator when filling reservoir.
Replace element if bypassing. d. Keep the system activated until the pump stalls
out or the pressure switch closes.
3. Check all grease feed line hoses from the SL-1
e. With the pump in the stalled-out mode, check
Injectors to the lubrication points.
each SL-1 injector assembly.
a. Repair or replace all damaged feed line hoses. The cycle indicator pin should be retracted inside
b. Make sure that all air is purged and all new feed the injector body.
line hoses are filled with grease before sending f. Once all of the SL-1 injectors have been inspect-
the truck back into service. ed under pressure remove the jumper wire be-
4. Inspect key lubrication points for a bead of lubricant tween the “SOL” terminal and “LUBE SW”
around seal. If a lubrication point appears dry, terminal on the timer assembly or open test
troubleshoot and repair problem. switch. The pump should shut off and the pres-
sure in the system should drop to zero, venting
250 Hour Inspection back to the grease reservoir.
g. With the system vented, check all of the SL-1
1. Check all grease feed line hoses from the SL-1
injector indicator pins; all of the pins should be
Injectors to the lubrication points (see, Figure 3-2).
visible. Replace or repair injectors, if defective.
a. Repair or replace all worn / broken feed line
h. Reinstall all injector cover caps.
hoses.
i. Check timer operation.
b. Make sure that all air is purged and all new feed
line hoses are filled with grease before sending Note: With engine running, lube system should activate
the truck back into service. within 5 minutes. The system should build 2000 to 2500
psi within 25-40 seconds.
2. Check all grease supply line hoses from the pump
to the SL-1 injectors. j. If the system is working properly, the machine is
ready for operation.
a. Repair or replace all worn / broken supply lines.
k. If the system is malfunctioning, refer to the trou-
b. Make sure that all air is purged and all new supply
bleshooting chart.
line hoses are filled with grease before sending
the truck back into service.
3. Check grease reservoir level. 1000 Hour Inspection
a. Fill reservoir if low.
1. Check pump housing oil level.
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.
4. Inspect all bearing points for a bead of lubricant
around the bearing seal.
It is good practice to manually lube each bearing
point at the grease fitting provided on each Injector.
Maintenance - Section 4 OM4035.2 02/03
Page 4- 30 Automatic Lube System

NOTES
OM5029 Specifications - Section 5
Page 5-1

MAJOR COMPONENT DESCRIPTION

The KOMATSU Model 730E Dump Truck is an electric drive, off-highway, rear dump truck whose gross vehicle
weight is 715,000 lbs. (324 324 kg) rated for a maximum payload of 210 tons (190 t).

ENGINE POWER STEERING

The KOMATSU 730E Dump Truck is powered by a The KOMATSU 730E Dump Truck is equipped with a
Komatsu SSA16V159 engine rated at 2000HP (1492 full time power steering system which provides posi-
kW). tive steering control with a minimum of effort by the
operator. The system includes nitrogen-charged
accumulators which automatically provide emer-
gency power if the steering hydraulic pressure is
ALTERNATOR (GE GTA-22) reduced below an established minimum.
The diesel engine drives an alternator mounted in-
line with the engine. The alternating current (AC) out-
put of the alternator is rectified to direct current (DC)
and sent to the DC drive wheel motors.
DYNAMIC RETARDING
The dynamic retarding is used to slow the truck dur-
WHEEL MOTORS (GE 788) ing normal operation or control speed coming down a
grade. The dynamic retarding ability of the DC elec-
The output of the alternator supplies electrical energy
tric system is controlled by the operator through the
to the two wheel motors attached to the rear axle
activation of the retarder pedal in the operators cab
housing. The two wheel motors convert electrical
and by setting the RSC (Retarder Speed Control).
energy back to mechanical energy through built-in
Dynamic Retarding is automatically activated if truck
gear trains within the wheel motor assembly. The
goes to a preset overspeed setting.
direction of the wheel motors is controlled by a for-
ward or reverse hand selector switch located on a
console to the right side of the operator.

BRAKE SYSTEM
BLOWER The wheel service brakes are caliper/dry disc brakes
The blower supplies cooling air for the rectifiers, AC applied by an all hydraulic actuation system.
alternator, and to both wheel motors, where it is then Depressing the brake pedal actuates wheel-speed
exhausted to atmosphere. single disc front brakes and armature-speed dual
disc rear brakes. The rear brakes can also be acti-
vated by operating a switch on the instrument panel.

OPERATOR'S CAB All wheel brakes will be applied automatically if sys-

tem pressure decreases below a preset minimum.
The Operator's Cab for the KOMATSU 730E Dump
Truck has been engineered for operator comfort and The parking brake is a caliper/disc type, mounted on
to allow for efficient and safe operation of the truck. each rear wheel motor, and is spring-applied and
hydraulically-released with wheel speed application
The cab provides for wide visibility, with an integral 4- protection (will not apply with truck moving).
post ROPS/FOPS structure, and an advanced ana-
log operator environment. It includes a tinted safety-
glass windshield and power-operated side windows,
a deluxe interior with a fully adjustable seat with lum- SUSPENSION
bar support, a fully adjustable/tilt steering wheel, con-
HYDRAIR®II suspension cylinders located at each
trols mounted within easy reach of the operator, and
wheel provide a smooth and comfortable ride for the
an analog instrument panel which provides the oper-
operator and dampens shock loads to the chassis
ator with all instruments and gauges which are nec-
during loading and operation.
essary to control and/or monitor the truck's operating
systems.
Specifications - Section 5 OM5029
Page 5-2

730E MAJOR COMPONENTS

OM5029 Specifications - Section 5
Page 5-3

SPECIFICATIONS
These specifications are for the standard 730E Dump Truck. Customer Options may change this listing.

ENGINE SERVICE CAPACITIES

. . . . . . . . . . . . . . . . . . . . U.S. Gallons . . . . . . Liters
Komatsu SSA16V159
Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . 16 Crankcase (Includes lube oil filters)

Operating Cycle. . . . . . . . . . . . . . . . . . . . . . 4-Stroke Komatsu . . . . . . . . . . . . . . . . . 59.0 . . . . . . . . . . .223

Cooling System . . . . . . . . . . . 108. . . . . . . . . . . .409
Rated Brake HP. 2000 HP (1492 kW) @ 1900 RPM
Flywheel HP . . . 1860 HP (1388 kW) @ 1900 RPM Fuel . . . . . . . . . . . . . . . . . . . . 850 . . . . . . . . . .3217

Weight (Wet) . . . . . . . . . . . . . . 11,670 lbs. (5717 kg) Hydraulic System . . . . . . . . . . 193 . . . . . . . . . . .731
Wheel Motor Gear Box. . . 10.5/Wheel . . . 40/Wheel

ELECTRIC DRIVE SYSTEM HYDRAULIC SYSTEM

Pumps:
STATEX III w/Fuelsaver . . . . . . . . . AC/DC Current
Hoist (gear type). . . . . . . . . . 135.6 GPM (513 l/min.)
Alternator . . . . . . . . . . . . . General Electric GTA - 22
. . . . . . . . . . . at 2500 psi (17240 kPa)@ 1900 RPM
Motorized Wheels . . . . . . . . . . General Electric 788*
Steering/Brake (vane) . . . . . . . .62 GPM (235 l/min.)
Standard Gear Ratio* . . . . . . . . . . . . . . . . . 26.825:1
. . . . . . . . . . . at 2750 psi (18 960 kPa) @ 1900 RPM
Maximum Speed . . . . . . . . . . 34.6 MPH (55.7 km/h)
Relief Pressure- Hoist . . . . . . . 2500 psi (17.2 MPa)
*NOTE: Wheel motor application depends upon GVW, haul road
grade, haul road length, rolling resistance, and other parameters. Relief Pressure- Steering . . . . . 4000 psi (27.5 MPa)
KOMATSU & G.E. must analyze each job condition to assure Hoist . . . . . . . . . . . .Two 3-Stage Hydraulic Cylinders
proper application.
Tank . . . . . . . Vertical - Cylindrical, Non-Pressurized
Service Capacity . . . . . . . 193 U.S. Gal. (731 Liters)
Filtration . . . . . . . . . . . . In-line replaceable elements
DYNAMIC RETARDING Suction . . . . . . . . . . . . . Single, Full Flow, 100 Mesh
Electric Dynamic Retarding . . . . . . . . . . . . Standard Hoist & Steering High Pressure Filters
Maximum Retarding . . . . . . . . . 3700 HP (2759 kW) . . . . . . . . . . . . . . . . . . . . . Dual, Full Flow, 7 Micron
. . . With Continuous Rated (18 resistor) Blown Grids . . . . . . . . . . . . . . . . . . . . . . . . . Beta 12 rating = 200
. . 2-Speed Overspeed & Extended Range Retarding
. . . . . . . . . . . . . . . . . . . . . . . . . . . Reverse Retarding
SERVICE BRAKES
Actuation . . . . . . . All Hydraulic - Caliper/Disc
. . . . . . . . . . . . . . .(Front) . . . . . . . . . . . . . . . .(Rear)
BATTERY ELECTRIC SYSTEM Type . . . . . . . . . Single Disc. . . . . . . . . . . . Dual Disc
Batteries - . bumper-mounted in polyethylene boxes . . . . . . . . . . . . Wheel Speed . . . . . .Armature Speed
. . . . . . . . . . Four 12 Volt Batteries in Series/Parallel
. . . . . . . . . . . . . . . . . . . . 220 Ampere-Hour Capacity
STEERING
. . . . . . . . . . . . . . . . . . . . . . . With Disconnect Switch
Turning Circle (SAE). . . . . . . . . . . . . . 92 ft. (28.0 m)
Alternator . . . . . . . . . . . 24 Volt, 220 Ampere Output
Twin hydraulic cylinders with accumulator assist to
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volt
provide constant rate steering.
Starters (2). . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Volt
Emergency Power Steering provided by Accumula-
tors
Specifications - Section 5 OM5029
Page 5-4

STANDARD DUMP BODY* WEIGHT DISTRIBUTION

Capacity: EMPTY . . . . . . . . Pounds . . . . . . . . . . Kilograms
Struck . . . . . . . . . . . . . . . 101 yds³. . . . . . 77 m³ Front Axle . . . . 144,594 . . . . . . . . . . . . 65 587
Heaped @ 2:1 (SAE) . . . 145 yds³ . . . . . .111 m³ Rear Axle . . . . 160,457. . . . . . . . . . . . 72 784
Width (Inside) . . . . . . . . . . . . . . 22 ft. 6 in. (6.85 m) Total . . . . . . . . 305,051 . . . . . . . . . . . 138 371
Depth . . . . . . . . . . . . . . . . . . . . 6 ft. 10 in. (2.08 m) LOADED
Loading Height . . . . . . . . . . . . . . 18 ft. 5 in. (5.61 m) Front Axle . . . . 241,670 . . . . . . . . . . . 109 621
Dumping Angle. . . . . . . . . . . . . . . . . . . . . . . . . . 45° Rear Axle . . . . 473,330 . . . . . . . . . . . 214 703
* OPTIONAL Capacity Dump Bodies are available. Total . . . . . . . . 715, 000. . . . . . . . . . . 324 324
Not to exceed 715, 000 lbs. (324 324 kg), including
options, fuel, and payload. Weights in excess of this
TIRES amount require Komatsu / G.E. approval.
Radial Tires (standard) . . . . . . . . . . . . . . 37.00 R57
Rock Service, Deep Tread . . . . . . . . . . . . Tubeless
Rims . . (patented Phase II New Generation™ rims)
Tires and Rims . . . . . . . . . . . . . . . Interchangeable
OM6008 02/03 Optional Equipment - Section 6
Payload Meter III Page 6-1

PAYLOAD METER III TM

INDEX

OPERATION SECTION .................................................................................................................................3

INTRODUCTION ...........................................................................................................................................3
DATA SUMMARY ..........................................................................................................................................3
DATA GATHERING .......................................................................................................................................3
COMPONENT DESCRIPTION ......................................................................................................................4
System Diagram .........................................................................................................................................4
Suspension Pressure Sensors ...................................................................................................................4
Inclinometer ................................................................................................................................................4
Operator Display .........................................................................................................................................4
Operator Switch ..........................................................................................................................................5
Speed Input ................................................................................................................................................5
Body-up Switch ...........................................................................................................................................5
Brake Lock Switch ......................................................................................................................................5
Payload Meter ............................................................................................................................................5
Communications Ports ...............................................................................................................................5
Keyswitch Input ..........................................................................................................................................6
Payload Meter Power .................................................................................................................................6
Load Lights .................................................................................................................................................6
Wiring and Termination ..............................................................................................................................7
TCI Outputs ................................................................................................................................................7
OPERATOR’S DISPLAY AND SWITCH .......................................................................................................8
Reading the Speedometer ..........................................................................................................................8
Reading the Load Display ..........................................................................................................................8
Using the Operator ID .................................................................................................................................8
Using the Load and Ton Counter ...............................................................................................................8
Total Ton Counter ....................................................................................................................................8
Total Load Counter ..................................................................................................................................9
Clearing the Counters ..............................................................................................................................9
Viewing Live Sensor Data ..........................................................................................................................9
Other Display Messages ............................................................................................................................9
PAYLOAD OPERATION & CALCULATION ..................................................................................................10
Description of Haul Cycle States ................................................................................................................10
"States" or stages of a typical haul cycle .................................................................................................10
Haul Cycle Description ............................................................................................................................10
Load Calculation .........................................................................................................................................11
Carry Back ..................................................................................................................................................11
Measurement Accuracy ..............................................................................................................................11
Sources for Payload Error ..........................................................................................................................11
Payload Error ...........................................................................................................................................11
Loading Conditions ..................................................................................................................................12
Pressure Sensors ....................................................................................................................................12
Swingloads ..............................................................................................................................................12
Speed and Distance ................................................................................................................................12
HAUL CYCLE DATA .....................................................................................................................................12
Haul Cycle Data ..........................................................................................................................................13
Haul Cycle Warning Flags ..........................................................................................................................14
Alarm Records ............................................................................................................................................15
Frame Torque Data ....................................................................................................................................15
Sprung Weight Data ...................................................................................................................................16
Maximum Speed Data ................................................................................................................................16
Optional Equipment - Section 6 OM6008 02/03
Page 6-2 Payload Meter III

PC SOFTWARE OVERVIEW ........................................................................................................................ 16

PC Overview ............................................................................................................................................... 16
System Configuration .................................................................................................................................. 16
Installing the Payload Meter III Software .................................................................................................... 16
DOWNLOADING DATA ................................................................................................................................ 17
PLMIII SYSTEM CONFIGURATION .............................................................................................................. 18
Starting Communications ........................................................................................................................... 18
Displayed Payload Units........................................................................................................................... 18
Time Units ................................................................................................................................................ 18
Connection Menu ....................................................................................................................................... 18
Connecting to the Payload Meter ............................................................................................................... 19
Configure the Payload Meter ...................................................................................................................... 19
Setting the Date and Time ....................................................................................................................... 19
Setting the Truck Type ............................................................................................................................ 20
Setting the Gauge Display Units .............................................................................................................. 20
Setting the Frame Serial Number ............................................................................................................ 20
Setting the Truck Number ........................................................................................................................ 20
Setting the KMS Distributor ..................................................................................................................... 20
Setting the KMS Customer ...................................................................................................................... 20
Clean Truck Tare ........................................................................................................................................ 21
Inclinometer Calibration .............................................................................................................................. 21
DATA ANALYSIS ......................................................................................................................................... 22
Creating a Query ........................................................................................................................................ 22
Sorting on Truck Unit Number ................................................................................................................. 22
Sorting on Truck Type ............................................................................................................................. 22
Sorting on Date Range ............................................................................................................................ 23
Sorting on Time Range ............................................................................................................................ 23
Payload Detail Screen ................................................................................................................................ 24
Creating Reports ........................................................................................................................................ 24
Summary - one page report ..................................................................................................................... 25
Detailed - multi-page report ..................................................................................................................... 25
Creating Graphs ......................................................................................................................................... 26
Exporting Data ............................................................................................................................................ 26
CSV Export .............................................................................................................................................. 26
Compressed ............................................................................................................................................ 27
Importing Data ............................................................................................................................................ 28
Deleting Haul Cycle Records ...................................................................................................................... 28
Viewing Alarms ........................................................................................................................................... 29
Deleting Alarm Records .............................................................................................................................. 29
OM6008 02/03 Optional Equipment - Section 6
Payload Meter III Page 6-3

OPERATION SECTION Data Gathering

Windows 95/98/NT software is available to
INTRODUCTION download, store and view payload and fault
Payload Meter III (PLMIII) measures, displays and information. The PC software will download an entire
records the weight of material being carried by an off- truck fleet into one Paradox database file. Users can
highway truck. The system generally consists of a query the database by date, time, truck type and
payload meter, a gauge display, deck-mounted lights, truck number to produce reports, graphs and export
and sensors. The primary sensors are four the data. The software can export the data in '.CSV'
suspension pressures and an inclinometer. Other format that can be easily imported into most
inputs include a body up signal, brake lock signal, spreadsheet applications. The Windows software is
and speed. not compatible with the Payload Meter 2 system.

It is important that each payload meter be configured

Data Summary for each truck using the PC software. The
5208 haul cycles can be stored in memory. The information for frame serial number and truck
following information is recorded for each haul cycle: number is used by the database program to organize
• Payload the payload data. In addition, the payload meter
• Operator ID number (0000-9999) must be configured to make calculations for the
• Distance traveled loaded and empty proper truck model. Improper configuration can lead
• The amount of time spent empty run/stop, to data loss and inaccurate payload calculations.
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
Optional Equipment - Section 6 OM6008 02/03
Page 6-4 Payload Meter III

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
used for speed and can display metric (km/h) or
the overload limit is 10,000 psi (700 kg/cm2). One
English (mph) units. Grounding terminal #4 on the
wire to the sensor is the supply voltage and the other
back of the speedometer will switch the meter to
is the signal. The 0-4000 psi range is converted into
display metric units. Leaving terminal #4
an electrical current between 4-20 ma. The supply
unconnected will cause the gauge to display English
voltage for the sensor is nominally +18vdc. Each
units. The speedometer can be adjusted using a
pressure sensor has an 90" length of cable that is
calibration potentiometer in the back just like existing
terminated with #10 ring terminals. The cable is
speedometers.
specially shielded and reinforced to provide
mechanical strength and electronic noise immunity.
The payload meter uses the lower display for
A typical part number for the pressure sensor is
payload information. The normal display mode
PC0328.
shows the current payload. The display can be
changed to show the load and total tons counter or
Inclinometer the Operator ID. Using the operator switch on the
dash panel, the current suspension pressures and
The inclinometer is used to increase the accuracy of
incline can be displayed. The units for display are
load calculations on an incline. The inclinometer
set using the PC software. Payloads can be
uses three wires. For the sensor, red is the +18vdc
displayed in Short Tons, Long Tons or Metric Tons. A
supply voltage, black is ground and the white is the
typical part number for this gauge is the PC0550.
signal. The incline signal is a voltage between 1 and
4 volts. Zero degrees of incline is represented by
2.6vdc on the signal line. The voltage signal will be
decreased by 0.103vdc for every degree of nose up
incline. A typical part number for the inclinometer
assembly is 7861-92-5330.
OM6008 02/03 Optional Equipment - Section 6
Payload Meter III Page 6-5

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. housing. There is a small window on the face of the
It is also used to enter the Operator ID number (0- unit. Status and active alarm codes can be viewed
9999). This switch can also be used to view the through the window. During normal operation, a two-
suspension pressures and inclinometer. The digit display flashes 0 back and forth. Active fault
payload meter operator switch is located on the codes will be displayed for two seconds. These
dashboard. It is a two-way momentary switch. The codes are typically viewed using the laptop computer
top position is the SELECT position. The SELECT connected to the serial communications port.
position is used step through the different displays.
The lower position is the SET position. The SET There is one 40-pin connector on the payload meter.
position is used to set the Operator ID or clear the A jack-screw is used to hold the payload meter and
load and total ton counters. Normally the inputs from wire harness connector housings together. This
the switch to the payload meter are open circuit. The screw requires a 4mm or 5/32 hex wrench. The
switch momentarily connects the circuit to ground. correct tightening torque for this screw is 25 lb-in.
Four bolts hold the payload meter housing to its
mounting bracket in the cab.
Speed Input
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 withstand the harsh operating environment of the
displayed to the operator is used by the system. mining industry. Opening the payload meter housing
Distance calculations are made based on the rolling will result in voiding the warranty.
radius of 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 communications ports and two CAN ports.
magnetic switch located on the inside of the truck Connections for the two serial ports are available
frame, forward the pivot pin of the truck body. This is inside the payload meter junction box. The two CAN
the 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
and completes the circuit to 71-Control Power. Serial port #1 is used to communicate with the
24vdc indicates the body is down. Open circuit dashboard display. It is also used to connect to the
indicates that the body is up. laptop computer. The display gauge will remain blank
when the PC is using the serial port. This port
initially operates with serial settings at 9600,8,N,1.
Brake Lock Switch These 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
brake lock applied, the payload meter will not Serial port #2 is used to communicate to other on-
calculate swingloads during the loading process. board electronics like Modular Mining's Dispatch®
Without the brake lock, the payload meter will system or the Scoreboard from KMS. This port uses
assume that the truck was loaded using a continuous a 3-wire hardware connection. Connections to this
loader and flag the haul cycle record. All other serial port need to be approved by KMS. Several
functions will be normal regardless of brake lock protocol options are available and detailed technical
usage. The brake lock input comes from the switch information is available depending on 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.
Optional Equipment - Section 6 OM6008 02/03
Page 6-6 Payload Meter III

Keyswitch Input Load Lights

PLMIII monitors the status of the keyswitch. 24vdc PLMIII uses load lights to indicate to the shovel
indicates that the keyswitch is on, open indicates the operator the approximate weight of the material in
keyswitch is off. The payload meter does not receive the truck. The load lights are illuminated only when
its electrical power from the keyswitch 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 keyswitch is removed. When the keyswitch 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 keyswitch 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 keyswitch 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
enough time is given for these operations. The reduces the inrush current when the light is fully
display may blink briefly. illuminated. This lengthens the operating life of the
load lights.

Payload Meter Power

The payload meter receives its power from the The load lights progressively indicate to the shovel
battery circuit on the truck. Removing battery power operator the approximate weight of the material in
from the payload meter before removing keyswitch the truck.
and waiting 15 seconds may result in lost haul cycle
data. The payload meter turns itself off approximately A flashing green light indicates the next swingload
15 seconds after the keyswitch power is removed. will make the measured load greater than 50% of
Some haul cycle data will be lost if battery power is rated load. A solid green light indicates that the
removed before waiting 15 seconds. The payload current load is greater than 50% of rated capacity.
meter system operates at a nominal voltage of 24vdc
at 1 to 2 amps depending on options. The payload A flashing amber light indicates the next swingload
meter is designed to turn itself off if the supply will make the measured load greater than 90% of
voltage rises above 36vdc. The payload meter is also rated load. A solid amber light indicates that the
protected by a 5 amp circuit breaker located in the current load is greater than 90% of rated capacity.
junction box.
Power to the load lights comes from the same battery A flashing red light indicates the next swingload will
circuit. The load lights are powered through a relay. make the measured load greater than 105% of rated
The keyswitch circuit controls the relay. The load load. A solid red light indicates that the current load
lights are also protected by a 15 amp circuit breaker is greater than 105% of rated capacity.
in the junction box.
The optimal loading target is a solid green and amber
lights with a flashing red light. This indicates that the
load is between 90% and 105% of rated load for the
truck and the next swingload will load the truck over
105%.
OM6008 02/03 Optional Equipment - Section 6
Payload Meter III Page 6-7

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. A typical part number for this
wire is LW086-63. This wire is typically terminated
with a #10 ring terminal, part number VH2584. Most
connections for the PLMIII system are made in the
payload meter junction box.

TCI Outputs
The GE drive system on the 930E 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.
Optional Equipment - Section 6 OM6008 02/03
Page 6-8 Payload Meter III

Operator's Display and Switch Using the Operator ID

The current Operator ID number is recorded with
each haul cycle. The number can be between 0 and
Reading the Speedometer 9999.
The top window of the speedometer/display gauge is
the speedometer section. The display shows the To set the Operator ID:
speed indicated by the frequency being received by 1. Press the “SELECT” switch until id= is dis-
the gauge. This can be adjusted using the played.
potentiometer on the back of the gauge. In addition,
2. Hold the “SET” button until 0000 is displayed.
the units for the display can be changed. Terminal #4
The first digit should be flashing.
controls the displayed units. If #4 is grounded, the
display will be metric. If terminal #4 is left open, the 3. Press the “SET” button again to change the
display will be in English units. digit.
4. Press the “SELECT” button once to adjust the
second digit.
Reading the Load Display
The lower display on the speedometer/display gauge 5. Use the “SET” button again to change the digit.
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
• Id= Operator ID enter the ID.
• tl= Total Shift Tons If no buttons are pressed for 30 seconds, the display
• l(= 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 Using the Load and Ton Counter
PLMIII allows the truck operator to monitor and track
• rr= Right Rear Suspension Pressure the total tons hauled and the number of haul cycles
• in= Inclinometer during the shift. This display can be cleared at the
beginning of each shift to allow the operator to record
The display holds the displayed information until the how many loads and tons have been hauled during
SELECT switch is pressed again. The suspension the shift.
pressures, inclinometer, and payload displays are
Total Ton Counter
based on current sensor inputs.
Communications to the display use the same serial The Total Ton Counter records the number of tons
link as the download connection. Whenever another hauled since the last time it was cleared. This
computer is connected to serial port #1 to download display is in 100’s of tons. For example, if the display
or configure the system, the lower display will blank. shows 432 the total tons is 43,200. This display
This is not the same connection used by mine
can be cleared at the beginning of each shift to allow
dispatch systems.
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.
OM6008 02/03 Optional Equipment - Section 6
Payload Meter III Page 6-9

Total Load Counter The inclinometer displays whole degrees of incline.

The Total Load Counter records the number of loads Positive incline is truck nose up. The gauge will
hauled since the last time it was cleared. This quickly display the type of information shown every
display can be cleared at the beginning of each shift 10 seconds. For example, if the left-front pressure is
to allow the operator to record how many loads have
been hauled during the shift.
being displayed, Lf= will flash on the display

every minute. Only the payload display, pl=

• To view the Total Load Counter press and does not display this information.
release the “SELECT” switch until l(= is • Left Front Pressure - To display the pressure in
the left-front suspension, press and release the
displayed on the gauge.
“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
clears both records.
“SELECT” switch until rf= is displayed.
• 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 • Right Rear Pressure - To display the pressure in
the right-rear suspension, press and release the
l(= is displayed.
“SELECT” switch until rr= is displayed.
2. Hold the “SET” button until the display clears. • 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
Other Display Messages
during regularly scheduled service periods to check
the state of the suspensions. These displays are live On startup of the payload meter system, the gauge
and will update as the values change. display will scroll the truck type that the PLMIII is
configured for. For example, on a 930E, the gauge
The live displays cannot be cleared and the SET will scroll, ----930E---.
button will have no effect.
If the PLMIII encounters memory problems, it will
The units for the display are controlled by the
configuration of the payload meter. If the payload display ER88 where 88 is the specific memory
meter is set to display metric units, the pressures will error. In this very rare circumstance, the system
be displayed in tenths of kg/cm2. For example, if the should be turned off for 30 seconds and restarted.

display shows 202 the actual value is 20.2 kg/

cm2. If the payload meter is set to display short tons,
the pressures will be displayed in psi (lbs/in2). To
convert from kg/cm2 to psi, multiply by 14.2. 1 1kg/
cm2 = 14.2 psi. There is no way to detect the units
setting for the gauge without the PC software.
Optional Equipment - Section 6 OM6008 02/03
Page 6-10 Payload Meter III

Payload Operation & Calculation 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
Description of Haul Cycle States above 50% of rated load for 10 seconds without the
brake lock applied, the meter will switch to loading
The typical haul cycle can be broken down into eight
and record the continuous_loading flag in the haul
distinct stages or states. Each state requires the
cycle.
payload meter to make different calculations and
store different data.
The payload meter switches from loading to
maneuvering as soon as the truck begins moving.
"States" or stages of a typical haul cycle
The maneuvering zone is 160m and is designed to
1. Tare Zone allow the operator to reposition the truck under the
2. Empty shovel. More payload can be added anytime within
the maneuvering zone. Once the truck travels 160m
3. Loading (0.1 miles) the payload meter switches to the
4. Maneuvering final_zone and begins calculating payload. If the
body is raised while the payload meter is in the
5. Final Zone maneuvering state, the no_final_load flag will be
6. Hauling recorded in the haul cycle record, no payload will be
calculated, and the meter will switch to the dumping
7. Dumping
state.
8. After Dump
While in the final_zone moving faster than 5 km/h (3
mph), the payload meter calculates the loaded
Haul Cycle Description sprung weight of the truck. The same advanced
A new haul cycle is started after the load has been algorithm is used to calculate the empty and loaded
dumped from the previous cycle. The payload meter sprung weights. The payload meter will switch from
will stay in the after_dump state for 10 seconds to the final_zone to the dumping state if the Body-Up
confirm that the load has actually been dumped. If signal is received. If the truck has moved for less
the current payload is less than 20% of rated load, than 1 minute in the final_zone, the payload meter
the payload meter will switch to the tare_zone and will calculate the final payload using an averaging
begin calculating a new empty tare. If, after technique which may be less accurate. If this
dumping, the payload has not dropped below 20% of happens, the average_load flag will be recorded in
rated load the meter will return to the maneuvering or the haul cycle.
hauling states. In this case, the false_body_up flag
will be recorded in the haul cycle record. The payload meter switches to the dumping state
when the dump body rises. The payload meter will
While in the tare_zone state, and moving faster than switch from dumping to after_dump when the dump
5 km/h (3 mph), the payload meter calculates the body comes back down.
empty sprung weight of the truck. This tare value will
be subtracted from the loaded sprung weight to
calculate the final payload. The payload meter will From the after_dump, the payload meter will switch
switch from the tare_zone or empty to the loading to one of three states:
state if swingloads are detected. By raising the
dump body while in the empty state the payload
1. If the average payload is greater than 20% of
meter can be manually switched back to the
rated load and no final payload has been calcu-
tare_zone to calculate a new tare.
lated, the payload meter will return to the
maneuvering state. After the truck travels
From the empty state, the payload meter will switch
160m (0.1 mile) the meter will switch to the
to the loading state through one of two means. If the
final_zone and attempt to calculate the payload
brake lock is applied, the payload meter will be
again. The false_body_up flag will be recorded
analyzing the suspension pressures to detect a
in the haul cycle record.
swingload. If a swingload is detected, the meter will
switch to the loading state. The minimum size for
swingload detection is 10% of rated load. Swingload
detection usually takes 4-6 seconds. The second
OM6008 02/03 Optional Equipment - Section 6
Payload Meter III Page 6-11

2. If the average payload is greater than 20% of Sources for Payload Error
rated load and the final payload has been cal-
culated, the payload meter will switch back to
the hauling state. The false_body_up flag will Payload Error
be recorded in the haul cycle record.
The number one source of error in payload
3. If the average payload is less than 20% of rated calculation is improperly serviced suspensions. The
load, the payload meter will switch to the payload meter calculates payload by measuring
tare_zone and begin to calculate a new empty differences in the sprung weight of the truck when it
tare. is empty and when it is loaded. The sprung weight is
the weight of the truck supported by the suspensions.
The only method for determining sprung weight is by
Load Calculation measuring the pressure of the nitrogen gas in the
The final load calculation is different from the last suspensions. If the suspensions are not properly
swingload calculation. The accuracy of the swing maintained, the payload meter cannot determine an
load calculation depends on loading conditions and accurate value for payload. The two critical factors
the position of the truck during loading. The last are proper oil height and proper nitrogen charge.
swingload calculation is not the value recorded in
memory as the final load. The final load is If the suspensions are overcharged, the payload
determined by a series of calculations made while meter will not be able to determine the empty sprung
the truck is traveling to the dump site. 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
Carry Back push the suspension rod to full extension. In this
Carry back is calculated as the difference between case, the pressure inside the cylinder does not
the current truck tare and the clean truck tare. The accurately represent the force necessary to support
clean truck tare is calculated using the PC software. that portion of the truck.
When the suspensions are serviced or changes are
made that may affect the sprung weight of the truck,
a new clean truck tare should be calculated. If the suspensions are undercharged, the payload
meter will not be able to determine the loaded sprung
weight of the truck. The suspension cylinder must be
Measurement Accuracy able to travel up and down as the truck drives loaded.
Payload measurements are typically repeatable If the pressure in an undercharged suspension
within 1%. Accuracy for a particular scale test cannot support the load, the suspension will collapse
depends on specific combinations of pressure and make metal-to-metal contact. In this case, the
sensors and payload meters as well as the specifics pressure inside the cylinder does not accurately
of each scale test. Comparisons from different scale represent the force necessary to support that portion
tests are often made without considering the of the truck.
differences introduced by the specific installation and
operation of the scales for each test. In addition, Low oil height can also introduce errors by not
each pressure sensor and payload meter introduces correctly supporting a loaded truck. This is why the
it's own non-linearity. Each truck becomes an correct oil height and nitrogen charge are the most
individual combination of sensors and payload meter. critical factors in the measurement of payload. If the
Errors from these sources can introduce up to a ±7% suspensions are not properly maintained, accurate
bias in the payload meter calculations for a specific payload measurement is not possible. In addition,
scale test, for an individual truck. suspension maintenance is very important to the life
of the truck.
Because the PLMIII calculates a new empty tare for
each payload, a detailed scale test must weigh the
trucks empty and loaded for each haul cycle. Using
a simple average of 2 or 3 empty truck weights as an
empty tare for the entire scale test will introduce
significant error when comparing scale weights to
PLMIII weights.
Optional Equipment - Section 6 OM6008 02/03
Page 6-12 Payload Meter III

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
Small variations in sensors can also contribute to PLMIII can store 512 alarm records in memory.
payload calculation error. Every pressure sensor is When the memory is full, the payload meter will
slightly different. The accuracy differences of erase the oldest 312 alarm records and continue
individual sensors along the range from 0 to 4000 psi recording.
can add or subtract from payload measurements. All data is calculated and stored in metric units within
This is also true of the sensor input circuitry within the payload meter. The data is downloaded and
individual payload meters. These differences can stored in metric units within the Paradox database on
stack up 7% in extreme cases. These errors will be the PC. The analysis program converts units for
consistent and repeatable for specific combinations displays, graphs and reports.
of payload meters and sensors on a particular truck.
The units noted in the Table 1 are the actual units
stored in the data file. The value for the haul cycle
Swingloads
start time is the number of seconds since January 1,
Swingload calculations can be affected by conditions 1970 to the start of the haul cycle. All other event
at the loading site. Parking the truck against the times are referenced in seconds since the haul cycle
berm or large debris can cause the payload meter to start time. The PC download and analysis program
inaccurately calculate individual swingloads. While converts these numbers into dates and times for
the PLMIII system uses an advanced calculation graphs and reports.
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.
 OM6008 02/03 Optional Equipment - Section 6
Payload Meter III Page 6-13
Haul Cycle Data
The following information is recorded for each haul cycle:

Table 4: 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 the
numeric 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 transi-
tions 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
Optional Equipment - Section 6 OM6008 02/03
Page 6-14 Payload Meter III

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
to be generated. Each one indicates an unusual is 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 The Body-Up signal indicated that the truck was
sensing swingloads. This indicates that a continuous dumping, but the weight of the truck did not fall below
loading operation was used to load the truck. It may 20% of the rated load.
also indicate that the payload meter did not receive
the Brake Lock input while the truck was being
loaded. There may be a problem with the wiring or I: Body Up Signal Failed
the Brake Lock was not used. The payload meter will This message indicates that the load was dumped
not measure swingloads unless the Brake Lock is without a Body-Up signal being received by the
used during the loading process. payload meter. The weight of the truck fell below
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
senses a body up input during the loading process. J: Speed Sensor Failed
This message is usually accompanied by a This message indicates that the payload meter
no_final_load flag. sensed the truck loading and dumping without
receiving a speed signal.

C: No Final Load
This message is generated when the payload meter K: New Tare Not Calculated
is unable to determine the final payload in the truck. The payload meter was not able to accurately
Typically, this means that the payload meter switched calculate a new empty sprung weight for the truck to
from a loaded state to the dumping state before the use as the tare value for the haul cycle. The tare
load could be accurately measured. value from the last haul cycle was used to calculate
payload.

D: Maneuvering to Dumping Transition

This message is generated when the payload meter L: Incomplete Haul Cycle
senses a Body-Up input during the maneuvering or The payload meter did not have proper data to start
repositioning process indicating that the operator has the haul cycle with after powering up. When the
dumped the load. It may also be generated if the PLMIII powers off, it records the data from the haul
Body-Up signal is not properly reaching the payload cycle in progress into memory. This flag indicates
meter and the weight in the truck falls dramatically that this data was not recorded the last time the
while the truck is maneuvering or repositioning. payload meter was shut down. This can happen
when the main battery disconnect is used to shut the
truck down instead of the keyswitch. 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.
OM6008 02/03 Optional Equipment - Section 6
Payload Meter III Page 6-15

M: Haul Cycle Too Long Alarm Records

The haul_cycle_too_long flag indicates that the haul The payload meter stores alarm records to give
cycle took longer than 18.2 hours to complete. The service personnel a working history of the system.
times stored for particular events may not be All codes are viewed using the PC connected to the
accurate. This does not affect the payload payload meter. Active codes are also displayed on
calculation. the two-digit display on the meter itself. Each code
has a specific cause and should lead to an
investigation for correction. Some failures can be
N: Sensor Input Error overcome by the payload meter. Haul cycle data will
An alarm was set for one of the 5 critical sensor indicate if an alarm condition was present during the
inputs during the haul cycle. The five critical sensors cycle. Failures with the suspension or inclinometer
are the four pressure sensors and the inclinometer. sensors cannot be overcome.
Without these inputs, the payload meter cannot
calculate payload. A haul cycle with this warning flag
should not be considered accurate. 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.
Table 5: Fault Code Data
Fault
Name Description
Code
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
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.
24 System key-on status Payload Meter failed to correctly start at power up. Cycle power and recheck.
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

Frame Torque Data

Payload meter records the top 5 peak positive and For example, if the left front and right rear pressure
negative frame torque values and the time they rises as the right front and left rear pressure drops,
occurred. The frame torque is a measure of the the truck frame experiences a twisting motion along
twisting action along the centerline of the truck. the longitudinal centerline. In this case, the payload
Positive frame torque is measured when the meter will record a positive frame torque.
suspension forces on the front of the truck act to twist
the frame in the clockwise direction as viewed from The 5 highest values in the positive and negative
the operator's seat. Negative frame torque is direction are stored in permanent memory within the
measured when the forces from the suspensions act payload meter.
in the opposite direction.
Optional Equipment - Section 6 OM6008 02/03
Page 6-16 Payload Meter III

Sprung Weight Data System Configuration

The payload meter is constantly monitoring the live PLMIII needs to be configured for operation when it
payload calculation. This value naturally rises and is first installed on the truck. This process requires
falls for a loaded truck depending on road and driving several steps and uses the laptop computer to make
conditions. The payload meter records the top 5 the necessary settings. The setup procedure can be
highest payload calculations and the time they broken down into several steps:
occurred. This information is stored in permanent
memory inside the meter. • Connecting the laptop to the PLMIII system.
• Starting communications
• Setting the time & date
Maximum Speed Data • Setting the truck type
The payload meter records the top 5 highest speeds • Setting the truck ID
• Setting the speedometer/display gauge units
and the time they occurred. This information is
stored in permanent memory inside the meter.
Installing the PLMIII Software
The CD ROM containing the Payload Data
Management (PDM) Software will automatically
begin installation when it is inserted into the drive on
the PC. If this does not happen, the software can be
PC Software Overview installed by running the Setup.exe program on the
CD ROM.
PC Overview
The PC software has several basic functions: The minimum PC requirements for running the
• Configure the PLMIII system on the truck. software is a Pentium 133Mhz with 64 MB of ram and
• Troubleshoot and check the PLMIII system.
at least 300 MB of free hard drive space available.
• Download data from the PLMIII system.
• Analyze data from the payload systems. For improved performance, the recommended PC
would be a Celeron, AMD K6-2 or better processor
Configuration, troubleshooting and downloading with 128 MB of ram running at 400 Mhz. The PDM
require a serial connection to the payload meter on Software uses a powerful database to manipulate the
the truck. Analysis can be done at any time without a large amounts of data gathered from the PLMIII
connection to the payload meter. system. Using a more powerful computer and added
memory to run the software can result in a significant
Payload data is downloaded from several trucks into improvement in performance. The software is written
one database on the PC. The database can be to use a minimum 800x600 screen resolution.
queried to look at the entire fleet, one truck or truck
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.
OM6008 02/03 Optional Equipment - Section 6
Payload Meter III Page 6-17

Downloading Data
To download the payload meter:
PLMIII records many types of data. The PLMIII PC
software is designed to download the data from a
whole truck fleet. Instead of creating one data file for 1. Connect to the payload meter and start the PC
each truck, the PC software combines all the data software.
from many trucks into one database on the hard 2. From the main menu, select "Connect to Pay-
drive of the computer. The software then allows load Meter". The PC will request the latest sta-
users to query the database to create custom reports tus information from the payload meter. The
and graphs. Data for individual trucks or groups of number of haul cycles and alarms will be dis-
trucks can be easily analyzed. This same data can played.
be exported for use in other software applications like
word processors and spreadsheet applications. 3. Select the " Begin Download" button. The PC
will request the payload and alarm data from
As the database grows, performance of the PC the payload meter and save it into the data-
software for analysis will slow down. It may be base. This may take several minutes. A
helpful to periodically export data. For example, progress bar at the bottom will show the
query the database to show the oldest quarter, approximate time left.
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
Optional Equipment - Section 6 OM6008 02/03
Page 6-18 Payload Meter III

PLMIII System Configuration Short Tons: Payload is displayed in short tons,

distances and speeds will be displayed in
Starting Communications
Miles
The PDM software allows users to download and
configure the system.
Metric Tons: Payload is displayed in metric
tons, distances and speeds are displayed in
Kilometers
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
From the main menu, click the "Connect to Payload truck by the mine.
Meter" button. The PC will try to connect to the • The Payload Meter Date / Time values come
payload meter and request basic information from from the payload meter at the moment of
the system. In the event of communications trouble, connection.
the PC will try 3 times to connect before "timing-out". • Number of Haul Cycle Records is the number of
This may take several seconds. haul cycles records stored in memory and
available for download.
• Number of Active Alarms shows how many
Displayed Payload Units alarms are currently active in the system at the
time of connection. If there are active alarms,
the "Display Active Alarms" button is available.
• Number of Inactive Alarms shows how many
alarms have been recorded in memory and are
available for download.
Three options are available for the display of units in • PLM Software Version displays the current
the PC software, reports, and graphs: version of software in the payload meter.
The information on the connection menu comes from
the configuration of the payload meter system on the
truck.
OM6008 02/03 Optional Equipment - Section 6
Payload Meter III Page 6-19

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
is maintained by a very large capacitor when the
• Connect the laptop to the system using the power is removed from the payload meter. This will
EF9160 communications harness. The download maintain the date and time settings for approximately
connector is typically located on the housing 30 days. After this time, it is possible for the payload
mounted in the cab to the back wall. The PLMIII meter to lose the date and time setting. It is
system uses the same connection as the recommended that the system be powered every 20
Payload Meter 2 system. days to maintain the date and time. If the date and
time is lost, simply reset the information using this
Configure the Payload Meter procedure. It takes approximately 90 minutes to
Configuration of the payload meter requires a serial recharge the capacitor.
connection to the PLMIII system. Clicking the
"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
1. Click on the digit that needs to be changed.
"Save Changes" button must be pressed to save the
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.
Optional Equipment - Section 6 OM6008 02/03
Page 6-20 Payload Meter III

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
truck number in the appropriate field.
Setting the Gauge Display Units
The Payload Meter Speedometer / Display Gauge 2. Press the "Save Changes" button to program
displays the speed on the upper display. The units the change into the payload meter.
for 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 This field in the haul cycle record can hold the name
changed from metric to short tons or long tons using of the Komatsu distributor that helped install the
the Truck Configuration screen. This selection also system. Komatsu also assigns a distributor number
to each distributor. This number is used on all
switches between metric (kg/cm2) and psi (lbs/in2) warranty claims. This Komatsu distributor number
for the live display of pressure on the gauge. can also be put into this field. The field will hold 20
alpha-numeric characters.
1. From the Truck Configuration screen, select the
payload units to be used on the lower display of 1. On the Truck Configuration screen, enter the
the speedometer/display gauge. distributor name or number in the appropriate
2. Press the "Save Changes" button to program field.
the change into the payload meter. 2. Press the "Save Changes" button to program
the change into the payload meter.
Setting the Frame Serial Number
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
customer. This number is used on all warranty
claims. This Komatsu customer number can also be
The frame serial number is located on the plate put into this field. The field will hold 20 alpha-
mounted to the truck frame. The plate is outboard on numeric characters.
the lower right rail facing the right front tire. It is very
important to enter the correct frame serial number.
This number is one of the key fields used within the 1. On the Truck Configuration screen, enter the
haul cycle database. The field will hold 20 alpha- customer name or number in the appropriate
numeric characters. field.
2. Press the "Save Changes" button to program
1. On the Truck Configuration screen, enter the the change into the payload meter.
truck frame serial number in the appropriate
field.
2. Press the "Save Changes" button to program
the change into the payload meter.
OM6008 02/03 Optional Equipment - Section 6
Payload Meter III Page 6-21

Clean Truck Tare Inclinometer Calibration

The payload meter uses the clean truck tare value to

calculate carry-back load for each haul cycle. The The inclinometer calibration procedure is designed to
carry-back stored in the haul cycle record is the new compensate for variations in the mounting attitude of
empty tare minus the clean truck tare. the inclinometer. The inclinometer input is critical to
the payload calculation.
This procedure should be performed after service to
the suspensions or when significant changes are This procedure should be performed on relatively flat
made to the sprung weight of the truck. Before ground. Often the maintenance area is an ideal
performing this procedure, be sure the suspensions location for this procedure.
are properly filled with oil and charged. It is critical to 1. After cleaning debris from the truck and check-
payload measurement that the proper oil height and ing to see that the suspensions are properly
gas pressure be used. serviced, use the PLMIII software to connect to
the payload meter.
Once the clean tare process is started, the payload
2. From the "Truck Configuration" screen, select
meter will begin to calculate the clean empty sprung
"Inclinometer".
weight of the truck. This calculation continues while
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 pay-
to monitor the process with the PC. The truck does load 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 check- and park in the exact same spot as before, fac-
ing to see that the suspensions are properly ing the other direction.
serviced, use the PLMIII software to connect to 5. With the truck stopped and the brake lock on,
the payload meter. press the “Start” button. This instructs the pay-
2. From the "Truck Configuration" screen, select load meter to sample the inclinometer again.
"Clean Truck Tare". The payload meter will average the two sam-
ples to determine the average offset.
3. Be sure to follow the screen instructions.
6. Be sure to follow the screen instructions.
Optional Equipment - Section 6 OM6008 02/03
Page 6-22 Payload Meter III

Data Analysis Sorting on Truck Unit Number

The data analysis tools allow the user to monitor the The truck unit number is the truck unit number
performance of the payload systems across the fleet. entered into the payload meter when it was
Analysis begins when the "View Payload Data" configured at installation. The query can be set to
button is pressed. This starts an "all trucks, all dates, look for all trucks or one particular truck number.
all times" query of the database and displays the When the program begins, it searches through the
results in the Payload Summary Form. database for all the unique truck numbers and
creates a list to select from.
The user can change the query by changing the
dates, times, or trucks to include in the query for Choosing one particular truck number will limit the
display. data in the displays, summaries and reports to the
one selected truck. To create reports for truck
Haul cycles in the data grid box at the bottom can be number 374, select 374 from the pull-down menu
double-clicked to display the detailed results of that and hit the "Query Database and Display" button.
haul.

Payload Summary Form

Creating a Query Sorting on Truck Type

The program defaults to show all trucks, all types, all The truck type is the size of the truck from the family
dates and all times for the initial query. The display of Komatsu trucks. This allows the user to quickly
can be narrowed by selecting which trucks or types view results from different types of trucks on the
to view and for what dates and times. property. For example, a separate report can be
generated for 830E and 930E trucks.
The query items are added in the "AND" condition. If
the user selects a truck # and date range, the query
will sort the data for that truck number AND the date
range.
OM6008 02/03 Optional Equipment - Section 6
Payload Meter III Page 6-23

Sorting on Date Range 2. Change the “From” date to July 1, 2000.

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 July 31, 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 12:00
the results.

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 24:00
that occurred between those times for each day of
Query : Date: 1/5/00 to 1/8/00
the date range. Times are entered in 24:00 format. Daily Shift Time: 6:00 to 18:00
Haul Cycles Included in the Query

To view the haul cycle reports from the first shift for
truck 374 from January 5, 2000 to January 8, 2000: The shift times selected can extend the query past
the original date. If the dates set for the query are
January 5 to January 8 and the times were changed
1. Select truck 374 from the Truck Unit pull-down to query the 6:00 PM (18:00) to 6:00 AM (06:00) shift,
menu. the results would extend into the morning of the 9th.
This can been seen in the following example:
Optional Equipment - Section 6 OM6008 02/03
Page 6-24 Payload Meter III

Date Creating Reports

Time

0:00
Jan 5, 2000 Jan 6, 2000 Jan 7, 2000 Jan 8, 2000 Jan 9, 2000
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
6:00
report printed would only contain data from truck 374
during the month of July 2000, from 8:00 AM to 5:00
PM.
12:00
It is important to carefully select the query data and
press the "Query Database & Display" button before
printing a report.
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

Payload Detail Screen

The Payload Detail screen gives the details for any
individual haul cycle. From the “Payload Summary”
screen, double-click on any haul cycle to display the
detail.
OM6008 02/03 Optional Equipment - Section 6
Payload Meter III Page 6-25

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.
Optional Equipment - Section 6 OM6008 02/03
Page 6-26 Payload Meter III

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
with other software applications. The data is
1. From the Payload Summary Screen select the
selected from the currently displayed query. The
“Graph” button at the bottom. The Histogram
exported data can be put into a ".CSV" file or a
Setup screen will display
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 low-

est 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 high-
est value on the graph. Payloads over this
value will be summed in the last bar.
CSV stands for Comma Separated Value. This is an
4. Enter the "Incremental Change". This will deter- ASCII text file format that allows spreadsheet
mine the number of bars and the distance applications like Excel and Lotus 123 to import data
between them. The program limits the number easily. To export the data into a ".csv" file, press the
of bars to 20. This allows graphs to fit on the "Export" button at the bottom of the payload sumary
screen and print onto 1 page. screen and select "To CSV". The program will
5. Press the “Create Graph” button. request a filename and location for the file.

The graph will be displayed based on the query

settings from the Payload Summary screen. The
graph can be customized and printed.
OM6008 02/03 Optional Equipment - Section 6
Payload Meter III Page 6-27

. • 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
• Haul cycle start date The second series of data below the haul cycle data
• Haul cycle start time is the alarms. The alarm columns, left to right are:
• Payload
• Swingloads • The alarm type
• Operator ID • The date the alarm was set
• Warning Flags • The time the alarm was set
• Carry Back • Alarm description
• Total Haul Cycle time • The date the alarm was cleared
• Empty Running Time • The time the alarm was cleared
• Empty stop time
• Loading time
• Loaded running time Compressed
• 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
occurred useful when a service laptop is used to download
• 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
• Average Rear Tire-kilometer-hour The file format is a compressed binary form of the
• Frame serial number displayed query. The file can only be imported by
another computer running the PDM Software.
Optional Equipment - Section 6 OM6008 02/03
Page 6-28 Payload Meter III

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
“Payload Summary” screen. The program will
2. From the payload summary screen, press the display a summary of the records from the displayed
"EXPORT" button and select "To ZIP". query. To delete a record, select one at a time and
3. The program will ask for a filename and loca- press the "Delete" button. It is recommended that
tion. records 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"
Importing Data button will select all the records from the current
This import function allows the data from one laptop query and delete them.
to be transferred to another computer. This can be
useful when a service laptop is used to download NOTE: There is no recovery for records that have
multiple machines and transfer the data to a central been deleted from the main database. It is highly
computer for analysis. This can also be used to copy recommended that all records be exported and
haul data from a particular truck from a diskette into a archived in a compressed file format for future
database for analysis. 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.
OM6008 02/03 Optional Equipment - Section 6
Payload Meter III Page 6-29

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
Payload Summary screen. Alarms can be displayed summary of the alarms from the query. To delete an
as Active or Inactive. alarm, 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.
OM6008 02/03 Optional Equipment - Section 6
Payload Meter III Page 6-30

NOTES:

PORTIONS OF THIS PRODUCT RELATING TO PAYLOAD MEASURING SYSTEMS ARE

MANUFACTURED UNDER LICENSE F ROM

L.G. HAGENBUCH holder of

U.S. Patent Numbers 4,831,539 and 4,839,835
OM7001 Optional Equipment - Section 7
Cab Radio Page 7-1

RADIO, AM / FM STEREO CASSETTE

FIGURE 7-1. CAB RADIO

SETTING THE TIME GENERAL RECEIVER FUNCTIONS

1. Turn the key switch "ON". The receiver is equipped with two FM radio bands,
FM1 and FM2. The two bands are identical, however,
2. Press and hold DSPL/TM SET (9) for 2 sec-
each one allows the operator to set 6 preset
onds. When the number display flashes, time
channels for a total of 12 FM presets overall.
set mode is active.
3. Press TUNE / SEEK (7 & 8) to change the hour TURNING THE POWER "ON" AND "OFF"
setting.
1. Turn the key switch to "ON".
4. Press the DSPL/TM button to switch to minutes.
2. Press PWR (1) to turn the receiver "ON" and
The minute digits will flash when in this mode.
"OFF". Pushing ON/AUDIO (6) may also be
5. Press TUNE / SEEK to change the minute set- used to turn the receiver power "ON".
ting.
After 5 seconds of inactivity has elapsed, the display DISPLAY
will return to the default mode. The clock will now
display the correct time of day. With the receiver "OFF", the clock will be displayed.
Momentarily pressing DSP/TM SET (9) with the
receiver "ON" will allow the operator to toggle
between displays.

• When the receiver is in AM, FM1, FM2, or WX,

the display will toggle between the frequency and
the clock.
Optional Equipment - Section 7 OM7001
Page 7-2 Cab Radio

• When the receiver is in the cassette mode, the Manual Tuning: Press TUNE (8) to tune to the next
display will toggle between TP SIDE 1 or TP higher frequency. Press SEEK (7) to tune to the next
SIDE 2, and the clock. lower frequency. Holding either of the buttons for
more than 0.5 seconds will activate fast tuning for
increased speed.
SETTING THE DEFAULT DISPLAY
1. Press and hold DSPL/TM (9) for 2 seconds until Seek Mode: In seek mode, the receiver will only stop
the hour digits flash. on stations that have a strong signal. To scroll
through these stations, press TUNE (8) for at least
2. Press push-button 6/FF (15) to change the
0.5 seconds to activate seek mode. The receiver will
default display.
move to the next highest frequency and pause for 3
After 5 seconds of inactivity has elapsed, the
seconds. After 3 seconds, the receiver will move to
selected default will display.
the next higher frequency. This pattern will continue
until the TUNE button is pressed again. Press SEEK
ADJUSTING DISPLAY BRIGHTNESS (7) for at least 0.5 seconds to activate seek mode for
the next lower frequency station. The receiver will
1. Press and hold DIM (14) until "DIM" appears on momentarily stop on strong stations until the SEEK
the display. button is pressed again.
2. Rotate ON/AUDIO knob (6) clockwise or coun-
terclockwise until the desired brightness is NOTE: If the receiver can not find a strong
obtained. enough signal after two band cycles, the seek
mode will discontinue and the receiver will return
to the initial station.

OPERATING THE RADIO SCAN (10): Press the SCAN button to scan all
stations on the current band. When a strong
BAND (2): Press Band (2) to switch between FM1, frequency is found, the receiver will pause on that
FM2, AM, and WX Weather (US). station for about 5 seconds and then continue
scanning. Scan will appear on the display along with
TUNE / SEEK (7 & 8): Allows you to move up or the frequency when this mode is active. To stop
down in frequency to other stations. There are two scanning, press the SCAN button again.
modes of operation for finding other stations, manual
tuning and seek mode. Press and hold both TUNE AUTO (12): AUTO allows the receiver to store the 6
(8) and BAND (2) for 2 seconds to toggle between strongest stations onto push-buttons 1 through 6.
the two modes. The display will read either Press AUTO until "AUTO" and "AS" appear on the
"MANUAL" or "SEEK" to indicate the mode the display. The presets on the current band only will
receiver is in. now be programmed with the 6 strongest
frequencies. Presets on the other bands will not be
changed. Pressing AUTO again will delete the
stations and default to the original preset stations.
OM7001 Optional Equipment - Section 7
Cab Radio Page 7-3

PROGRAMMING PRESET STATIONS

Presets are stations that are stored on each of the 6 The frequency associated with each channel is as
push-buttons. After a station has been programmed follows:
into one of the preset buttons, pushing the preset
provides a quick return to that station. The six 1. 162.550 MHz 5. 162.450 MHz
buttons can each store a preset channel per band. 2. 162.400 MHz 6. 162.500 MHz
Perform the following steps for programming presets: 3. 162.475 MHz 7. 162.525 MHz
4. 162.425 MHz
1. Turn the receiver "ON".
2. Select the band and the desired station. The National Weather Service operates
3. Press and hold one of the six push-buttons for approximately 372 stations. Close to 90 percent of
at least 2 seconds. During the 2 second period, the nation's population is within the listening range of
receiver output will be muted and the push-but- a NOAA Weather Radio broadcast.
ton number will show on the display. When the
station has been committed to memory, the
ADJUSTING THE RECEIVER SETTINGS
audio and the preset icon will return.
4. Repeat steps 1 through 3 for the remaining VOLUME: Rotate ON/AUDIO (6) knob clockwise to
available presets. increase the volume and counter-clockwise to
decrease the volume. "VOL" will be displayed along
NOTE: Six presets may be stored on AM, FM1, with the volume level.
and FM2 for a total of 18 presets. BASS: Push and release ON/AUDIO (6) knob until
"BASS" and the current bass level is displayed.
Rotate the knob clockwise to increase the bass and
counter-clockwise to decrease the bass.
TREBLE: Push and release ON/AUDIO (6) knob
OPERATION OF THE WEATHERBAND (U.S.)
until "TREB" and the current treble level is displayed.
Rotate the knob clockwise to increase the treble and
NOAA - Weather Radio is a service of the "Voice of counter-clockwise to decrease the treble.
the National Weather Service". It provides FADE: Push and release ON/AUDIO (6) knob until
continuous broadcasts of the latest weather "FADE" and the current level is displayed. Rotate the
information directly from the National Weather knob clockwise to move the sound to the front
Service offices. Taped weather messages are speakers and counter-clockwise to move the sound
repeated every four to six minutes and are routinely to the rear speakers.
revised every one to three hours, or more frequently BALANCE: Push and release ON/AUDIO (6) knob
if needed. Most of the stations operate 24 hours, until "BAL" and the present level is displayed. Rotate
daily. the knob clockwise to move the sound to the front
The weather for the area you are in may be found on speakers and counter-clockwise to move the sound
one of 7 stations. When in the Weatherband mode, to the rear speakers.
the display will show the "WX" icon and "CHAN #" to SPEAKER: Push and release ON/AUDIO (6) knob
indicate the channel. The channel may be adjusted until "SPKR" and the current setting is displayed.
through the TUNE /SEEK buttons, and may be Rotate the ON/AUDIO knob to select 2-speaker or 4-
preset as in the radio mode. speaker operation. When 2-speaker operation active,
the rear speakers are muted and the FADE option
will not appear on the menu.
Optional Equipment - Section 7 OM7001
Page 7-4 Cab Radio

PROGRAMMABLE EJECT DEFAULT PLAYING A CASSETTE

The cassette player has been pre-programmed to

1. Turn the receiver "ON".
return to the radio after a tape has been ejected. This
default may be changed to an “eject audio mute” 2. Insert a cassette into the player. The cassette
mode. This mode will mute the radio after a cassette icon will appear on the display. The tape will
has been ejected. When this occurs, “NO TAPE” will begin to play when the icon appears.
appear on the display and the radio will remain
muted until BAND (2) is pressed. Pressing this button NOTE: Press button (3) to change from the
will enable the radio. radio to a cassette. "TP SIDE 1" or "TP SIDE 2"
Perform the following steps to change the eject will appear on the display depending on which
default mode: side of the cassette is currently being played. If a
6. Press and hold DSP/TM SET (9) for at least 2 cassette is not loaded in the player, "NO TAPE"
seconds until the hour digits flash. will appear on the display.

7. Press button (3) to toggle between

“P.PLAY” and “EJMUTE”. After 5 seconds of
inactivity, the receiver will return to the default CASSETTE FUNCTIONS
display.
4/REV (17): This button rewinds the cassette. The
cassette will continue to rewind until the button is
CASSETTE PLAYER pressed again, or until the cassette reaches the end
of the tape. "<REW" will appear on the display as the
The cassette player that the radio is equipped with cassette is rewinding.
works best with cassettes that range from 30 to 90 6/FF (15): This button fast forwards the cassette. The
minutes long. Cassettes that are longer than 90 cassette will continue to fast forward until the button
minutes have thinner tape, and do not work well in is pressed again, or until the cassette reaches the
this model cassette player. end of the tape. "FWD>" will appear on the display as
It is also important to only use cassettes that are in the cassette is fast forwarding.
good condition. Cassettes that are dirty, damaged, or
have been exposed to excessive heat and/or sunlight Eject (5): Press this button to eject the cassette
could cause damage to the cassette player and from the player. When the eject button is held, it acts
possible failure. as a stop button.
The cassette player is equipped with automatic (4): This button causes the cassette player to
equalization and metal tape sensing functions. An reverse directions and play the opposite side of the
"M" will appear on the display when a metal tape is cassette. Pressing the button a second time will
sensed. reverse the cassette back to the original side.
Cleaning the cassette player is a recommended
maintenance item. It should be performed at 35 hour NOTE: The cassette will automatically flip to the
(cassette play) intervals. Failure to clean the cassette opposite side when the end of the tape is
player may diminish sound quality and cause reached.
cassette player failure.
OM7001 Optional Equipment - Section 7
Cab Radio Page 7-5

BAD TAPE DETECT CASSETTE PLAYER CLEANING

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 5 seconds. This indicates that it is
ejected. If this occurs, the cassette should be time to clean the cassette player.
removed from the player and should not be re- 1. Turn the key switch to "ON", and turn the
inserted. receiver "OFF".

If it is desired to use a cleaning tape or a CD adapter 2. Disable "BAD TAPE DETECT" mode.
in the cassette player, the bad tape detector must be 3. Turn the receiver "ON".
turned “OFF”. Perform the following steps in order to
4. Insert a wet-type, non-abrasive, scrubbing cas-
disable this mode:
sette cleaner. Follow the instructions provided
1. Turn the receiver “OFF” and turn the key switch with the cleaner.
to “OFF”.
5. Reset the clean tape timer. With the receiver
2. Press and hold button (3) for 5 seconds. "ON", press and hold the eject button for 5 sec-
“BAD TAPE DETECT OFF” will appear on the onds. "TP CLEAN" will appear on the display
display. When this is displayed, the detector and the tape icon will flash after 3 seconds has
has been disabled. elapsed. After 5 seconds “CLN RST” will
Repeat this procedure to reactivate the bad tape appear on the display. When this occurs, the
detector. “BAD TAPE DETECT ON” will appear on clean tape timer will be reset to zero hours. If
the display after the detector has been activated. the button was released before “CLN RST” was
displayed, the timer will not be reset.
Optional Equipment - Section 7 OM7001
Page 7-6 Cab Radio

NOTES
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Komatsu America Corp.
2300 N. E. Adams Street Peoria, IL 61639 Phone: 309-672-7577 Fax: 309-672-7072 Printed in U.S.A. 02/2003