830ac mp y opr

CEAM016300

Operation & MaintenanceManual

DUMP TRUCK

SERIAL NUMBERS A30001 & UP

®

CALIFORNIAProposition 65 Warning

Diesel engine exhaust, some of its constituents, and certain vehiclecomponents contain or emit chemicals known to the State of Californiato cause cancer, birth defects or other reproductive harm.

CALIFORNIAProposition 65 Warning

Battery posts, terminals and related accessories contain lead and leadcompounds, chemicals known to the State of California to cause cancerand birth defects or other reproductive harm. Wash hands after handling.

Unsafe use of this machine may cause serious injury or death. Operators and maintenance per-sonnel must read and understand this manual before operating or maintaining this machine.

This manual should be kept in or near the machine for reference, and periodically reviewed by allpersonnel who will come into contact with it.

This material is proprietary to Komatsu America Corp (KAC), and is not to be reproduced, used, or dis-closed except in accordance with written authorization from KAC.

It is the policy of the Company to improve products whenever it is possible and practical to do so. TheCompany reserves the right to make changes or add improvements at any time without incurring any obli-gation to install such changes on products sold previously.

Because of continuous research and development, periodic revisions may be made to this publication.Customers should contact their local Komatsu distributor for information on the latest revision.

NON-OEM PARTS IN CRITICAL SYSTEMS

For safety reasons, Komatsu America Corp. strongly recommends against the useof non-OEM replacement parts in critical systems of all Komatsu equipment. Criticalsystems include but are not limited to steering, braking and operator safety sys-tems.

Replacement parts manufactured and supplied by unauthorized sources may not bedesigned, manufactured or assembled to Komatsu's design specifications; accord-ingly, use of such parts may compromise the safe operation of Komatsu productsand place the operator and others in danger should the part fail.

Komatsu is also aware of repair companies that will rework or modify an OEM partfor reuse in critical systems. Komatsu does not generally authorize such repairs ormodifications for the same reasons as noted above.

Use of non-OEM parts places full responsibility for the safe performance of theKomatsu product on the supplier and user. Komatsu will not in any case acceptresponsibility for the failure or performance of non-OEM parts in its products,including any damages or personal injury resulting from such use.

CEHQ000700 - Komatsu America International Company 12/99

EMISSION CONTROL WARRANTY

EMISSION CONTROL WARRANTY STATEMENT (APPLIES TO CANADA ONLY)

1. Products Warranted

Komatsu America International Company, Komatsu Mining Systems Inc. and Komatsu Utility Corporation (collectively “Komatsu”) produce and/or market products under brand names of Komatsu, Dresser, Dressta, Haulpak and Galion. This emissions warranty applies to new engines bearing the Komatsu name installed in these products and used in Canada in machines designed for industrial off-highway use. This warranty applies only to these engines produced on or after January 1, 2000. This warranty will be administered by Komatsu distribution in Canada.

2. Coverage

Komatsu warrants to the ultimate purchaser and each subsequent purchaser that the engine is designed, built and equipped so as to conform, at the time of sale by Komatsu, with all U.S. Federal emission regulations applicable at the time of manufacture and that it is free from defects in workmanship or material which would cause it not to meet these regulations within five years or 3,000 hours of operation, whichever occurs first, as measured from the date of delivery of the engine to the ultimate purchaser.

3. Limitations

Failures, other than those resulting from defects in materials or workmanship, are not covered by this warranty. Komatsu is not responsible for failures or damage resulting from what Komatsu determines to be abuse or neglect, including, but not limited to: operation without adequate coolant or lubricants; over fueling; over speeding; lack of maintenance of lubricating, cooling or intake systems; improper storage, starting, warm-up, run-in or shutdown practices; unauthorized modifications of the engine. Komatsu is also not responsible for failures caused by incorrect fuel or by water, dirt or other contaminants in the fuel. Komatsu is not responsible for non-engine repairs, “downtime” expense, related damage, fines, all business costs or other losses resulting from a warrantable failure. KOMATSU IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

This warranty, together with the express commercial warranties, are the sole warranties of Komatsu. THERE ARE NO OTHER WARRANTIES, EXPRESS OR IMPLIED, OR OF MERCHANTABILITY OR FITNESS FOR A PARTICUALR PURPOSE.

GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS ÉNONCÉ DE GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS (APPLICABLE AU CANADA SEULEMENT): 1. Produits garantis:

Komatsu America International Company, Komatsu Mining Systems Inc. et Komatsu Utility Corporation (collectivement Komatsu) produisent et/ou font la mise en marché de produits portant les noms de marque Komatsu, Dresser, Dressta, Haulpak et Galion. Cette garantie sur les émissions s’applique à tous les nouveaux moteurs portant le nom Komatsu, installés dans ces produits et utilisés au Canada dans des machines conçues pour utilisation industrielle non-routière. Cette garantie s’applique seulement sur les moteurs produits à partir du 1er Janvier 2000. Cette garantie sera administrée par la distribution de Komatsu au Canada.

2. Couverture:

Komatsu garantit à l’acheteur ultime et chaque acheteur subséquent que le moteur est conçu, construit et équipé en toute conformité, au moment de la vente par Komatsu, avec toutes les Réglementations fédérales américaines sur les émissions applicables au moment de la fabrication et qu’il est exempt de défauts de construction ou de matériaux qui auraient pour effet de contrevenir à ces réglementations en dedans de 5 ans ou 3000 heures d’opération, mesuré à partir de la date de livraison du moteur au client ultime.

3. Limitations:

Les bris, autres que ceux résultant de défauts de matériaux ou de construction, ne sont pas couverts par cette Garantie. Komatsu n’est pas responsable pour bris ou dommages résultant de ce que Komatsu détermine comme étant de l’abus ou négligence, incluant mais ne se limitant pas à: l’opération sans lubrifiants ou agent refroidissants adéquats; la suralimentation d’essence; la survitesse; le manque d’entretien des systèmes de lubrification, de refroidissement ou d’entrée; de pratiques non-propices d’entreposage, de mise en marche, de réchauffement, de conditionnement ou d’arrêt; les modifications non-autorisées du moteur. De plus, Komatsu n’est pas responsable de bris causés par de l’essence inadéquate ou de l’eau, des saletés ou autres contaminants dans l’essence. Komatsu n’est pas responsable des réparations non-reliées au moteur, des dépenses encourues suite aux temps d’arrêts, des dommages relatifs, amendes, et de tout autre coût d’affaires ou autres pertes résultant d’un bris couvert par la garantie.

KOMATSU N’EST PAS RESPONSABLE DES INCIDENTS OU DOMMAGES CONSÉQUENTS. Cette garantie, ainsi que les garanties expresses commerciales, sont les seules garanties de Komatsu. IL N’Y A AUCUNE AUTRE GARANTIE, EXPRESSE OU SOUS -ENTENDUE, MARCHANDABLE OU PROPICE A UNE UTILISATION PARTICULIÈRE.

AVERTISSEMENTS PEUVENT RÉSULTER ET LA GARANTIE RPM DU TAUX D’ESSENCE OU L’ALTITUDE ALEURS MAXIMALES PUBLIÉES POUR CE DÈLE ET SON APPLICATION.

NO. SÉRIE

DÉPLACEMENT

LITRES

SÉQUENCE DE MISE À FEU

mm3/BATTEMENT

TAUX D’ESSENCE À ADV.

LIMITE D’ÉMISSION DELA FAMILLE

DATEDE FABRICATION

INFORMATION IMPORTANTE SUR LE MOTEURCE MOTEUR EST CONFORME AUX NORMES AMÉRICAINES DE L’EPA (ANNÉE DU

MODÈLE) ET DE LA CALIFORNIE POUR LES MOTEURS LARGES NON-ROUTIERS A IGNI-TION PAR COMPRESSION. CE MOTEUR EST CERTIFIÉ POUR OPERATION À ESSENCE

DIÉSEL.

DES BLESSURES’ANNULER SI LESEXCÈDENT LES V

MO

IMPORTANT ENGINE INFORMATION THIS ENGINE CONFORMS TO YYYY MODEL YEAR U.S. EPA REGULATION AND THE CALIFORNIAREGULATIONS LARGE NON ROAD COMPRESSION IGNITION ENGINES. THIS ENGINE IS CERTI-

FIED TO OPERATE ON DIESEL FUEL.

MODÈLE DU MOTEUR WARNINGINJURY MAY RESULT AND WARRANTY IS VOIDED IF FUEL RATE RPM OR ALTITUDES EXCEED

PUBLISHED MAXIMUM VALUES FOR THIS MODEL AND APPLICATION.FAMILLE DU MOTEUR ENGINE MODEL SERIAL NO.

SYSTÈME DE CONTROLE DES ÉMISSIONS D’ÉCHAPPEMENT

ENGINE FAMILY DISPLACEMENT LITERS

EXHAUST EMISSIONCONTROL SYSTEM

FIRING ORDER 1 - 5 - 3 - 6 - 2 - 4

CHARGE DE SORTIE ADV.ADV. LOAD OUTPUT

Kw ( HP) RPM

PORTÉE DE VALVE À FROID (mm)

VALVE LASHCOLD (mm)

IN. EX. FUEL RATE AT ADV.

mm3/STROKE

VITESSE STATIQUE IDLE SPEED RPM FAMILY EMISSION LIMIT

INITIAL INJECTION TIMING

DEG. BTDC DATE OF MANUFACTURE

RÉGLAGE DE L’ALLUMAGE - INJECTION INITIALE

_____________________________________________ KOMATSU LTD.MADE IN JAPAN

DEG. BTDC

KOMATSU LTÉEFABRIQUÉ AU JAPON

ENGINE DATAPLATE - ENGLISH / FRENCH

OM1053 Introduction - Section 10Page 10-1

FOREWORD

This manual is written for use by the operator and/or the service technician and is designed to help these personsto become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently.

All operators and maintenance personnel must read and understand the materials in this manual before operatingthe truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings and cau-tions are to be understood and followed when operating or accomplishing repairs on the truck.

The first section is an introduction to the manual and contains a table of contents to locate specific areas of inter-est. Other sections include Safety, Operation, Maintenance, Specifications, and Optional Equipment.

The illustrations used in this manual are TYPICAL of the component shown and may not be an exact reproductionof 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 truckmodel number, product identification number (vehicle serial number), and maximum GVW (Gross Vehicle Weight)rating.

The KOMATSU truck model designation consists of three numbers and one letter (i.e. 830E). The three numbers represent the basic truck model. The letter “M”, when present, designates a Mechanical drive system; The letter “E”, when present, designates an Electrical wheel motor drive system.

The product identification number (vehicle serial number) contains information which will identify the original manu-facturing bill of material for this unit. This complete number will be necessary for proper ordering of many serviceparts and/or warranty consideration.

The GVW is what determines the load on the drive train, frame, tires, and other components. The vehicle designand application guidelines are sensitive to the total maximum GVW. GVW is TOTAL WEIGHT: the EmptyVehicle Weight + the fuel & lubricants + the payload.

To determine allowable payload: Service all lubricants for proper level and fill fuel tank of empty truck (whichincludes all accessories, body liners, tailgates, etc.) and then weigh truck. Record this value and subtract from theGVW rating. The result is the allowable payload.

NOTE: Accumulations of mud, frozen material, etc. become a part of the GVW and reduces allowable payload. Tomaximize payload and to keep from exceeding the GVW rating, these accumulations should be removed as oftenas practical.

Exceeding the allowable payload will reduce expected life of truck components.

Introduction - Section 10 OM1053Page 10-2

ALERTS PAGE

This “ALERT” symbol is used with the signal words,“CAUTION”, “DANGER”, and “WARNING” in this manualto alert the reader to hazards arising from improper oper-ating and maintenance practices.

“DANGER” identifies a specific potential hazard

WHICH WILL RESULT

in either INJURY OR DEATH

if proper precautions are not taken.

“WARNING” identifies a specific potential hazard

WHICH COULD RESULT

in either INJURY OR DEATH

if proper precautions are not taken.

“CAUTION” is used for general reminders

of proper safety practices

OR

to direct the reader’s attention to avoid unsafe

or improper practices which may result

in damage to the equipment.


TABLE OF CONTENTS

SUBJECT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION / PAGE

FOREWARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1

“Alerts” Page - a description of DANGER, WARNING, and CAUTION symbols. . . . . . . . . . . . . . . .10-2TABLE OF CONTENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-3

Truck Model Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-11

STANDARD CHARTS AND TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-1

GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1

Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1Truck Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1Clothing And Personal Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1Unauthorized Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1Leaving The Operator’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1Mounting And Dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-2Fire Extinguishers And First Aid Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-2Precautions For High Temperature Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-2Asbestos Dust Hazard Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-2Fire Prevention For Fuel And Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-3ROPS Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-3Preventing Injury From Work Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-3Precautions For Optional Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-3Precautions When Starting The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-3

PRECAUTIONS FOR TRUCK OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-4Safety Is Thinking Ahead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-4Safety At The Worksite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-4Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-4Preparing For Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-4Ventilation For Enclosed Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-4Mirrors, Windows, And Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-4In The Operator’s Cab - Before Starting The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-5

OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-5Starting The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-5Truck Operation - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-5Traveling In The Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-6Precautions When Traveling In Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-6Traveling On Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-6Ensuring Good Visibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-7Operating On Snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-7

Introduction - Section 10 OM1053-4

TABLE OF CONTENTSSUBJECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION / PAGEAvoid Damage To The Dump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-7Driving Near High Voltage Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-7When Loading The Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-8When Dumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-8Working On Loose Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-8Parking The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-8TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-8

WORKING NEAR BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-9Jump Starting With Booster Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-9

PRECAUTIONS FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10BEFORE PERFORMING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10

Stopping The Engine Before Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10Warning Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10Proper Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10Securing The Dump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10

DURING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11Working Under The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11Keeping The Machine Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11Rules To Follow When Adding Fuel Or Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11Radiator Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11Use Of Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11Precautions With The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12Handling High Pressure Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12Precautions With High Pressure Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12Maintenance Near High Temperatures And High Pressures . . . . . . . . . . . . . . . . . . . . . . . . . 20-12Rotating Fan And Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12Waste Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12

TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-13Handling Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-13Storing Tires After Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-13

ADDITIONAL JOB SITE RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-14WHEN REPAIRS ARE NECESSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-15SPECIAL PRECAUTIONS FOR WORKING ON A 830E-AC TRUCK . . . . . . . . . . . . . . . . . . . . . 20-16

Preliminary Procedures before Welding or Performing Maintenance . . . . . . . . . . . . . . . . . . . 20-16Engine Shutdown Procedure before Welding or Performing Maintenance . . . . . . . . . . . . . . 20-16

WARNINGS AND CAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-1


TABLE OF CONTENTSSUBJECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION / PAGE

TRUCK OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-1

PREPARING FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-1Safety Is Thinking Ahead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-1

WALK AROUND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-1ENGINE START-UP SAFETY PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-5AFTER ENGINE HAS STARTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-6

Additional Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-6MACHINE OPERATION SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-6MACHINE OPERATION ON THE HAUL ROAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-7STARTING ON A GRADE WITH A LOADED TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-8PASSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-8LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-8DUMPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-8

Raising The Dump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-8Lowering The Dump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-9

SUDDEN LOSS OF ENGINE POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-10SAFE PARKING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-11NORMAL ENGINE SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-11DELAYED ENGINE SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-12EMERGENCY STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-13

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-13Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-13

DISABLED TRUCK DUMPING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-14Hookup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-14Raising the Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-14Lowering the Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-14

TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-15RESERVE ENGINE OIL SYSTEM (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-16

OPERATOR CAB AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-1

STEERING WHEEL AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-2Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-2Tilt / Telescope Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-2Multi-Function Turn Signal Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-2

PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-3Service Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-3Dynamic Retarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-3Dynamic Retard Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-3Throttle/Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-4

GRADE/SPEED RETARD CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-4OVERHEAD PANEL AND DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-6CENTER CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-7


TABLE OF CONTENTSSUBJECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION / PAGEP-F-N-R Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-7Override/Fault Reset Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-8Engine Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-8L.H. Window Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-8R.H. Window Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-8Hoist Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-8Raising The Dump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-8Lowering The Dump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-8Retard Speed Control (RSC) Adjust Dial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-9Retard Speed Control (RSC) Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-9Data Store Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-10VHMS Snapshot In Progress Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-10Link Energized Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-10Service Engine Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-10DIAGNOSTIC PORTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-10VHMS Diagnostic Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-10Interface Module (IM) Diagnostic Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-10Payload Meter Diagnostic Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-10Truck Control Interface (TCI) Diagnostic Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-10Propulsion System Controller (PSC) Diagnostic Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-10Engine Diagnostic Port (CENSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-10Engine Diagnostic Port (QUANTUM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-10

OPERATOR’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-11Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-11

HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS . . . . . . . . . . . . . . . . . . . . . 32-12Fan Control Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-12Temperature Control Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-12Directional Control Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-12Heater Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-12

INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-13Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-15Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-15Engine Stop Switch with Five Minute Idle Timer Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-15Rotating Beacon Light Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-16Heated Mirror Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-16Rest Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-16Wheel Brake Lock Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-16Hazard Warning Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-16Cab/Air Conditioner Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-16Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-17Right Turn Signal Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-17Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-17


TABLE OF CONTENTSSUBJECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION / PAGEHigh Beam Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-17Speedometer/Payload Meter Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-17Left Turn Signal Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-17Water Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-17Lamp Test Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-17Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-17Ladder Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-18Manual Backup Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-18Fog Lights (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-18Payload Meter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-18Panel Light Dimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-18Hydraulic Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-19Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-19Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-19

OVERHEAD STATUS / WARNING INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-20Status / Warning Indicator Light Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-21

VEHICLE HEALTH MONITORING SYSTEM (VHMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-26Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-26Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-27Basic Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-27

FUSE BLOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-28CIRCUIT BREAKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-29

LUBRICATION AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-1

830E SERVICE CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-1HYDRAULIC TANK SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-1

Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-1WHEEL MOTOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-1COOLANT LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-2RADIATOR FILLING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-2RESERVE ENGINE OIL SYSTEM (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-2

Reserve Oil Tank Filling Procedure (Remote fill) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-2LUBRICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-310 HOUR (DAILY) INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-450 HOUR LUBRICATION AND MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-7100 HOUR LUBRICATION AND MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-8250 HOUR LUBRICATION AND MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-9500 HOUR LUBRICATION AND MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-121000 HOURS LUBRICATION AND MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . .40-142500 HOUR MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-155000 HOUR MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-1510,000 HOUR MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-16


TABLE OF CONTENTS

SUBJECT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION / PAGE

AUTOMATIC LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-1

GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-1SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-3SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-4

Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-4GENERAL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-5

Required Lubricant For System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-5System Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-5Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-5

LUBRICANT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-6Pump Housing Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-6Pump Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-6Pressure Control Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-6

INJECTORS (SL-1 Series “H”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-7Injector Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-7Injector Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-7

INJECTOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-8SYSTEM CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-9

Lubrication Controller Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-9Lubrication Controller Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-9Lubrication Controller Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-9Lubrication Controller Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-9

SYSTEM TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-11PREVENTIVE MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-13

Daily Lubrication System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-13250 Hour Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-13

1000 Hour Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-13

MAJOR COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1

PAYLOAD METER III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-1


TABLE OF CONTENTSSUBJECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION / PAGE

RADIO / CASSETTE PLAYER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-1

GENERAL RECEIVER FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-1Turning The Power On And Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-1Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-1Setting The Default Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-1Adjusting Display Brightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-1

SETTING THE TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-2OPERATING THE RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-2

BAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-2TUNE/SEEK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-2Manual Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-2SEEK Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-2SCAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-2AUTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-2

ADJUSTING THE RECEIVER SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-3PROGRAMMING PRESET STATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-3OPERATION OF THE WEATHERBAND (U.S.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-3SATELLITE RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-4

Operating Satellite Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-4Program Type Search (PTY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-4

CASSETTE PLAYER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-5Playing A Cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-5Cassette Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-5Programmable Eject Default . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-5Bad Tape Detect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-6Cleaning The Cassette Player . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-6


TRUCK MODEL ILLUSTRATION

KOMATSU MODEL 830E-AC DUMP TRUCK


ABOUT THIS MANUALThis manual is written for use by the operator and/or the service technician. It is designed to help these personslearn how to operate the truck and its systems in order to keep it operating safely and efficiently. All operators andmaintenance personnel must read and understand the materials in this manual before operating the truck or per-forming maintenance and/or operational checks on the truck. All safety notices, warnings, and cautions should beunderstood and followed when operating or performing repairs on the truck.

The front cover of this manual includes a form number. This form number should be referenced when orderingadditional copies of this manual, or for any other correspondence regarding the coverage in this manual.

Direct all inquiries to: Komatsu America Corp. Datakom, Peoria Technical Publications P.O. Box 240 Peoria, IL 61650-0240 United States of America Fax (309) 672-7072

This first section is an introduction to the manual and contains the table of contents to locate specific areas of inter-est. Other sections include Safety, Operating Instructions, Lubrication and Service, etc.

When searching for a specific area of interest, go first to the table of contents to locate the section in which the sub-ject might generally be included. Then, go to that section of the table of contents to find a subject description thatmost closely describes the specific area of interest to find a page number and go to that page. Section numbersand page numbers are located at the top, outside corner of the page.

At the top, inside corner of the page is a document (module) number. If there is ever a question regarding the infor-mation in a particular section, refer to the document (module) number, the manual form number, and use theaddress shown above to correspond. If there is a date (month/year) behind the document (module) number, thatindicates 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 reproductionof 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 beassumed. Standard torque requirements are shown in torque charts on the following pages of this section, and inthe General Information section of the truck service manual. Individual torques when provided in the text are in boldface type, such as 135 N.m (100 ft lbs). All torque specifications have ±10% tolerance unless otherwise specified.


NOTES

OM1200 3/05 Standard Charts and Tables - Section 12Page 12-1

STANDARD CHARTS AND TABLESThis manual provides dual dimensioning for mostspecifications. U.S. standard units are specified first,with metric (SI) units in parentheses.

References throughout the manual to standard torquesor other standard values will be to one of the followingcharts or tables. For values not shown in these chartsor tables, standard conversion factors for mostcommonly used measurements are provided in TABLEXIII, page 12-6.

Standard torque values are not to be used when “turn-of-the-nut” tightening procedures are recommended.

INDEX OF TABLESTABLE I . . . . . . . Standard Torque Chart (SAE) . . 12-1TABLE II . Standard Torque, 12-Point, Grade 9 . . 12-2TABLE III . . Standard Metric Assembly Torque . . 12-2TABLE IV . . . . . . JIC Swivel Nuts Torque Chart . . 12-3TABLE V . . . . . . . . .Pipe Thread Torque Chart . . 12-3TABLE VI . . . . . . . . O-Ring Boss Torque Chart . . 12-3TABLEVII . . . . O-Ring Face Seal Torque Chart . . 12-3TABLE VIII . Torque Conversions (ft lbs to N•m) . . 12-4TABLE IX . Torque Conversions (ft lbs to kg•m) . . 12-4TABLE X . . Pressure Conversions (psi to kPa) . . 12-4TABLE XI . Pressure Conversions (psi to MPa) . . 12-5TABLE XII . . . . . . . .Temperature Conversions . . 12-5TABLE XIII . . .Common Conversion Multipliers . . 12-6

EFFECT OF SPECIAL LUBRICANTSOn Fasteners and Standard Torque ValuesThe Komatsu engineering department does notrecommend the use of special friction-reducinglubricants, such as Copper Coat, Never-Seez®, andother similar products, on the threads of standardfasteners where standard torque values are applied.The use of special friction-reducing lubricants willsignificantly alter the clamping force being applied tofasteners during the tightening process.

If special friction-reducing lubricants are used with thestandard torque values listed below in Table I (and inKomatsu shop manuals), excessive stress andpossible breakage of the fasteners may result.

Where the torque tables specify “Lubricated Threads”for the standard torque values listed, these standardtorque values are to be used with simple lithium basechassis grease (multi-purpose EP NLGI) or a rust-preventive grease (see list, page 12-2) on the threadsand seats unless specified otherwise.

NOTE: Ensure the threads of fasteners and tappedholes are free of burrs and other imperfections beforeassembling.

TABLE I. STANDARD TORQUE CHARTSAE HEX HEAD CAP SCREW AND NUT ASSEMBLY

(LUBRICATED THREADS)TOLERANCES ±10%

Capscrew Thread

Size

TORQUE - GRADE 5

TORQUE - GRADE 8

Capscrew Thread

Size

TORQUE - GRADE 5

TORQUE - GRADE 8

ft lbs kg•m N•m ft lbs kg•m N•m ft lbs kg•m N•m ft lbs kg•m N•m

1/4-20 7 0.97 9.5 10 1.38 13.6 3/4-16 235 32.5 319 335 46.3 454

1/4-28 8 1.11 10.8 11 1.52 14.9 7/8-9 350 48.4 475 500 69.2 678

5/16-18 15 2.07 20.3 21 2.90 28 7/8-14 375 51.9 508 530 73.3 719

5/16-24 16 2.21 22 22 3.04 30 1.0-8 525 72.6 712 750 103.7 1017

3/8-16 25 3.46 34 35 4.84 47 1.0-12 560 77.4 759 790 109.3 1071

3/8-24 30 4.15 41 40 5.5 54 1.0-14 570 78.8 773 800 110.6 1085

7/16-14 40 5.5 54 58 8.0 79 1 1/8-7 650 89.9 881 1050 145 1424

7/16-20 45 6.2 61 62 8.57 84 1 1/8-12 700 96.8 949 1140 158 1546

1/2-13 65 9 88 90 12.4 122 1 1/4-7 910 125.9 1234 1480 205 2007

1/2-20 70 9.7 95 95 13.1 129 1 1/4-12 975 134.8 1322 1580 219 2142

9/16-12 90 12.4 122 125 17.3 169 1 3/8-6 1200 166 1627 1940 268 2630

9/16-18 95 13.1 129 135 18.7 183 1 3/8-12 1310 181 1776 2120 293 2874

5/8-11 125 17.3 169 175 24.2 237 1 1/2-6 1580 219 2142 2560 354 3471

5/8-18 135 18.7 183 190 26.2 258 1 1/2-12 1700 235 2305 2770 383 3756

3/4-10 220 30.4 298 310 42.8 420

1 ft. lbs. = 0.138 kg•m = 1.356 N•m

Grade 5 Grade 8

Standard Charts and Tables - Section 12 OM1200 3/05Page 12-2

STANDARD ASSEMBLY TORQUESFor 12-Point, Grade 9 Cap screws (SAE)The following specifications apply to required assemblytorques for all 12-point, grade 9 (170,000 psi minimumtensile) cap screws.

• Cap screw threads and seats shall be lubricatedwhen assembled.

NOTE: Unless the instructions specifically recommendotherwise, these standard torque values are to be usedwith simple lithium base chassis grease (multi-purposeEP NLGI) or a rust preventive grease (see list, thispage) on the threads.

• Torques are calculated to give a clamping force ofapproximately 75% of proof load.

• The maximum torque tolerance shall be ±10% ofthe torque value shown.

STANDARD ASSEMBLY TORQUES For Class 10.9 Cap screws & Class 10 NutsThe following specifications apply to required assemblytorques for all metric Class 10.9 finished hexagon headcap screws and Class 10 nuts.

• Cap screw threads and seats shall not belubricated when assembled. These specificationsare based on all cap screws, nuts, and hardenedwashers being phosphate and oil coated.

NOTE: If zinc-plated hardware is used, each piecemust be lubricated with simple lithium base chassisgrease (multi-purpose EP NLGI) or a rust preventivegrease (see list, this page) to achieve the sameclamping forces provided below.

• Torques are calculated to give a clamping force ofapproximately 75% of proof load.

• The maximum torque tolerance shall be within±10% of the torque value shown.

Suggested* Sources for Rust Preventive Grease: • AMERICAN ANTI-RUST GREASE #3-X from

Standard Oil Company (also American Oil Co.)

• GULF NORUST #3 from Gulf Oil Company.

• MOBILARMA 355, Product No. 66705 from MobilOil Corporation.

• RUST BAN 326 from Humble Oil Company.

• RUSTOLENE B GREASE from Sinclair Oil Co.

• RUST PREVENTIVE GREASE - CODE 312 fromthe Southwest Grease and Oil Company.

NOTE: This list represents the current engineeringapproved sources for use in Komatsu manufacture. It isnot exclusive. Other products may meet the samespecifications of this list.

TABLE II. STANDARD ASSEMBLY TORQUEfor 12-Point, Grade 9 Cap screws

CAPSCREW SIZE*

TORQUEft lbs

TORQUEN•m

TORQUEkg•m

0.250 - 20 12 16 1.70.312 - 18 24 33 3.30.375 - 16 42 57 5.80.438 -14 70 95 9.70.500 -13 105 142 14.50.562 - 12 150 203 20.70.625 - 11 205 278 28.30.750 - 10 360 488 49.70.875 - 9 575 780 79.41.000 - 8 860 1166 119

1.000 - 12 915 1240 1261.125 - 7 1230 1670 170

1.125 - 12 1330 1800 1841.250 - 7 1715 2325 237

1.250 - 12 1840 2495 2541.375 - 6 2270 3080 313

1.375 - 12 2475 3355 3421.500 - 6 2980 4040 411

1.500 - 12 3225 4375 445* Shank Diameter (in.) - Threads per inch

This table represents standard values only. Do not use these values to replace torque values which are specified in assembly instructions.

TABLE III. STANDARD ASSEMBLY TORQUEfor Metric Class 10.9 Cap screws & Class 10 Nuts

CAPSCREW SIZE*

TORQUEN•m

TORQUEft lbs

TORQUEkg•m

M6 x1 12 9 1.22M8 x 1.25 30 22 3.06M10 x 1.5 55 40 5.61M12 x 1.75 95 70 9.69M14 x 2 155 114 15.81M16 x 2 240 177 24.48M20 x 2.25 465 343 47.43M24 x 3 800 590 81.6M30 x 3.5 1600 1180 163.2M36 x 4 2750 2028 280.5

* Shank Diameter (mm) - Threads per millimeterThis table represents standard values only. Do not use these values to replace torque values which are specified in assembly instructions.


TABLE IV. TORQUE CHART FOR JIC 37° SWIVEL NUTS

WITH OR WITHOUT O-RING SEALS

SIZECODE

TUBE SIZE (O.D.)

THREADS UNF-2B

TORQUE FT. LBS.

– 2 0.125 0.312 – 24 4 ±1

– 3 0.188 0.375 – 24 8 ±3

– 4 0.250 0.438 – 20 12 ±3

– 5 0.312 0.500 – 20 15 ±3

– 6 0.375 0.562 – 18 18 ±5

– 8 0.500 0.750 – 16 30 ±5

– 10 0.625 0.875 – 14 40 ±5

– 12 0.750 1.062 – 12 55 ±5

– 14 0.875 1.188 – 12 65 ±5

– 16 1.000 1.312 – 12 80 ±5

– 20 1.250 1.625 – 12 100 ±10

– 24 1.500 1.875 – 12 120 ±10

– 32 2.000 2.500 – 12 230 ±20

TABLE VI. TORQUE CHART FOR

O-RING BOSS FITTINGS

SIZECODE

TUBE SIZE (O.D.)

THREADS UNF-2B

TORQUE FT. LBS.

– 2 0.125 0.312 – 24 4 ±2

– 3 0.188 0.375 – 24 5 ±2

– 4 0.250 0.438 – 20 8 ±3

– 5 0.312 0.500 – 20 10 ±3

– 6 0.375 0.562 – 18 13 ±3

– 8 0.500 0.750 – 16 24 ±5

– 10 0.625 0.875 – 14 32 ±5

– 12 0.750 1.062 – 12 48 ±5

– 14 0.875 1.188 – 12 54 ±5

– 16 1.000 1.312 – 12 72 ±5

– 20 1.250 1.625 – 12 80 ±5

– 24 1.500 1.875 – 12 80 ±5

– 32 2.000 2.500 – 12 96 ±10

TABLE V. TORQUE CHART FOR

PIPE THREAD FITTINGS

SIZECODE

PIPE THREAD

SIZE

WITH SEALANTFT. LBS.

WITHOUTSEALANT FT. LBS.

– 2 0.125 – 27 15 ±3 20 ±5

– 4 0.250 – 18 20 ±5 25 ±5

– 6 0.375 – 18 25 ±5 35 ±5

– 8 0.500 – 14 35 ±5 45 ±5

– 12 0.750 – 14 45 ±5 55 ±5

– 16 1.000 – 11.50 55 ±5 65 ±5

– 20 1.250 – 11.50 70 ±5 80 ±5

– 24 1.500 – 11.50 80 ±5 95 ±10

– 32 2.000 – 11.50 95 ±10 120 ±10

TABLE VII. TORQUE CHART FOR

O-RING FACE SEAL FITTINGS

SIZECODE

TUBE SIZE (O.D.)

THREADS UNF-2B

TORQUE FT. LBS.

– 4 0.250 0.438 – 20 11 ±1

– 6 0.375 0.562 – 18 18 ±2

– 8 0.500 0.750 – 16 35 ±4

– 10 0.625 0.875 – 14 51 ±5

– 12 0.750 1.062 – 12 71 ±7

– 16 1.000 1.312 – 12 98 ±6

– 20 1.250 1.625 – 12 132 ±7

– 24 1.500 1.875 – 12 165 ±15


TABLE X. PRESSURE CONVERSIONSPounds per square inch (psi) to Kilopascals (kPa)

Formula: psi x 6.895 = kPa

psi 0 1 2 3 4 5 6 7 8 90 (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 12-5 regarding table usage.

TABLE VIII. TORQUE CONVERSIONSFoot Pounds (ft. lbs.) to Newton-meters (N•m)

ft lbs 0 1 2 3 4 5 6 7 8 90 (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


TABLE IX. TORQUE CONVERSIONSFoot Pounds (ft. lbs.) to kilogram-meters (kg•m)

ft lbs 0 1 2 3 4 5 6 7 8 90 (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



TABLE XII. TEMPERATURE CONVERSIONSFormula: F° - 32 ³ 1.8 = C° or C° x 1.8 + 32 = F°

CELSIUSC°

FAHRENHEITF°

CELSIUSC°

FAHRENHEITF°

CELSIUSC°

FAHRENHEITF°

121 250 482 63 145 293 4 40 104118 245 473 60 140 284 2 35 95116 240 464 57 135 275 – 1 30 86113 235 455 54 130 266 – 4 25 77110 230 446 52 125 257 – 7 20 68107 225 437 49 120 248 – 9 15 59104 220 428 46 115 239 – 12 10 50102 215 419 43 110 230 – 15 5 4199 210 410 41 105 221 – 18 0 3296 205 401 38 100 212 – 21 – 5 2393 200 392 35 95 293 – 23 – 10 1491 195 383 32 90 194 – 26 – 15 588 190 374 29 85 185 – 29 – 20 – 485 185 365 27 80 176 – 32 – 25 – 1382 180 356 24 75 167 – 34 – 30 – 2279 175 347 21 70 158 – 37 – 35 – 3177 170 338 18 65 149 – 40 – 40 – 4074 165 329 15 60 140 – 43 – 45 – 4971 160 320 13 55 131 – 46 – 50 – 5868 155 311 10 50 122 – 48 – 55 – 6766 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.

TABLE XI. PRESSURE CONVERSIONSPounds per square inch (psi) to Megapascals (MPa)

Formula: psi x 0.0069 = MPa

psi 0 10 20 30 40 50 60 70 80 900 (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).

1. Select Table X.

2. Go to psi row 90, column 7; read 668.897 psi = 668.8 kPa.

3. Multiply by 10:970 psi = 6688 kPa.

4. Go to psi row 0, column 5; read 34.475 psi = 34.47 kPa. Add to step 3.

5. 970 + 5 psi = 6688 + 34 = 6722 kPa.


Table XIII. TABLE XIIICOMMON CONVERSION MULTIPLIERS

COMMON CONVERSION MULTIPLIERSENGLISH TO METRIC

To ConvertFrom TO

MultiplyBy

inch – in. millimeter (mm) 25.40

inch – in. centimeter (cm) 2.54

foot – ft. meter (m) 0.3048

yard – yd. meter (m) 0.914

mile – mi. kilometer (km) 1.61

sq. in. – in.2 sq. centimeters (cm2) 6.45

sq. ft. – ft.2 sq. centimeters (cm2) 929

cu. in. – in.3 cu. centimeters (cm3) 16.39

cu. in. – in.3 liters (l) 0.016

cu. ft. – ft.3 cu. meters (m3) 0.028

cu. ft. – ft.3 liters (l) 28.3

ounce – oz. kilogram (kg) 0.028

fluid ounce – fl. oz. milliliter (ml) 29.573

pound (mass) kilogram (kg) 0.454

pound (force) – lbs. Newton (N) 4.448

in. lbs. (force) Newton-meters (N•m) 0.113

ft. lbs. (force) Newton-meters (N•m) 1.356

ft. lbs. (force) kilogram-meters (kg•m) 0.138

psi (pressure) kilopascals (kPa) 6.895

psi (pressure) megapascals (MPa) 0.007

psi (pressure) kilograms/cm2 (kg/cm2) 0.0704

ton (short) kilogram (kg) 907.2

ton (short) metric ton 0.0907

quart – qt. liters (l) 0.946

gallon – gal. liters (l) 3.785

HP (horsepower) Watts 745.7

HP (horsepower) kilowatts (kw) 0.745

COMMON CONVERSION MULTIPLIERSMETRIC TO ENGLISH

To Convert From TOMultiply

Bymillimeter (mm) inch – in. 0.0394

centimeter (cm) inch – in. 0.3937

meter (m) foot – ft. 3.2808

meter (m) yard – yd. 1.0936

kilometer (km) mile – mi. 0.6210

sq. centimeters (cm2) sq. in. – in.2 0.1550

sq. centimeters (cm2) sq. ft. – ft.2 0.001

cu. centimeters (cm3) cu in – in.3 0.061

liters (l) cu in – in.3 61.02

cu. meters (m3) cu ft – ft.3 35.314

liters (l) cu ft – ft.3 0.0353

grams (g) ounce – oz. 0.0353

milliliter (ml) fluid ounce – fl. oz. 0.0338

kilogram (kg) pound (mass) 2.2046

Newton (N) pound (force) – lbs. 0.2248

Newton-meters (N•m) kilogram-meters (kg•m) 0.102

Newton-meters (N.m) ft lbs 0.7376

kilogram-meters (kg•m) ft lbs 7.2329

kilogram-meters (kg•m) Newton-meters (N•m) 9.807

kilopascals (kPa) psi 0.1450

megapascals (MPa) psi 145.038

kilograms/cm2 (kg/cm2) psi 14.2231

kilograms/cm2 (kg/cm2) kilopascals (kPa) 98.068

kilogram (kg) ton 0.0011

metric ton ton 1.1023

liters (l) quart – qt. 1.0567

liters (l) gallon – gal. 0.2642

Watts Horsepower HP 0.00134

kilowatts (kw) Horsepower HP 1.3410

OM2038 Safety - Section 20Page 20-1

GENERAL SAFETYSafety records of most organizations will show thatthe greatest percentage of accidents are caused byunsafe acts of persons. The remainder are causedby unsafe mechanical or physical conditions. Reportall unsafe conditions to the proper authority.

The following safety rules are provided as a guide forthe operator. However, local conditions and regula-tions may add many more to this list.

Read and follow all safety precautions. Failure todo so may result in serious injury or death.

Safety Rules

• Only trained and authorized personnel canoperate and maintain the machine.

• Follow all safety rules, precautions andinstructions when operating or performingmaintenance on the machine.

• When working with another operator or a personon work site traffic duty, ensure all personnelunderstand all hand signals that are to be used.

Truck Safety Features

• Ensure all guards and covers are in their properposition. Repair any damaged guards andcovers. (See Walk-Around Inspection, later inthis section.)

• Learn the proper use of safety features such assafety locks, safety pins, and seat belts. Alwaysuse these safety features, properly.

• Never remove any safety features. Always keepsafety features in good operating condition.

• Improper use of safety features may result inserious bodily injury or death.

Clothing And Personal Items

• Avoid wearing looseclothing, jewelry,and loose long hair.They can catch oncontrols or in movingparts and causeserious injury ordeath. Additionally,never wear oilyclothes as they areflammable.

• Wear a hard hat, safety glasses, safety shoes, amask and gloves when operating or maintaininga machine. Always wear safety goggles, a hardhat and heavy gloves if your job involvesscattering metal chips or minute materials. Thisis particularly important when driving pins with ahammer or when cleaning air cleaner elementswith compressed air. Also, ensure that the workarea is free of other personnel during such tasks.

Unauthorized Modification

• Any modification made to this vehicle withoutauthorization from Komatsu America Corp. canpossibly create hazards.

• Before making any modification, consult yourauthorized regional Komatsu America Corp.distributor. Komatsu will not be responsible forany injury or damage caused by anyunauthorized modification.

Leaving The Operator’s Seat

While leaving the operator's seat, DO NOT touch anycontrols. To prevent accidental operations fromoccurring, always perform the following:

• Move the shift control lever/switch to NEUTRALand apply the parking brake.

• Lower the dump body, and move the hoist controllever to the FLOAT position.

• Stop the engine. When exiting the machine,always lock compartments, and take the keyswith you to prevent entry from unauthorizedpersons.

Safety - Section 20 OM2038Page 20-2

Mounting And Dismounting

• Never jump on or off the machine. Never climb onor off a machine while it is moving.

• When climbing on or off a machine, face themachine and use the hand-hold and steps.

• Never hold any control levers when getting on oroff a machine.

• Always maintain three-point contact with thehand-holds and steps to ensure that you supportyourself.

• When bringing tools up to the operating deck,always pass them by hand or pull them up byrope.

• If there is any oil, grease, or mud on the hand-holds or steps, wipe them clean immediately.Always keep these components clean. Repairany damage and tighten any loose bolts.

• Use the handrails and steps marked by arrows inthe diagram below when getting on or off themachine.

Fire Extinguishers And First Aid Kits

• Ensure fire extinguishersare accessible andproper usage techniquesare known.

• Provide a first aid kit atthe storage point.

• Know what to do in the event of a fire.

• Keep the phone numbers of persons you shouldcontact in case of an emergency on hand.

Precautions For High Temperature Fluids

• Immediately after machineoperation, engine coolant,engine oil, and hydraulic oil areat high temperatures and arepressurized. If the cap isremoved, the fluids drained, thefilters are replaced, etc., thereis danger of serious burns. Allow heat andpressure to dissipate before performing suchtasks and follow proper procedures as outlined inthe service manual.

• To prevent hot coolant from spraying:

1. Stop the engine, and wait for the coolant tem-perature to decrease.

2. Depress the pressure relief button on the radia-tor cap.

3. Turn the radiator cap slowly to allow pressure todissipate.

• To prevent hot engine oil spray:

1. Stop the engine.2. Wait for the oil temperature to cool down.3. Turn the cap slowly to allow pressure to dissi-

pate.

Asbestos Dust Hazard Prevention

Asbestos dust is hazardous toyour health when inhaled. If youhandle materials containingasbestos fibers, follow theguidelines below:

• Never use compressed airfor cleaning.

• Use water for cleaning and to control dust.

• Operate the machine or perform tasks with thewind to your back, whenever possible.

• Use an approved respirator, when necessary.


Fire Prevention For Fuel And Oil

• Fuel, oil, and antifreeze can be ignited by aflame. These fluids are extremely flammable andhazardous.

• Keep flames away from flammable fluids.

• Stop the engine while refueling.

• Never smoke while refueling

• Tighten all fuel and oil tank caps securely.

• Refuel and maintain oil in well ventilated areas.

• Keep oil and fuel in a designated location. DONOT allow unauthorized persons to enter.

ROPS Precautions

• The Rollover Protection Structure (ROPS) mustbe properly installed for machine operation.

• The ROPS is intended to protect the operator ifthe machine should roll over. It is designed notonly to support the load of the machine, but alsoto absorb the energy of the impact.

• ROPS structures installed on equipmentmanufactured and designed by Komatsu fulfillsall of the regulations and standards for allcountries. If it is modified or repaired withoutauthorization from Komatsu, or is damaged whenthe machine rolls over, the strength of thestructure will be compromised and will not beable to fulfill its intended purpose. Optimumstrength of the structure can only be achieved if itis repaired or modified as specified by Komatsu.

• When modifying or repairing the ROPS, alwaysconsult your nearest Komatsu distributor.

• Even with the ROPS installed, the operator mustalways use the seat belt when operating themachine.

Preventing Injury From Work Equipment

• Never position any part of your body betweenmovable parts such as the dump body, chassisor cylinders. If the work equipment is operated,clearances will change and may cause seriousbodily injury or death.

Precautions For Optional Attachments

• When installing and using optional equipment,read the instruction manual for the attachmentand the information related to attachments in thismanual.

• DO NOT use attachments that are not authorizedby Komatsu, or the authorized regional Komatsudistributor. Use of unauthorized attachmentscould create a safety problem and adverselyaffect the proper operation and useful life of themachine.

• Any injuries, accidents, and product failuresresulting from the use of unauthorizedattachments will not be the responsibility ofKomatsu America Corp., or the authorizedregional Komatsu distributor.

Precautions When Starting The Machine

• Start the engine from theoperator’s seat, only.

• Never attempt to start theengine by shorting across thestarter terminals. This maycause fire, or serious injury ordeath to anyone in themachine’s path.


PRECAUTIONS FOR TRUCK OPERATION

Safety Is Thinking Ahead

Prevention is the best safety program. Prevent apotential accident by knowing the employer's safetyrequirements and all necessary job site regulations.In addition, know the proper use and care of all thesafety equipment on the truck. Only qualified opera-tors or technicians may attempt to operate or main-tain a Komatsu machine.

Safe practices start before the operator gets to theequipment!

Safety At The Worksite

• When walking to and from a truck, maintain asafe distance from all machines even when theoperator is visible.

• Before starting the engine, thoroughly check thearea for any unusual conditions that could bedangerous.

• Examine the road surface at the job site anddetermine the best and safest method ofoperation.

• Choose an area where the ground is ashorizontal and firm as possible before performingthe operation.

• If you need to operate on or near a public road,protect pedestrians and cars by designating aperson for work site traffic duty or by installingfences around the work site.

• The operator must personally check the workposition, the roads to be used, and existence ofobstacles before starting operations.

• Always determine the travel roads to be used atthe work site. Travel roads must be maintained inorder to ensure safe machine travel.

• If travel through wet areas is necessary, checkthe depth and flow of water before crossing theshallow parts. Never drive through water whichexceeds the permissible water depth.

Fire Prevention

• Remove all wood chips,leaves, paper and otherflammable itemsaccumulated in the enginecompartment, as they couldcause a fire.

• Check fuel, lubrication, and hydraulic systems forleaks. Repair any leaks. Clean any excess oil,fuel or other flammable fluids, and dispose ofproperly.

• Ensure a fire extinguisher is present and inproper working condition.

• DO NOT operate the machine near open flames.

Preparing For Operation

• Always mount and dismount while facing thetruck. Never attempt to mount or dismount thetruck while it is in motion. Always use handrailsand ladders when mounting or dismounting thetruck.

• Check the deck areas for debris, loose hardware,and tools. Check for people and objects thatremain on or around the truck.

• Become familiar with and use all protectiveequipment devices on the truck and ensure thatthese items (anti-skid material, grab bars, seatbelts, etc.) are securely in place.

Ventilation For Enclosed Areas

• If it is necessary to start theengine in an enclosed area,provide adequate ventilation.Exhaust fumes from theengine can kill.


Mirrors, Windows, And Lights

• Remove any dirt from the surface of thewindshield, cab windows, mirrors and lights.Good visibility may prevent an accident.

• Adjust the mirrors to a position where theoperator can see best from the operator's seat.

• Ensure headlights, work lights and taillights are inproper working order. Ensure that the machine isequipped with the proper work lamps needed forthe operating conditions.

• Replace any broken mirrors, windows or lights.

In The Operator’s Cab - Before Starting TheEngine

• DO NOT leave tools or spare parts lying aroundor allow trash to accumulate in the cab of thetruck. Keep all unauthorized reading material outof the truck cab.

• Keep the cab floor, controls, steps, and handrailsfree of oil, grease, snow, and excess dirt.

• Check the seat belt, buckle and hardware fordamage or wear. Replace any worn or damagedparts. Always use the seat belts when operatinga machine.

• Read and understand the contents of theOperation & Maintenance manual. Read safetyand operating instructions with special attention.Become thoroughly acquainted with all gauges,instruments and controls before attemptingoperation of the truck.

• Read and understand the WARNING andCAUTION decals in the operator's cab.

• Ensure the steering wheel, horn, controls andpedals are free of any oil, grease or mud.

• Check operation of the windshield wiper,condition of wiper blades, and check the washerfluid reservoir level.

• Be familiar with all steering and brake systemcontrols, warning devices, road speeds andloading capabilities, before operating the truck.

OPERATING THE MACHINE

Starting The Engine

• NEVER ATTEMPT TO START THE MACHINEBY SHORTING ACROSS THE STARTERTERMINALS. This may cause fire, or seriousinjury or death to anyone in machine’s path.

• NEVER start the engine if a warning tag hasbeen attached to the controls.

• When starting the engine, sound the horn as analert.

• Start and operate the machine only while seatedin the operator’s seat.

• DO NOT allow any unauthorized persons in theoperator's compartment or any other place onthe machine.

Truck Operation - General

• WEAR SEAT BELTS AT ALL TIMES.

• Only authorized persons are allowed to ride inthe truck. Passengers must be in the cab andbelted in the passenger seat.

• DO NOT allow anyone to ride on the decks or onthe steps of the truck.

• DO NOT allow anyone to get on or off the truckwhile it is in motion.

• DO NOT move the truck in or out of a buildingwithout a signal person present.

• Know and obey hand signal communicationsbetween the operator and spotter. When othermachines and personnel are present, theoperator should move in and out of buildings,loading areas and through traffic, under thedirection of a signal person. Courtesy at alltimes is a safety precaution!

• Immediately report any adverse conditions onhaul road, pit or dump area that may cause anoperating hazard.


• Check for flat tires periodically during a shift. Ifthe truck has been operating on a “flat”, the truckmust not be parked indoors until the tire cools. Ifthe tire must be changed, DO NOT stand in frontof the rim and locking ring when inflating a tiremounted on the machine. Observers should notbe permitted in the area and should be keptaway from the side of such tires.

A tire and rim assembly may explode if subjectedto excessive heat. Personnel must move to aremote or protected location if there is a fire nearthe tire and wheel area or if the smell of burningrubber or excessively hot brakes is evident.

If the truck must be approached, such as to fighta fire, those personnel must do so only while fac-ing the tread area of the tire (front or back),unless protected by use of large heavy equip-ment as a shield. Stay at least 50 ft. (15 m) fromthe tread of the tire.

In the event of fire in the tire and wheel area(including brake fires), stay away from the truckfor at least 8 hours or until the tire and wheel arecool.

• Keep serviceable fire fighting equipment onhand. Report used extinguishers for replacementor refilling.

• Always apply the parking brake when the truck isparked and unattended. DO NOT leave the truckunattended while the engine is running.

• Park the truck a safe distance away from othervehicles as determined by the supervisor.

• Stay alert at all times! In the event of anemergency, be prepared to react quickly andavoid accidents. If an emergency arises, knowwhere to get prompt assistance.

Traveling In The Truck

• When traveling on rough ground, travel at lowspeeds. When changing direction, avoid turningsuddenly.

• Lower the dump body and move the dump leverto the FLOAT position before traveling.

• If the engine should stop when the machine is inmotion, the emergency steering system will beactivated. Apply the brakes immediately and stopthe machine as quickly and safely as possible(off of the haul road, if possible). Apply theparking brake.

Precautions When Traveling In Reverse

Before operating themachine or work equip-ment, do as follows:

• Ensure the backup alarm works properly.

• Sound the horn to warn people in the area.

• Check for personnel near the machine. Do athorough check behind the machine.

• When necessary, designate a person to watchthe area for the truck operator. This is particularlynecessary when traveling in reverse.

• When operating in hazardous areas and areaswith poor visibility, designate a person to directwork site traffic.

• DO NOT allow any one to enter the line of travelof the machine. This rule must be strictly obeyedeven with machines equipped with a back-upalarm or rear view mirror.


Traveling On Slopes

• Traveling on slopes could result in the machinetipping over or slipping.

• DO NOT change direction on slopes. To ensuresafety, drive to level ground before turning.

• DO NOT travel up and down on grass, fallenleaves, or wet steel plates. These materials maymake the machine slip on even the slightestslope. Avoid traveling sideways, and alwayskeep travel speed low.

• When traveling downhill, use the retarder toreduce speed. DO NOT turn the steering wheelsuddenly. DO NOT use the foot brake except inan emergency.

• If the engine should stop on a slope, apply theservice brakes to fully and stop the machine.Apply the parking brake after the machine hasstopped.

Ensuring Good Visibility

• When working in dark places, install work lampsand head lamps.

• Discontinue operations if visibility is poor, such asin mist, snow, or rain. Wait for the weather toimprove to allow the operation to be performedsafely.

Operating On Snow

• When working on snowy or icy roads, there isdanger that the machine may slip to the side oneven the slightest slope. Always travel slowlyand avoid sudden starting, turning, or stopping inthese conditions.

• Be extremely careful when clearing snow. Theroad shoulder and other objects are buried in thesnow and cannot be seen. When traveling onsnow-covered roads, always install tire chains.

Avoid Damage To The Dump Body

• When working in tunnels, on bridges, underelectric cables, or when entering an enclosedarea where there are height limits, always useextreme caution. The dump body must becompletely lowered before driving.

Driving with a raised dump body or raising thedump body in an enclosed area, may result inserious damage and bodily injury or death.Always drive with the dump body resting on theframe.

Driving Near High Voltage Cables

• Driving near high-voltage cables can causeelectric shock. Always maintain the safedistances between the machine and the electriccable as listed below.

The following actions are effective in preventing acci-dents while working near high voltages:

• Wear shoes with rubber or leather soles.

• Use a signalman to give warning if the machineapproaches an electric cable.

• If the work equipment should touch an electriccable, the operator should not leave the cab.

• When performing operations near high voltagecables, DO NOT allow anyone to approach themachine.

• Check with the electrical maintenancedepartment about the voltage of the cablesbefore starting operations.

Voltage Minimum Safe Distance6.6 kV 3 m 10 ft.

33.0 kV 4 m 14 ft.66.0 kV 5 m 17 ft.

154.0 kV 8 m 27 ft.275.0 kV 10 m 33 ft.


When Loading The Truck

• Ensure the surrounding area is safe. If so, stopthe machine in the correct loading position andevenly load the body.

• DO NOT leave the operator's seat during theloading operation.

When Dumping

• Before dumping, check that there is no person orobjects behind the machine.

• Stop the machine in the desired location. Checkagain for persons or objects behind the machine.Give the determined signal, then slowly operatethe dump body. If necessary, use blocks for thewheels or position a flagman.

• When dumping on slopes, machine stability ispoor and there is danger of tip over. Alwaysperform such operations using extreme care.

• Never travel with the dump body raised.

Working On Loose Ground

• Avoid operating the machine near cliffs,overhangs, and deep ditches. If these areascollapse, the machine could fall or tip over andresult in serious injury or death. Remember thatground surfaces in these areas may beweakened after heavy rain or blasting.

• Freshly laid soil and the soil near ditches is loose.It can collapse under the weight or vibration ofthe machine. Avoid these areas wheneverpossible.

Parking The Machine

• Choose a horizontal road surface to park themachine. If the machine must be parked on aslope, put blocks under all the wheels to preventthe machine from moving.

• When parking on public roads, provide fences,flags or lights, on the machine to warnpedestrians and other vehicles. Ensure that themachine, flags, or lights DO NOT obstruct thetraffic.

Before leaving the machine, lower the dump bodyfully, activate the parking brake, stop the engine, andlock everything. Always take the key with you.

TOWINGImproper towing methods may lead to serious per-sonal injury and/or damage.

• Tow with a solid tow bar. Do not tow with a cable.

• Use a towing device with ample strength for theweight of this machine.

• Never tow a machine on a slope.

• When connecting a machine to be towed, DONOT allow anyone to go between the towmachine and the disabled machine.

• Set the coupling of the disabled machine in astraight line with the towing portion of the towmachine, and secure it in position.

• DO NOT stand next to the towing device whilethe truck is moving.

(For towing method, see the Operation and Mainte-nance Manual, Section 30, Operating Instructions -Towing.)


WORKING NEAR BATTERIES

Battery Hazard Prevention

• Battery electrolyte contains sulfuric acid and canquickly burn the skin and eat holes in clothing. Ifelectrolyte comes in contact with skin,immediately flush the area with water.

• Battery acid can cause blindness if splashed intothe eyes. If acid gets into the eyes, flush themimmediately with large quantities of water andsee a doctor immediately.

• If acid is accidentally ingested, drink a largequantity of water, milk, beaten eggs or vegetableoil. Call a doctor or poison prevention centerimmediately.

• Always wear safety glasses or goggles whenworking with batteries.

• Batteries generate hydrogen gas. Hydrogen gasis very explosive and is easily ignited with a smallspark of flame.

• Batteries generate hydrogen gas. Hydrogen gasis very EXPLOSIVE, and is easily ignited with asmall spark or flame.

• Before working with batteries, stop the engineand turn the key switch to the OFF position.

• Avoid short-circuiting the battery terminalsthrough accidental contact with metallic objects,such as tools, across the terminals.

• When removing or installing a battery, positivelyidentify the positive (+) terminal and negative (-)terminal and use precautions not to short circuitthe terminals.

• Tighten battery caps securely.

• Tighten battery terminals securely. Looseterminals can generate sparks and lead to anexplosion.

Jump Starting With Booster Cables

• Always wear safety glasses or goggles whenstarting the machine with booster cables.

• While jump starting with another machine, DONOT allow the two machines to touch.

• Be sure to connect thepositive (+) cable firstwhen installing boostercables. Disconnect theground or negative (-)cable first during removal.

• If any tool touchesbetween the positive (+) terminal and thechassis, it will cause sparks. Always use cautionwhen using tools near the battery.

• Connect the batteries in parallel: positive topositive and negative to negative.

• When connecting the ground cable to the frameof the disabled machine, connect the ground asfar as possible from the battery.


PRECAUTIONS FOR MAINTENANCE

BEFORE PERFORMING MAINTENANCE

Stopping The Engine Before Service

• Before performing inspections or maintenance,stop the machine on firm flat ground, lower thedump body, stop the engine and apply theparking brake. Put blocks under the wheels.

• If the engine must be operated during service,always move the shift control lever to theNEUTRAL position and apply the parking brake.Always perform this work with two people. Oneperson must sit in the operator's seat to stop theengine if necessary. Never move any controlsnot related to the task at hand during thesesituations.

• When servicing the machine, use care not totouch any moving parts. Never wear looseclothing.

• When performing service with the dump bodyraised, always place the dump lever in the HOLDposition, and apply the lock (if equipped). Installthe body-up safety pins or cable securely.

Warning Tag

• Never start theengine or operatethe controls while aperson is performingmaintenance.Serious injury ordeath may result.

• Always attach a warning tag to the control lever inthe operator's cab to alert others that you areworking on the machine. Attach additionalwarning tags around the machine, if necessary.

• These tags are available from your Komatsudistributor.

• Part No. 09963-03000

Proper Tools

• Use only tools suited tothe task. Usingdamaged, low quality,faulty, or makeshift toolscan cause personalinjury.

• Extra precaution should be used when grinding,welding, and using a sledge-hammer.

Securing The Dump Body

Any time personnel are required to perform main-tenance on the vehicle with the dump body in theraised position, the body-up retention cableMUST be installed.

1. To hold the dump body in the up position, raisethe body to it's maximum height.

2. Remove cable (3) from its stored position on thebody, and install between rear body ear (1) andaxle housing ear (4).

3. Secure the cable clevis pins with cotter pins.4. Return the cable to stored position (2) after

maintenance is complete.


DURING MAINTENANCE

Personnel

• Only authorized personnel can service and repairthe machine.

Attachments

• Place attachments that havebeen removed from themachine in a safe place andmanner to prevent them fromfalling.

Working Under The Machine

• Always lower all movable workequipment to the ground or totheir lowest position beforeperforming service or repairsunder the machine.

• Always block the tires of the machine securely.

• Never work under the machine if the machine ispoorly supported.

Keeping The Machine Clean

• Spilled oil, grease,scattered tools, etc.can cause you toslip or trip. Alwayskeep your machineclean and tidy.

• If water gets intothe electricalsystem, there is danger that the machine maymove unexpectedly and/or damage tocomponents may occur. DO NOT use water orsteam to clean any sensors, connectors, or theinside of the operator's compartment.

• Use extreme care when washing the electricalcontrol cabinet. DO NOT allow water to enter thecontrol cabinet around the doors or vents. DONOT allow any water to enter the cooling air inletduct above the electrical control cabinet. If waterenters the control cabinet (through any openingor crevice) major damage to the electricalcomponents may occur.

• Never spray water into the rear wheel electricmotor covers. Damage to the wheel motorarmatures may occur.

• DO NOT spray water into the retarding grids.Excess water in the retarding grids can cause aground fault, which will prevent propulsion.

Rules To Follow When Adding Fuel Or Oil

• Spilled fuel and oil may cause slipping. Alwaysclean up spills, immediately.

• Always tighten the cap of the fuel and oil fillerssecurely.

• Never use fuel for washing any parts.

• Always add fuel and oil in a well-ventilated area.

Radiator Coolant Level

• If it is necessary to addcoolant to the radiator, stopthe engine. Allow theengine and radiator to cooldown before adding thecoolant.

• Depress the pressure relief button on the radiatorcap to releive any pressure.

• Slowly loosen the cap to relieve pressure duringremoval.

Use Of Lighting

• When checking fuel, oil, coolant, or batteryelectrolyte, always use lighting with anti-explosion specifications. If lighting without thisprotection is used, there is a danger of explosion.


Precautions With The Battery

• When repairing theelectrical system orwhen performingwelding, remove thenegative (-) terminal ofthe battery to stop theflow of current.

Handling High Pressure Hoses

• DO NOT bend high-pressure hoses or hit themwith hard objects. DO NOT use any bent orcracked piping, tubes or hoses. They may burstduring use.

• Always repair any loose or broken hoses. Fueland/or oil leaks may result in a fire.

Precautions With High Pressure Oil

• Always remember that work equipment circuitsare always under pressure.

• DO NOT add oil, drain oil, or performmaintenance or inspections before completelyreleasing the internal pressure.

• Small, high pressure pin-hole leaks are extremelydangerous. The jet stream of high-pressure oilcan pierce the skin and eyes. Always wear safetyglasses and thick gloves. Use a piece ofcardboard or a sheet of wood to check for oilleakage.

• If you are hit by a jet of high-pressure oil, consulta doctor immediately for medical attention.

Maintenance Near High Temperatures And HighPressures

• Immediately after stopping thetruck, the engine coolant andoperating oils are at hightemperature and under highpressure. In these conditions,opening the system orreplacing filters may result in burns or otherinjury. Wait for the temperature to cool andpressure to subside before performing theinspection and/or maintenance as outlined in theservice manual.

Rotating Fan And Belts

• Keep a safe distance fromrotating parts such as theradiator fan and fan belts.

• Serious bodily injury mayresult from direct or indirectcontact with rotating parts and flying objects.

Waste Materials

• Never dump oil or otherharmful fluids into a sewersystem, rivers, etc.

• Obey appropriate laws andregulations when disposingof harmful objects such asoil, fuel, coolant, solvent,filters, batteries, and others.

• Always put fluids drained from your machine inappropriate containers. Never drain fluids directlyonto the ground.


TIRES

Handling Tires

If tires are not used under the specified conditions,they may overheat and burst, or be cut and burst bysharp stones on rough road surfaces. This may leadto serious injury or damage.

To maintain tire safety, always adhere to the followingconditions:

• Inflate the tires to the specified pressure.Abnormal heat is generated particularly when theinflation pressure is too low.

• Use the specified tires.

The tire inflation pressure and permissible speedsare general values. The actual values may differdepending on the type of tire and the condition whichthey are used. For details, please consult the tiremanufacturer.

When tires become hot, a flammable gas is pro-duced, and may ignite. It is particularly dangerous ifthe tires become overheated while the tires are pres-surized. If the gas generated inside the tire ignites,the internal pressure will suddenly rise, and the tirewill explode, resulting in danger to personnel in thearea. Explosions differ from punctures or tire burstsbecause the destructive force is extremely large.Therefore, the following operations are strictly pro-hibited when the tire is pressurized:

• Welding the rim

• Welding near the wheel or tire.

• Smoking or creating openflames

If the proper procedure for performing maintenanceor replacement of the wheel or tire is not used, thewheel or tire may burst and cause serious injury ordamage. When performing such maintenance, con-sult your authorized regional Komatsu distributor, orthe tire manufacturer.

Storing Tires After Removal

• As a basic rule, store the tires in a warehouse inwhich unauthorized persons cannot enter. If thetires are stored outside, always erect a fencearound the tires and put up “No Entry” and otherwarning signs that even young children canunderstand.

• Stand the tire on level ground, and block itsecurely so that it cannot roll or fall over.

• If the tire should fall, flee the area as quickly aspossible. The tires for off-road equipment areextremely heavy. Never attempt to hold a tireupright when the tire is falling. This may lead toserious injury or death.


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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WHEN REPAIRS ARE NECESSARY1. Only qualified maintenance personnel who

understand the systems being repaired shouldattempt repairs.

2. Many components on the Komatsu truck arelarge and heavy. Ensure that lifting equipment -hoists, slings, chains, lifting eyes - are of ade-quate capacity to handle the lift.

3. DO NOT stand under a suspended load. DONOT work under raised body unless bodysafety cables, props, or pins are in place to holdthe body in up position.

4. DO NOT repair or service the truck while theengine is running, except when adjustmentscan only be made under such conditions. Keepa safe distance from moving parts.

5. When servicing any air conditioning system withrefrigerant, wear a face shield and cold resistantgloves for protection against freezing. Be cer-tain to follow all current regulations for handlingand recycling refrigerants.

6. Follow package directions carefully when usingcleaning solvents.

7. If an auxiliary battery assist is needed, first useone cable to connect the 24V positive (+) postof the disabled truck batteries to the 24V posi-tive (+) post of the auxiliary assist. Use secondcable to connect the 24V negative (-) post of theauxiliary assist battery to a frame ground (-) onthe disabled truck away from the battery.

8. Always disconnect the positive and negativebattery cables of the vehicle before doing anywelding on the unit. Failure to do so may seri-ously damage the battery and electrical equip-ment. Disconnect the battery chargingalternator lead wire and isolate electronic con-trol components before making welding repairs.(It is not necessary to disconnect or remove anycontrol circuit cards on electric drive dumptrucks or any of the Alarm Indicating Device(AID) circuit control cards.)Always fasten the welding machine ground (-) lead to the piece being welded; the grounding clamp must be attached as near as possible to the weld area. Never allow welding current to pass through ball bearings, roller bearings, sus-pensions, or hydraulic cylinders. Always avoid laying welding cables over or near the vehicle electrical harnesses. Welding voltage could be induced into the electrical harness and cause damage to components.

9. If a truck is to be towed for any reason, use arigid tow bar. Check the truck cab for decals forspecial towing precautions. (Also refer to theOperation and Maintenance Manual, OperatingInstructions - Towing.)

10. Drain, clean and ventilate fuel tanks and/orhydraulic tanks before making any weldingrepairs.

Any operating fluid, such as hydraulic oil orbrake fluid escaping under pressure, can havesufficient force to enter a person's body by pene-trating the skin. Serious injury and possiblydeath may result if proper medical treatment by aphysician familiar with this injury is not receivedimmediately.

11. Relieve pressure in lines or hoses before mak-ing any disconnects.

12. After adjustments or repairs, replace all shields,screens and clamps.

13. Working near tires can be dangerous. Useextreme caution when working around tires.

DO NOT stand in front of a rim and locking ringwhen inflating a tire mounted on the machine.Observers must not be permitted in the area.

DO NOT weld or apply heat to the rim assemblywith the tire mounted on the rim. Resulting gasesinside the tire may ignite, causing explosion ofthe tire and rim.

14. Only a qualified operator or experienced main-tenance personnel who are also qualified inoperation can move the truck under its ownpower in the repair facility or during road testingafter repairs are complete.


SPECIAL PRECAUTIONS FOR WORKING ON A 830E-AC TRUCKPreliminary Procedures before Welding or Per-forming Maintenance

Prior to welding and/or repairing a 830E-AC dumptruck, maintenance personnel should attempt tonotify a Komatsu service representative. Only quali-fied personnel, specifically trained for servicing theAC drive system, should perform this service.

If it is necessary to perform welding or repair to thetruck without the field engineer present, the followingprocedures should be followed to ensure that thetruck is safe for maintenance personnel to work onand to reduce the chance for damage to equipment.

Anytime the engine is operating:

• DO NOT open any of the cabinet doors orremove any covers.

• DO NOT use any of the power cables for handholds or foot steps.

• DO NOT touch the retarding grid elements.

Before opening any cabinets or touching a gridelement or a power cable, the engine must beshutdown and the red drive system warninglights must not be illuminated.

Engine Shutdown Procedure before Welding orPerforming Maintenance

Normal operation of the drive system at shutdownshould leave the system safe to maintain. However,in the event of a system failure, performing the fol-lowing procedure prior to any maintenance activitieswill ensure that no hazardous voltages are present inthe AC drive system.

1. Before shutting down the engine, verify the sta-tus of all the drive system warning lights on theoverhead display panel. Use the lamp testswitch to verify that all lamps are functioningproperly.

If any of the red drive system warning lightsremain on, DO NOT attempt to open any cabi-nets, disconnect any cables, or reach inside theretarder grid cabinet without a trained drive sys-tem technician present - even if engine is off. Only qualified personnel, specifically trained for servicing the A-C drive system, should perform this service.

2. If all red drive system warning lights are off, fol-low the “Normal Engine Shutdown Procedure”.

3. After the engine has been off for at least fiveminutes, inspect the link voltage lights on theexterior of the main control cabinet and rear ofthe center console. If all lights are off, the retardgrids, wheel motors, alternator, and relatedpower cables are safe to work on.

4. Locate the GF cut-out switch in the accesspanel on the left side of the main control cabi-net. Place the switch in the CUTOUT position.This will prevent the alternator from re-energiz-ing and creating system voltage until the switchis returned to the previous position.

5. Before welding on the truck, disconnect all elec-trical harnesses from the Engine Control Sys-tem (ECS) inside the electrical cabinet behindthe operator's cab. Also, disconnect the groundstrap from the ECS.


6. DO NOT weld on the rear of the control cabinet!The metal panels on the back of the cabinet arepart of capacitors and cannot be heated.

7. DO NOT weld on the retard grid exhaust lou-vers - they are made of stainless steel. Somepower cable panels throughout the truck arealso made of aluminum or stainless steel. Theymust be repaired with the same material or thepower cables may be damaged.

8. Power cables must be cleated in wood or othernon-ferrous materials. DO NOT repair cablecleats by encircling the power cables with metalclamps or hardware. Always inspect powercable insulation prior to servicing the cables andprior to returning the truck to service. Discardcables with broken insulation.

9. Power cables and wiring harnesses should beprotected from weld spatter and heat.

Always fasten the welding machine ground (-)lead to the piece being welded; the groundingclamp must be attached as near as possible tothe weld area.

Always avoid laying welding cables over ornear the vehicle electrical harnesses. Weldingvoltage could be induced into the electrical har-ness and cause damage to components.

Before doing any welding on the truck, alwaysdisconnect the battery charging alternator leadwire and isolate electronic control components.

In addition, always disconnect the positive andnegative battery cables of the vehicle. Failureto do so may seriously damage the battery andelectrical equipment.

Never allow welding current to pass throughball bearings, roller bearings, suspensions, orhydraulic cylinders.

10. If the red lights on the exterior of the controlcabinet and/or the back wall of the center con-sole continue to be illuminated after followingthe above procedure, a fault has occurred.

Leave all cabinet doors in place; DO NOT touchthe retard grid elements; DO NOT disconnectany power cables, or use them as hand or footholds.

Notify your Komatsu service representative,immediately. Only qualified personnel, specifi-cally trained for servicing the A-C drive system,should perform this service.

11. Replace all covers and doors and place the GFcutout switch and battery disconnect switchesin their original positions. Reconnect all har-nesses prior to starting the truck.

Leave the drive system in the rest mode untilthe truck is to be moved.

OM2212 Warnings And Cautions - Section 22Page 22-1

WARNINGS AND CAUTIONSThe following pages give an explanation of the warn-ing, caution, and service instruction plates anddecals attached to the truck. The plates and decalslisted here are typical of this Komatsu model, butbecause of customer options, individual trucks mayhave plates and decals that are different from thoseshown here.

The plates and decals must be kept clean and legi-ble. If any decal or plate becomes illegible or dam-aged, it must be replaced with a new one.

A warning decal surrounds the key switch located tothe right of the steering column on the instrumentpanel. The warning stresses the importance of read-ing the operator's manual before operation.

A grade/speed retard chart is located on the left frontpost of the operator's cab and provides the recom-mended MAXIMUM speeds to be used whendescending various grades with a loaded truck.Always refer to the decal in operator's cab. Thisdecal may change with optional truck equipmentsuch as: wheel motor drive train ratios, retarder grids,tire sizes, etc.

A plate attached to the right rear corner of thecab states the Rollover Protective Structure(ROPS) and Falling Object Protective Structure(FOPS) meets various SAE performancerequirements.

! WARNING! Do not make modifications tothis structure, or attempt to repair damagewithout written approval from Komatsu.Unauthorized repairs will void certification.

Warnings And Cautions - Section 22 OM2212Page 22-2

Attached to the exterior of both battery compart-ments is a danger plate. This plate stresses the needto keep from making any sparks near the battery.When another battery or 24VDC power source isused for auxiliary power, all switches must be OFFprior to making any connections. When connectingauxiliary power cables, positively maintain correctpolarity. Connect the positive (+) posts together andthen connect the negative (-) lead of the auxiliarypower cable to a good frame ground. Do not con-nect to the negative posts of the truck battery ora ground near the battery box. This hookup com-pletes the circuit but minimizes danger of sparks nearthe batteries.

Sulfuric acid is corrosive and toxic. Use proper safetygear, goggles, rubber gloves and rubber apron whenhandling and servicing batteries. Get proper medicalhelp immediately, if required.

This plate is placed on both battery boxes and nearthe battery disconnect switches to indicate that thebattery system (24VDC) is a negative (-) ground sys-tem.

These decals are placed above the battery discon-nect switches on the right side of the front bumper toindicate OFF and ON positions of the switches.


A warning plate is mounted on top of the radiatorsurge tank cover near the radiator cap. The enginecooling system is pressurized. Always turn the keyswitch OFF and allow the engine to cool beforeremoving the radiator cap. Unless the pressure isfirst released, removing the radiator cap after theengine has been operating for a time will result in thehot coolant being expelled from the radiator. Seriousscalding and burning may result.

Warning plates are mounted on the frame in front of,and to the rear, of both front tires. All personnel arewarned that the clearances change when the truck issteered and could cause serious injury.

Warning plates are attached to both the hydraulictank and fuel tank to alert technicians not to work onthe truck with the body in the raised position unlessthe body-up retention device (pins or cable) is inposition.


These danger plates are mounted on the outside ofeach frame rail to alert technicians to read the warn-ing labels attached to the side of each of the accumu-lators (see below) prior to releasing internal nitrogenpressure or disconnecting any hydraulic lines orhardware. There are similar decals mounted on topof each of the accumulators (both steering andbrake) with the same danger message.

This danger plate is attached to all four suspensions.

The plate contains instructions for releasing internalpressure before disconnecting any hardware.

Serious injury can occur if these directions are notfollowed.

A plate on the side of the hydraulic tank furnishesinstructions for filling the hydraulic tank.

Keep the system open to the atmosphere only aslong as absolutely necessary to lessen the chancesof system contamination. Service the tank with cleanType C-4 hydraulic oil. All oil being put into thehydraulic tank must be filtered using filters rated atthree microns.

A caution decal is attached below the hydraulic tankoil level sight gauge. Check level with body down,engine stopped, and key switch OFF. Add oil per fill-ing instructions, if oil level is below top of sight glass.


A warning plate is attached to the hydraulic tank toinform technicians that high pressure hydraulic oil ispresent during operation. When it is necessary toopen the hydraulic system, Ensure the engine isstopped and key switch is OFF to bleed downhydraulic pressure. There is always a chance ofresidual pressure being present. Open fittings slowlyto allow all pressure to bleed off before removing anyconnections.

Any operating fluid, such as hydraulic oil, escap-ing under pressure can have sufficient force toenter a person's body by penetrating the skin.Serious injury and possibly death may result ifproper medical treatment by a physician familiarwith this injury is not received immediately.

A wheel motor oil level decal is attached to the gearcover on both electric wheel motors. This decalstresses the fact that the truck must be on a levelsurface and parked for 20 minutes prior to checkingthe oil level. This is necessary in order to get anaccurate reading.

A decal plate located on the frame near the left hoistcylinder provides the operator or technician with thehook-up procedure for dumping a loaded, disabledtruck. The use of a functional truck for hydraulicpower is required.

Refer to the Section L for additional instructions forusing this procedure.

Warning decals are applied to both brake accumula-tors located inside the brake system cabinet behindthe operator cab. These decals remind servicingtechnicians to close the accumulator drain valvesafter they have been opened to bleed brake pres-sure. It further warns not to over-tighten the drainvalves to prevent damage to the valve seat(s).


A decal plate is located on the frame near the lefthoist cylinder. It provides the operator or technicianwith the hydraulic hook-up procedure before towing adisabled truck, by using a functional truck for hydrau-lic power.

This warning decal is located below the battery dis-connect switches to warn personnel not to discon-nect the batteries during the first 90 seconds afterturning the key switch off.

This decal is located on the automatic lubrication res-ervoir informing the technician that the cover shouldnever be removed for filling purposes as there ispotential for dirt or debris entering the system.Always fill the grease reservoir through the couplingprovided where the grease passes through a filterbefore entering the reservoir.


This caution decal is placed near the battery discon-nect switches on the right side of the front bumper toalert servicing technicians that before doing anywelding on the truck, always disconnect the batterycharging alternator lead wire and isolate electroniccontrol components before making welding repairs.

In addition, always disconnect the positive and nega-tive battery cables of the vehicle. Failure to do somay seriously damage the battery and electricalequipment.

Always fasten the welding machine ground (-) lead tothe piece being welded; grounding clamp must beattached as near as possible to the weld area.Never allow welding current to pass through ballbearings, roller bearings, suspensions, or hydrauliccylinders. Always avoid laying welding cables over ornear the vehicle electrical harnesses. Welding volt-age could be induced into the electrical harness andpossibly cause damage to components.

A high voltage danger plate is attached to the door ofthe rear hatch cover. High voltage may be present!

Only authorized personnel can access this rearhousing.

A caution decal is also attached to the door of therear hatch cover to alert personnel that hot exhaustair is present and may cause injury.

This caution decal is also placed around the retard-ing grid cabinet.

These warning plates are mounted on all of the ACdrive control housings and cabinets.

High voltage may be present, with or without, theengine running!

Only authorized personnel can access these cabi-nets.


This caution decal is placed on the back of the con-trol cabinet to alert service technicians that this areacontains capacitors and must not be disturbed in anymanner.

This information decal is placed on the outside of thedoor panel on the control cabinet wall that faces theright side of the operator cab.

This decal is placed near three different indicatorlights:

• In the operator cab, on the rear of the centerconsole.

• On the front of the control box which is mountedon the right side of the main control cabinet.

• On the outside of the left control cabinet wall thatfaces the right side of the operator cab. (See alsoInformation decal above.)

When any of these indicator lights are on, highvoltage is present throughout the propulsion andretarding system. Extreme care should be exer-cised!


This decal is placed on the ground level engine shut-down switch which is mounted on the right side of thefront bumper structure. It specifies that this switch isfor emergency shutdown only.

This page illustrates a variety of decals which aremounted on deck mounted cabinets, housings, andstructures which must be lifted in a specific manner,and from specific points, in order to safely move or liftany of these structures.

If any of these decals are damaged or defaced, sothat it is no longer legible, it should be replacedimmediately.

Maintenance personnel must follow these liftinginstructions.


A product identification plate is located on the framein front of the right side front wheel and shows thetruck model number, maximum GVW and ProductIdentification Number (PIN).

The PIN consists of 19 total characters. The first andlast characters are tamper preventative symbols (*).The remaining 17 alpha/numeric characters are usedto identify 5 characteristics of the machine. The 5characteristics are detailed below.

WMC - Character positions 1, 2 and 3 identify theWorldwide Manufacturer Code (WMC). The WMCdesignates the manufacturer of the product. Komatsubrand products are identified with the letters KMT.

MDS - Character positions 4, 5, 6, 7 and 8 identifythe Machine Descriptor Section (MDS). The MDScode identifies general information regardingmachine specifications. The MDS is a code for themachine type and model.

CL - Character position 9 identify the Check Letter(CL). The CL is used to verify the accuracy of theindividual PIN.

FC - Character positions 10 and 11 identify the Fac-tory Code (FC). The FC identifies the Komatsu fac-tory in charge of claims for the product. The FC forelectric drive trucks is 61.

SN - Character positions 12, 13, 14, 15, 16, and 17identify the Serial Number (SN). The SN is a uniquesequential number.


The lubrication chart is mounted on the right hand side of the radiator grille structure. Refer to Section P, Lubrica-tion and Service, in this manual for more complete lubrication instructions.


NOTES:

OM3047 Operating Instructions - Section 30Page 30-1

TRUCK OPERATION

PREPARING FOR OPERATIONThe safest trucks are those which have been prop-erly prepared for operation. At the beginning of eachshift, a careful check of the truck must be made bythe operator before starting the engine.

Safety Is Thinking Ahead

Prevention is the best safety program. Prevent apotential accident by knowing the employer's safetyrequirements, all necessary job site regulations, aswell as use and care of the safety equipment on thetruck. Only qualified operators or technicians canoperate or maintain a Komatsu truck.

Safe practices start before the operator gets to theequipment!

• Wear the proper clothing. Loose fitting clothing,unbuttoned sleeves and jackets, jewelry, etc.,can catch on a protrusion and cause a potentialhazard.

• Always use the personal safety equipmentprovided for the operator such as hard hats,safety shoes, safety glasses or goggles. Thereare some conditions when protective hearingdevices must also be worn for operator safety.

• When walking to and from the truck, maintain asafe distance from all machines, even if theoperator is visible.

WALK AROUND INSPECTIONAt the beginning of each shift, a careful walk aroundinspection of the truck must be performed before theoperator attempts engine start-up. A walk aroundinspection is a systematic ground level inspection ofthe truck and its components to ensure that the truckis safe to operate before entering the operator's cab.

Start at the left front corner of the truck (see illustra-tion, next page), and move in a counter-clockwisedirection. Move front-to-rear, across the rear, andcontinuing forward up the opposite side of the truckto the original starting point.

If these steps are performed in sequence, and arerepeated from the same point and in the same direc-tion before every shift, many potential problems maybe avoided, or scheduled for maintenance. Unsched-uled downtime and loss of production can bereduced as a result.

Local work practices may prevent an operator fromperforming all tasks suggested here. To the extentpermitted, the operator should follow this or a similarroutine.

High voltage may be present on this truck! DONOT open any electrical cabinet doors on thetruck while the engine is operating! Never climbon any power cables or use power cables forhandholds or footholds, unless the engine hasbeen shut off and the system has been verifiedas at rest!

1. Start at left front of the truck. While performingthe walk around inspection, visually inspect alllights and safety equipment for external dam-age from rocks or misuse. Ensure lenses areclean and unbroken.

Empty the dust pans on the left side of the aircleaners. Ensure the battery box covers are inplace and secure.

2. Move behind the front of the left front tire.Inspect the hub and brake assemblies for leaksand any abnormal conditions.

3. Check that all suspension attaching hardware issecure and inspect the mounting key area forevidence of wear. Check that the suspensionrod extension is correct, and that there are noleaks. Ensure the suspension protective boot isin good condition.

4. Inspect the anchor end of the steering cylinderfor proper greasing and all parts are secure.

5. With the engine stopped, check the engine oillevel. Use the service light if necessary.

6. Inspect air conditioner belts for correct tension,obvious wear, and tracking. Inspect fan guardsecurity and condition. When leaving this point,be sure to turn off the service light, if used.

7. Move outboard of the front wheel. Inspectattaching lugs/wedges to be sure all are tightand complete. Inspect the tires for cuts, dam-age or bubbles. Check tire inflation pressure.Check sight glass for front wheel oil level.

Operating Instructions - Section 30 OM3047Page 30-2

START HERE

Walk Around Inspection


8. Move behind the front wheel and inspect thesteering cylinder. Check for proper greasingand inspect the mounting hardware to ensure itis all in place. Inspect the suspension mountinghardware to ensure it is all in place. Ensure thesuspension protective boot is in good condition.Inspect the hub and brakes for any unusualconditions. Check the entire area for leaks.

9. Inspect the sight glass on the hydraulic tank.With the engine stopped and body down,hydraulic fluid must be visible in the upper sightglass.

10. Verify all hydraulic tank shut off valves arelocked in their fully open positions.

11. Move around the hydraulic tank and in front ofthe rear dual tires. Inspect the hoist cylinder forany damage and leaks. Inspect both upper andlower hoist cylinder pins for integrity and forproper greasing.

12. Before leaving this position, look under thelower edge of the chassis to ensure the flexibleduct that carries the air from the blower to thefinal drive housing is in good condition with noholes or breakage. Also, look up at the mainhydraulic pumps to see that there is no leakageor any other unusual condition with the pumpsor the pump drive shafts.

13. Move around the dual tires, and check to seethat all lugs/wedges are in place and tight.Inspect latches on the wheel cover to be surethey are properly latched. Inspect the wheel forany oil that would indicate brake leakage orwheel motor leakage.

Check the dual tires for cuts, damage or bub-bles. Verify that inflation appears to be correct.If the truck has operating on a flat tire, the tiremust be cool before moving the truck inside abuilding. Check for any rocks that might belodged between the dual tires. Inspect the rockejector condition and straightness so that it cannot damage a tire.

14. Inspect the left rear suspension for damage andfor correct rod extension. Check for leaks.Ensure that the covers over the chrome pistonrod are in good condition. Inspect for propergreasing.

15. Open the rear hatch cover, turn on work light, ifnecessary. Inspect for leaks around wheelmotor mounting to rear housing, and also brakehoses and fittings. ensure that covers on wheelmotor sump are in place, and that there are norags or tools left behind. Inspect condition ofhatch cover gasket, report any bad gasket tomaintenance. Turn off work light if used, closeand latch hatch.

16. While standing in front of the rear hatch, look upto see that rear lights are in good condition,along with the back-up horns. Look up at thepanhard rod to see that it is getting propergreasing. Also look at both body hinge pins forgreasing and any abnormal condition. Checkhoist limit switch and clear any mud/debris fromcontacts.

17. Perform the same inspection on the right rearsuspension as done on the left.

18. Move around the right dual tires. Inspectbetween the tires for rocks, and check the con-dition of the rock ejector. Inspect the tires forcuts or damage, and for correct inflation.

19. Perform the same inspection for wheel lugs/wedges, wheel cover latches, and wheel leaksthat was done on the left hand dual wheels.

20. Move in front of the right dual tires and inspectthe hoist cylinder in the same manner as the leftside. Check integrity and condition of the body-up limit switch. Remove any mud/dirt accumula-tion from the switch.

21. Move around the fuel tank. Inspect the fuel sightgauge, (this should agree with what will showon the gauge in the cab). Inspect the attachinghardware for the fuel tank at the upper saddles,and then at the lower back of the tank for thesecurity and condition of the mounts. Check thehoist filters for leaks.

22. Move behind the right front wheel, and inspectthe steering cylinder. Check for proper greasingand inspect the mounting hardware. Check thesuspension mounting hardware and suspensionextension. Ensure the suspension protectiveboot is in good condition. Inspect the hub andbrakes for any unusual conditions. Check theentire area for leaks.


23. Move around the right front wheel; check that alllugs/wedges are in place and tight.

24. Move in behind the front of the right front wheel,check the hub and brakes for leaks and anyunusual condition. Check the hoist filters forleaks. Inspect the steering cylinder for secure-ness and for proper greasing. Inspect theengine compartment for any leaks and unusualconditions. Inspect the fan guard and belts.Check for any rags or debris behind the radia-tor.

25. Inspect the auto lube system. See AutomaticLubrication System in Section P, for specificdetails concerning the auto lube system.

26. Move around to the right front of the truck, dropthe air cleaner pans and empty. Inspect the bat-tery box cover for damage and ensure it is inplace and secure.

27. As you move in front of the radiator, inspect forany debris in the radiator and remove. Checkfor any coolant leaks. Inspect headlights andfog lights.

28. Ensure the ground level engine shutdownswitch is ON. Inspect the fire control actuator toensure the safety pin is in place and the plastictie that prevents accidental actuation is in placeand in good condition. Ensure the battery dis-connect switches are ON. Always use grab railsand the ladder when mounting or dismountingthe truck. Clean the ladder and hand rails of anyforeign material, such as ice, snow, oil or mud.

29. Use the stairs and handrails while climbing fromthe first level to the cab deck.

Always mount and dismount ladders facing thetruck. Never attempt to mount or dismount whilethe truck is in motion.

30. When checking the coolant level in the radiator,use the coolant level sight gauge. If it is neces-sary to remove the radiator cap, relieve coolantpressure by depressing the pressure relief but-ton, and then slowly removing the radiator cap.

If the engine has been running, allow the coolantto cool before removing the fill cap or drainingthe radiator. Serious burns may result if skincomes in contact with hot coolant.

31. Inspect the covers over the retarding grids andensure they are secure. Inspect the main airinlet to ensure it is clear. Ensure all cabinet doorlatches are secure.

32. Move to the back of the cab. Open the doors tothe brake cabinet and inspect for leaks.

33. Clean the cab windows and mirrors. Clean outthe cab floor as necessary. Ensure steeringwheel, controls and pedals are free of any oil,grease or mud.

34. Stow personal gear in the cab in a manner thatdoes not interfere with truck operation. Dirt ortrash buildup, specifically in the operator's cab,must be cleaned. DO NOT carry tools or sup-plies in the cab of the truck or on the decks.

35. Adjust the seat and the steering wheel for use.

36. Read and understand the description of alloperator controls. Become familiar with all con-trol locations and functions before operating thetruck.


ENGINE START-UP SAFETY PRACTICES

Never attempt to start the engine by shortingacross the cranking motor terminals. This maycause a fire, or serious injury or death to anyonein the machine’s path.

Start the engine from the operator’s seat only.

1. Ensure all personnel are clear of the truckbefore starting the engine. Always sound thehorn as a warning before actuating any opera-tional controls. If the truck is in an enclosure,ensure there is adequate ventilation beforestart-up. Exhaust fumes are dangerous!

2. The P-F-N-R selector switch must be in thePARK position before starting.

NOTE: The park brake will always be appliedwhenever the P-F-N-R switch is in the park position.

Move the rest switch to the ON position to putthe drive system in rest mode of operation.Refer to discussion of the rest switch in Section32, Operator Cab Controls.

3. If the truck is equipped with auxiliary coldweather heater system(s), DO NOT attempt tostart the engine while the heaters are in opera-tion. Damage to coolant heaters will result!

4. The key switch is a three position (OFF, RUN,START) switch. When the switch is rotated oneposition clockwise, it is in the RUN position andall electrical circuits (except START) are acti-vated.

a. Turn key switch to the RUN (not START)position.

b. With the selector switch in PARK, rotate thekey switch fully clockwise to the START posi-tion, and hold this position until the enginestarts (see NOTE below). The START posi-tion is spring-loaded and will return to RUNwhen the key is released.

c. After the engine has started, place the restswitch in the OFF position to enable the drivesystem. Refer to the discussion on the restswitch, in 32, Operator Cab Controls.

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

If truck is equipped with optional engine starting aidand ambient temperature is below 10°C (50°F), turnthe key switch to the START position, and whilecranking the engine, move the engine starting aidswitch to the ON position for three seconds MAXI-MUM, then release engine starting aid. If the enginedoes not start, wait at least 15 seconds beforerepeating the procedure.

DO NOT crank electric cranking motors for morethan 30 seconds. Allow two minutes for coolingbefore attempting to start the engine again.Severe damage to the cranking motors mayresult from overheating.

NOTE: This truck is equipped with an engine prelubesystem. With this feature, a noticeable time delaymay occur (while engine lube oil passages are beingfilled and pressurized) before engine cranking willbegin.


AFTER ENGINE HAS STARTED1. Become thoroughly familiar with steering and

emergency controls. After the engine has beenstarted, do not accelerate engine speed ordrive truck until low pressure and warning sys-tems are normal, and the coolant temperatureis at least 71°C (160°F).

2. Test the truck steering in extreme right and leftdirections. If the steering system is not operat-ing properly, shut the engine off immediately.Determine the steering system problem andhave it repaired before resuming operation.

3. Operate each of the truck's brake circuits atleast twice prior to operating and moving thetruck. These circuits include individual activa-tion from the operator's cab of the servicebrake, parking brake, and brake lock. With theengine running and with the hydraulic circuitfully charged, activate each circuit individually.To operate the park brake, the P-F-N-R levermust be in the PARK position. If any applicationor release of any brake circuit appears sluggishor improper, or if warning alarms are activatedon application or release, shut the engine offand notify maintenance personnel. DO NOToperate the truck until the brake circuit in ques-tion is fully operational.

4. Check the gauges, warning lights and instru-ments before moving the truck to ensure propersystem operation and proper instrument func-tioning. Pay special attention to braking andsteering circuit hydraulic warning lights. If warn-ing lights come on, shut off the engine immedi-ately and determine the cause.

5. Ensure the headlights, work lights and taillightsare in proper working order. Good visibility mayprevent an accident. Check operation of thewindshield wipers.

Additional Guidelines1. When the truck body is raised, DO NOT allow

anyone beneath it unless the body-up retainingcable is in place.

2. DO NOT use the fire extinguisher for any pur-pose other than putting out a fire! If an extin-guisher is discharged, report the occurrence sothe used unit can be refilled or replaced.

3. DO NOT allow unauthorized personnel to ridein the truck. DO NOT allow anyone to ride onthe ladder or outside of the truck cab. Passen-gers must be belted into the passenger seatduring travel.

4. DO NOT leave the truck unattended while theengine is running. Move the P-F-N-R lever toPARK, then shut the engine off before gettingout of the cab.

MACHINE OPERATION SAFETY PRECAUTIONSAfter the truck engine is started and all systems arefunctioning properly, the operator must follow all localsafety rules to ensure safe machine operation.

If any of the red warning lights illuminate or if anygauge reads in the red area during truck opera-tion, a malfunction is indicated. Stop the truck assoon as safety permits, and stop the engine.Have the problem corrected before resumingtruck operation.

The truck is equipped with "slip/slide" control. Ifthis function should become inoperative, operat-ing the truck with stalled or free spinning wheelmotors may cause serious damage to wheelmotors! If the truck does not begin to movewithin ten seconds after depressing the throttlepedal (selector switch in a drive position),release the throttle pedal and allow wheels toregain traction before accelerating again.

1. Always look to the rear before reversing thetruck. Watch for and obey the ground spotter'shand signals before traveling in reverse. Soundthe horn (three blasts). The spotter will have aclear view of the total area at the rear of thetruck.

2. Operate the truck only while properly seatedwith seat belt fastened. Keep hands and feetinside the cab compartment while the truck is inoperation.


3. Check gauges and instruments frequently dur-ing operation for proper readings.

4. Observe all regulations pertaining to the jobsite's traffic patterns. Be alert to any unusualtraffic patterns. Obey the spotter's signals.

5. Match the truck speed to haul road conditionsand slow the truck in congested areas. Keep afirm grip on the steering wheel at all times.

6. DO NOT allow the engine to run at idle forextended periods of time.

7. Check the brake lock performance periodicallyto ensure safe loading and dumping.

DO NOT use the brake lock for parking. When theengine is turned off, hydraulic pressure will bleeddown, allowing the brakes to release!

8. Proceed slowly on rough terrain to avoid deepruts or large obstacles. Avoid traveling close tosoft edges and near the edges of a fill area.

9. Truck operation requires a concentrated effortby the driver. Avoid distractions of any kindwhile operating the truck.

MACHINE OPERATION ON THE HAUL ROAD

1. Always stay alert! If unfamiliar with the haulroad, drive with extreme caution. Cab doorsmust remain closed at all times if the truck is inmotion or unattended.

2. Obey all road signs. Keep the truck under con-trol at all times. Govern truck speed by the roadconditions, weather and visibility. Report poorhaul road conditions immediately. Muddy or icyroads, pot holes or other obstructions canpresent hazards.

3. Initial propulsion with a loaded truck shouldbegin from a level surface whenever possible.At times, starting on a hill or grade cannot beavoided. Refer to Starting On A Grade With ALoaded Truck later in this chapter.

4. Before traveling in reverse, give a back-up sig-nal of three blasts on the horn. Before startingforward, signal with two blasts on the horn.These signals must be given each time thetruck is moved forward or backward.

5. Use extreme caution when approaching a haulroad intersection. Maintain a safe distance fromoncoming vehicles.

6. Maintain a safe distance when followinganother vehicle. Never approach another vehi-cle from the rear, in the same lane, closer than15 m (50 ft). When driving on a down grade, thisdistance should not be less than 30 m (100 ft).

7. DO NOT stop or park on a haul road unlessunavoidable. If the truck must be stopped on ahaul road, park in a safe place, move the P-F-N-R selector to PARK, and shut the engine offbefore leaving the cab. Block the wheelssecurely and notify maintenance personnel forassistance.

8. While driving on a slope, maintain a speed thatwill ensure safe driving and provide effectiveretarding under all conditions (Refer to DynamicRetarding, in Section 32 Operator Cab Con-trols.) The grade/speed retard chart in the oper-ator's cab should always be referenced todetermine maximum safe truck speeds fordescending various grades with a loaded truck.

9. When operating the truck in darkness, or whenvisibility is poor, DO NOT move the truck unlessall headlights, clearance lights, and tail lightsare on. DO NOT back the truck if the back-uphorn or lights are inoperative. Always dim theheadlights when approaching oncoming vehi-cles.

10. If the emergency steering light and/or low brakepressure warning light illuminate during opera-tion, immediately steer the truck to a safe stop-ping area, away from other traffic if possible.Refer to item 7 above.

11. Check the tires for proper inflation during eachshift. If the truck has been operating on a flat orunder-inflated tire, the truck must remain out-side of any buildings until the tire cools.


STARTING ON A GRADE WITH A LOADED TRUCKInitial propulsion with a loaded truck should beginfrom a level surface whenever possible. There arecircumstances when starting on a hill or grade cannotbe avoided. In these instances use the following pro-cedure:

1. Fully depress the service brake pedal (DO NOTuse retarder lever) to hold the truck on thegrade. With the service brakes fully applied,move the selector switch to a drive position(FORWARD/REVERSE) and increase enginerpm with the throttle pedal.

2. As engine rpm approaches maximum, andwhen propulsion effort is felt working againstthe brakes, release the brakes and allow truckmovement. Be sure to completely release theservice brake pedal. As truck speed increasesabove 5-8 kph (3-5 mph) the PSC will drop pro-pulsion if the retarder is still applied.

NOTE: Releasing and reapplying dynamic retardingduring a hill start will result in loss of propulsion.

PASSING1. DO NOT pass another truck on a hill or on a

blind curve!2. Before passing, ensure the road ahead is clear.

If a disabled truck is blocking your lane, slowdown and pass with extreme caution.

3. Use only the areas designated for passing.

LOADING1. Approach the loading area with caution.

Remain at a safe distance while the truckahead is being loaded.

2. DO NOT drive over unprotected power cables.3. When approaching or leaving a loading area,

watch for other vehicles and for personnel work-ing in the area.

4. When pulling in under a loader or shovel, followthe spotter’s or the shovel operator’s signals.The truck operator may speed up loading byobserving the location and loading cycle of thetruck being loaded ahead, and then following asimilar pattern.

5. During loading, the operator must stay in thetruck cab with the engine running. Place theselector switch in NEUTRAL and apply thebrake lock.

6. When loaded, pull away from the shovel asquickly as possible with extreme caution.

DUMPING

Raising The Dump Body1. Approach the dump area with extreme caution.

Ensure the area is clear of persons andobstructions, including overhead utility lines.Obey signals as directed by the spotter, ifpresent.

2. Avoid unstable areas. Keep a safe distancefrom the edge of the dump area. Position thetruck on a solid, level surface before dumping.

As the body raises, the truck center of gravity willmove. The truck must be on level surface to pre-vent tipping/rolling!

3. Carefully maneuver the truck into the dumpposition. When backing the truck into the dumpposition, use only the brake pedal to stop andhold the truck; DO NOT rely on the brake lock tostop the truck; this control is not modulated andapplies the rear service brakes only.


4. When the truck is stopped and in dump posi-tion, apply the brake lock and move the selectorswitch to the NEUTRAL position.

The dumping of very large rocks (10% of payload,or greater) or sticky material (loads that do notflow freely from the body) may allow the materialto move too fast and cause the body to moveRAPIDLY and SUDDENLY. This sudden move-ment may jolt the truck violently and cause pos-sible injury to the operator, and/or damage to thehoist cylinders, frame, and/or body hinge pins. Ifit is necessary to dump this kind of material,slowly accelerate engine rpm while raising thebody. When the material starts to move, releasethe hoist lever to the HOLD position. If the mate-rial does not continue moving and clear the body,repeat this procedure until the material has beendumped.

5. Pull the lever to the rear (to HOIST position) toactuate the hoist circuit. (Releasing the leveranywhere during the raise cycle will hold thebody at that position.)

6. Raise engine rpm to accelerate hoist speed. 7. Reduce the engine rpm as the last stage of the

hoist cylinder begins to extend. Keep enginespeed at low idle as the last stage reaches half-extension.

8. Release the hoist lever as the last stage of thehoist cylinder reaches full extension.

Lowering The Dump Body

(When dumping on flat ground):

It is very likely when dumping on flat ground that thedumped material will build up enough to prevent thebody from lowering. In this case, the truck will have tobe driven forward a short distance (just enough toclear the material) before the body can be lowered.

1. Shift the selector switch to FORWARD, releasebrake lock, depress Override button and drivejust far enough forward for the body to clear thematerial. Stop, shift the selector switch to NEU-TRAL apply the brake lock.

2. Move the hoist lever forward to the DOWN posi-tion and release. Releasing the lever places thehoist control valve in the FLOAT position allow-ing the body to return to the frame.

NOTE: If dumped material buildsup at the rear of the body and thebody cannot be lowered, thenperform Steps "a" and "b" below:

a. Move the hoist lever back to the RAISE posi-tion to fully raise the dump body. Then,release the hoist lever so it returns to theHOLD position.

b. Move the shift selector switch to FORWARD,release the brake lock, depress the overridebutton and drive forward to clear the mate-rial. Stop, shift the selector switch to NEU-TRAL, apply the brake lock and lower thebody, again.

NOTE: When an attempt to lower the body isunsuccessful because of material obstruction, raisethe body back up. This will help to prevent the bodyfrom suddenly dropping when pulling away from theobstruction.

The truck is not to be moved with the dump bodyraised except for emergency purposes only. Fail-ure to lower the body before moving the truckmay cause damage to the hoist cylinders, frameand/or body hinge pins.

3. With the body returned to the frame, move theselector switch to FORWARD, release thebrake lock, and carefully leave the dump area.



(When dumping over a berm or into a crusher):

1. Move the hoist lever to the DOWN position andrelease. Releasing the lever places the hoistcontrol valve in the FLOAT position allowing thebody to return to the frame.

NOTE: If dumped material buildsup at the rear of the body and thebody cannot be lowered, performSteps a & b below:

a. Move the hoist lever backto the HOIST position tofully raise the dump body. Release the hoistlever to return it to the HOLD position.

NOTE: DO NOT drive forward if the tail of the bodywill not clear the crusher wall in the fully raisedposition.

b. Move the selector switch to FORWARD,release the brake lock. Depress the overridebutton and drive forward to clear the mate-rial. Stop, shift the selector switch to NEU-TRAL, apply the brake lock and lower thebody again.

NOTE: When an attempt to lower the body isunsuccessful because of material obstruction, raisethe body back up. This will help to prevent the bodyfrom suddenly dropping when pulling away from theobstruction.

CAUTION! DO NOT move the truck with the dumpbody raised except for emergency purposesonly. Failure to lower the body before moving thetruck may cause damage to the hoist cylinders,frame and/or body hinge pins.

2. With the body returned to the frame, move theselector switch to FORWARD, release thebrake lock, and carefully leave the dump area.

SUDDEN LOSS OF ENGINE POWERIf the engine suddenly stops, there is enough hydrau-lic pressure stored in the brake and steering accumu-lators to allow the operation of the steering and brakefunctions. However, this oil supply is limited so it isimportant to stop the truck as quickly and safely aspossible after the loss of engine power.

If the brake supply pressure drops to a pre-deter-mined level, the low brake pressure warning light willilluminate and a buzzer will sound. If the brake pres-sure continues to decrease, the auto-apply featurewill activate and the service brakes will apply auto-matically to stop the truck.

1. Bring the truck to a safe stop as quickly as pos-sible by using the foot pedal to apply the ser-vice brakes. If possible, safely steer the truck tothe side of the road while braking.

Dynamic retarding will not be available! DO NOTuse the service brakes for continuous retardingpurposes.

2. As soon as the truck has stopped moving, shiftthe P-F-N-R lever to PARK. This will apply theparking brake.

3. Turn the key switch OFF and notify mainte-nance personnel immediately.

4. If safe to do so, place wheel chocks in front orbehind the wheels so that truck can not roll.

5. If traffic is heavy near the disabled machine,mark the truck with warning flags during day-light hours or use flares at night. Adhere to localregulations.


SAFE PARKING PROCEDURESThe operator must continue to use safety precau-tions when preparing for parking and stopping theengine.

In the event that the equipment is being used in con-secutive shifts, any questionable truck performancethe operator may have noticed must be checked bymaintenance personnel before the truck is releasedto another operator.

1. Park the truck on level ground, if possible. If it isnecessary to park on a grade, the truck must bepositioned at right angles to the grade.

2. Place the P-F-N-R lever in the PARK position.This will apply the parking brake. Then placechocks fore/aft of the wheels so that the truckcannot roll. Each truck should be parked at areasonable distance from other trucks/equip-ment.

3. Haul roads are not safe parking areas. In anemergency, pick the safest spot most visible toother machines in the area. If the truckbecomes disabled where traffic is heavy, markthe truck with warning flags in daylight, or flaresat night.

NORMAL ENGINE SHUTDOWN PROCEDUREThe following procedure should be followed to stopthe engine.

1. Stop the truck out of the way of other traffic.Park on a level surface, free of overhead powerlines or other objects that could prevent raisingthe dump body.

a. Reduce engine speed to idle.

b. Place the selector switch in PARK. This willapply the parking brake.

c. Be sure the parking brake applied indicatorlight in the overhead display panel is illumi-nated.

d. Allow the engine to cool gradually by operat-ing at low idle for three to five minutes, or ifpreferred, activate the five minute shutdowndelay timer as described on the followingpage.

2. Place the rest switch in the ON position to putthe AC drive system in rest mode. Be sure therest indicator light in the overhead panel is illu-minated.

3. With the engine cooled down, turn the keyswitch counterclockwise to the OFF position tostop the engine.

If the engine does not turn off with the keyswitch, use the engine stop switch on operatorcab center console. Pull the switch up to stopthe engine. Push the switch back down toenable engine operation.

NOTE: There is also an engine stop switch located atat ground level at the right front corner of the truck.

4. With the key switch OFF and engine stopped,wait at least 90 seconds. Ensure the steeringcircuit is completely bled down by turning thesteering wheel back and forth several times. Nofront wheel movement will occur when hydraulicpressure is relieved. If the front tires continue tosteer after the engine is stopped, notify mainte-nance personnel.

5. Verify all link voltage lights are off (one on theback side of the center console inside the oper-ator cab, two on the electrical cabinet), andnotify maintenance personnel if the lightsremain illuminated longer than five minutesafter the engine has been stopped.

6. Close and lock all windows. Remove the keyfrom the key switch and lock the cab to preventpossible unauthorized truck operation. Properlydismount the truck. Put wheel chocks in place.


DELAYED ENGINE SHUTDOWN PROCEDURE

1. Stop the truck out of the way of other traffic.Park on a level surface, free of overhead powerlines or other objects that could prevent raisingthe dump body.

a. Reduce engine speed to low idle.

b. Place the selector switch in PARK. This willapply the parking brake.

c. Be sure the parking brake applied indicatorlight in the overhead display panel is illumi-nated.

2. Place the rest switch in the ON position to putthe AC drive system in the rest mode. Be surethe rest indicator light in the overhead panel isilluminated.

3. Refer to Instrument Panel and Indicator Lightsin Section 32 for location of the engine stopswitch with five minute idle timer delay. This is a3-position rocker-type switch (OFF-ON-MOMENTARY).

4. Press the top of the engineshutdown switch to select theON (center) position. Pressthe top of the switch again toactivate the timer delay(MOMENTARY position).Release the switch and allowit to return to the ON position.When the engine shutdowntimer has been activated, thetimer delay indicator light inthe overhead status panel willilluminate to indicate that theshutdown timing sequencehas started. The engine willcontinue to idle for approximately five minutesto allow for proper engine cool-down beforestopping.

5. Turn the key switch counterclockwise to theOFF position to cause the engine to stop whenthe timing sequence is complete. When theengine stops, the hydraulic bleed-down timerwill activate and the 24 VDC electric circuits willturn off.

6. With the key switch OFF and engine stopped,wait at least 90 seconds. Ensure the steeringcircuit is completely bled down by turning thesteering wheel back and forth several times. Nofront wheel movement will occur when hydraulicpressure is relieved. If the front tires continue tosteer after the engine has stopped, notify main-tenance personnel.

7. Verify all link voltage lights are off (one on theback side of the center console inside the oper-ator cab, two on the electrical cabinet), andnotify maintenance personnel if the lightsremain illuminated longer than five minutesafter the engine is shut down.

8. Close and lock all windows. Remove the keyfrom the key switch and lock the cab to preventpossible unauthorized truck operation. Properlydismount the truck. Put wheel chocks in place.

NOTE: To cancel the five minute idle timersequence, press the timer delay shutdown switch tothe OFF (lower) position.

• If the key switch is in the OFF position, theengine will stop.

• If the key switch is in the ON position, the enginewill continue to operate.

If engine does not stop with the key switch, useengine stop switch on operator cab center console.Pull the switch up to stop the engine. Push the switchback down to enable engine operation.

The ground level shutdown switch will also stop theengine during this time.


EMERGENCY STEERING SYSTEM

Operation

The truck is equipped with an emergency steeringsystem in the event of a failure in the oil supply to themain steering system. The emergency steering sys-tem was designed to meet or exceed SAE J1511 andISO 5010 standards.

If the low steering system pressure indicator light andalarm are activated, a failure in the hydraulic oil sup-ply to the steering and brake system exists. Whenthe alarm is activated, there is enough hydraulicpressure stored in the brake and steering accumula-tors to allow the operation of the steering and brakefunctions. However, this oil supply is limited. There-for, it is important to stop the truck as quickly andsafely as possible after the alarm is first activated.

If the oil supply pressure drops to a pre-determinedlevel, the low brake pressure warning light will alsoilluminate. If the oil pressure continues to decrease,the brake auto-apply feature will activate and the ser-vice brakes will apply automatically to stop the truck.

1. Stop the truck as quickly as possible by usingthe foot pedal to apply the service brakes. Ifpossible, steer the truck to the side of the roadwhile braking.

2. When stopped, shift the P-F-N-R selector leverto PARK. This will apply the parking brake.

3. Turn the key switch OFF and notify mainte-nance personnel.

4. If safe to do so, place wheel chocks in front orbehind the wheels so that truck can not roll.

5. If traffic is excessive near the disabled machine,mark the truck with warning flags during day-light hours or use flares at night. Adhere to localregulations.

Testing

Ensure no one is near the front tires during thistest. All personnel are warned that the clearanceschange when the truck is steered and this couldcause serious injury.

This test can only be performed with an empty truck.

1. Ensure no one is near the front tires during thistest. Use a spotter to keep the area around thefront tires clear of personnel during this test.

2. Start the engine and allow the hydraulic systemto reach full pressure and the accumulators tofill with oil.

3. Shut the engine off by using the engine stopbutton located on the center console. DO NOTturn the key switch OFF.

4. Turn the steering wheel.

If the front tires respond to the steeringwheel input, the emergency steeringsystem is functioning properly. Turn the keyswitch to the OFF position.

If the front tires do not steer, turn the keyswitch to the OFF position and notifymaintenance personnel immediately. Donot drive the truck until the problem hasbeen repaired and the truck can pass thistest.

If the truck passes this test, the emergency steeringsystem is functioning properly.


DISABLED TRUCK DUMPING PROCEDURESometimes it is necessary to dump a load from thebody of a truck when the hoist system is inoperable.The following instructions describe the use of a"good" truck to provide the hydraulic power requiredto raise the body of the "disabled" truck to dump theload.

In the example below, Figure 30-1 illustrates a typicalhookup from the good truck. The disabled truck maybe another Model 830E or a different Komatsumodel.

Hookup

Ensure there is an adequate, clear area to dump theloaded body. When the good truck is in position, stopthe engine and allow the hydraulic system to bleeddown. Ensure pressure has bled off before connect-ing hoses.

1. With the good truck parked as close as possibleto the disabled truck, attach a hose from thepower up quick disconnect (3, Figure 30-1) tothe power down circuit of the disabled truck.The hose must be rated to withstand 17 237kPa (2500 psi) or greater pressure.

NOTE: The power down circuit will use a smallerdiameter hose (tube) than the power up circuit.

2. Connect another hose from power down quickdisconnect (4) to the power up circuit of the dis-abled truck.

NOTE: If both trucks are a model 830E, the hoseswill be installed at the quick disconnects shown inFigure 30-1 and will be crossed when connected.

Raising the Body3. On the disabled truck, move the hoist control

lever to POWER UP and then release it to placethe hoist pilot valve in the HOLD position. Leavein this position during entire procedure.

4. Start the engine on the good truck. Place thehoist control in the POWER DOWN position andincrease engine rpm to high idle to dump thedisabled truck. If the body of the disabled truckfails to raise, increase the good truck powerdown relief pressure as follows:

a. Stop the engine and allow the hydraulic sys-tem to bleed down.

b. Remove the cap from the hoist pilot valverelief valve located in the hydraulics compo-nents cabinet behind the cab. While countingthe number of turns, slowly screw relief valveadjustment screw clockwise until it bottoms.

5. Repeat Step 4 to dump the disabled truck.

Lowering the Body6. Place the hoist lever of the good truck in FLOAT

to lower the body. If necessary, momentarilyplace the hoist control in POWER UP until thebody is able to descend in FLOAT. Do notaccelerate the engine.

7. After the body is lowered, stop the engine.Bleed the hydraulic system of pressure and dis-connect the hoses.

8. Reduce power down relief valve pressure tonormal on the good truck by turning the adjust-ment counterclockwise the same number ofturns as required in Step 4 b.

9. Check power down relief pressure per instruc-tions in the shop manual, Section L, HydraulicCheck-Out Procedure.

10. Check the hydraulic tank oil level.

FIGURE 30-1. PUMP MODULE, HOSE HOOKUP

1. Hoist Valve2. Overcenter Manifold3. Power Up Quick Disconnect (Connect to power

down circuit of disabled truck.)4. Power Down Quick Disconnect (Connect to

power up circuit of disabled truck.)


TOWINGPrior to towing a truck, many factors must be care-fully considered. Serious personal injury and/or sig-nificant property damage may result if importantsafety practices, procedures and preparation formoving heavy equipment are not observed. DO NOTtow the truck any faster than 8 kph (5 mph).

Attachments for towing the 830E are available fromKomatsu distributors as follows:

Front Bumper Modification Kit - XK0309: This kit con-tains the parts necessary to modify the front bumperfor installation of towing bosses. One XK0309 kit isrequired for each truck in the fleet.

Tow Adaptor Structure - MK3945: This structuremust be ordered (or designed) to mate with theintended towing vehicle and is intended for towing anunloaded vehicle only.

A disabled machine may be towed after the followingminimum precautions have been taken.

1. Shut the engine off.2. If equipped, install hydraulic connections for

steering and dumping between the tow vehiclethe and disabled vehicle. Check the disabledvehicle braking and steering systems for normaloperation.

3. If the disabled truck is loaded, dump the entireload. Never pull or tow a loaded truck.

4. Inspect the tow bar for adequacy. The bar mustbe approximately 1.5 times the gross vehicleweight of the truck being towed.

5. Ensure whether the tow vehicle has adequatecapacity to both move and stop the disabledtruck under all conditions.

6. Block the disabled truck to prevent movementwhile attaching tow bar.

7. Release the disabled truck brakes and removethe blocking.

8. Sudden movement may cause tow bar failure.Smooth, gradual truck movement is preferred.

9. Minimize tow angle at all times - never exceed30°. The disabled truck must be steered in thedirection of the tow bar.


RESERVE ENGINE OIL SYSTEM (Optional)The reserve oil tank for the engine is designed to addmore oil capacity to the engine and to make less fre-quent servicing of the engine oil. The circulation of oilbetween the engine sump and reserve tankincreases the total volume of working oil. This dilutesthe effects of contamination and loss of additives andmaintains the oil quality over longer periods. A filterin the supply circuit protects the pumping unit andprevents transfer of contaminants to the enginesump which might enter the tank during servicing. Italso gives an added level of oil cleanup.

Operation

Engine oil is circulated between the engine sump andthe reserve tank by two electrically driven pumpswithin a single pumping unit (11, Figure 30-2). Thepump unit is mounted on the side of the reserve tank,and is equipped with an LED monitor light on oneside.

Pump 1 (in the pump unit) draws oil from the enginesump at a preset control point determined by theheight of the suction tube. Oil above this point is with-drawn and transferred to reserve tank (9). This low-ers the level in the engine sump until air is drawn.

Air reaching the pumping unit activates pump 2 (inthe pump unit) which returns oil from the reserve tankand raises the engine sump level until air is no longerdrawn by pump 1. Pump 2 then turns off. The runninglevel is continuously adjusted at the control point byalternation between withdrawal and return of oil atthe sump.

LED Monitor Light• Steady - Pump 1 is withdrawing oil from the

engine sump and bringing down the oil level.• Regular Pulsing - Pump 2 is returning oil to the

engine sump and raising the oil level.• Irregular Pulsing - Oil is on the correct operat-

ing level.

Changing Oil1. Drain both the engine sump and the reserve

tank. Refill both the engine and reserve tankwith new oil to proper levels.

2. Change engine and reserve tank filters asrequired.

3. Start the engine and check for proper operation.

NOTE: Do not use the oil in the reserve tank to fill theengine sump. Both must be at proper level beforestarting the engine.

4. The engine oil level must be checked with theengine dipstick at every shift change. If the oillevel in the engine is incorrect, check for properoperation of the reserve engine oil system.

The oil level in the reserve tank must also bechecked at every shift change. Oil must be visi-ble in middle sight gauge (12). If not, add oil tothe reserve tank by using the quick fill systemutilizing tank fill valve (3). For filling instructions,refer to Section 40, Lubrication and Service.

FIGURE 30-2. RESERVE ENGINE OIL SYSTEM1. Oil Suction2. Oil Tank Fill3. Fill Valve4. Engine Fill Line5. Oil Level Sensor6. Air Valve

7. Tank Fill Line8. Fill Cap9. Reserve Oil Tank

10. Engine Fill Line11. Pump Unit12. Sight Gauge13. Tank Return Line

OM3221 Operator Cab And Controls - Section 32Page 32-1

OPERATOR CAB AND CONTROLS

FIGURE 32-1. CAB INTERIOR - OPERATOR VIEW

1. Steering Wheel2. Service Brake Pedal3. Retard Pedal4. Throttle/Accelerator Pedal5. Heater/Air Conditioner Vents

6. Heater/Air Conditioner Controls7. Instrument Panel8. Grade/Speed Retard Chart9. Radio Speakers

10. Warning Alarm Buzzer

11. Radio, AM/FM Stereo Cassette12. Warning Lights Dimmer Control13. Warning/Status Indicator Lights14. Air Cleaner Vacuum Gauges15. Windshield Wipers

Operator Cab And Controls - Section 32 OM3221Page 32-2

STEERING WHEEL AND CONTROLSSteering wheel (1, Figure 32-2) can be telescoped"in" and "out" and the lilt angle can be adjusted toprovide a comfortable steering wheel position formost operators.

Horn Button

Horn (2, Figure 32-2) is actuated by pushing the but-ton in the center of the steering wheel. Ensure thatthe horn operates before moving the truck. Observeall local safety rules regarding the use of the horn asa warning signal device before starting the engineand moving the vehicle.

Tilt / Telescope LeverThe steering column can be telescoped or the wheeltilted with lever (3, Figure 32-2).Adjust the tilt of the steering wheel by pulling the le-ver toward the steering wheel and moving the wheelto the desired angle. Releasing the lever will lock thewheel in the desired location.

Adjust the telescope function by pushing the leverforward to unlock. After positioning as desired,release the lever to the lock position.

Multi-Function Turn Signal Switch

Multi-function turn signal switch (4, Figure 32-2) isused to activate the turn signal lights, the windshieldwipers, and to select either high or low beam head-lights.

Turn Signal Operation

Move the lever upward to signal a right turn.

An indicator in the top, center of the instrument panel will illuminate to indicate turn direction selected. Refer to Instrument Panel and Indicator Lights in this section.

Move the lever downward to signal a left turn.

NOTE: The turn signal does not automatically cancel after the turn has been completed.

High Beam Headlight Operation

Pulling the lever inward (toward the rear of the cab) changes the headlights to high beam. When the high beams are selected, the indicator in the top center of the instrument panel will illuminate. Moving the switch back to the original position will return the headlights to low beam.

Windshield Wiper Operation

FIGURE 32-2. STEERING WHEEL & CONTROLS

1. Steering Wheel2. Horn Button

3. Tilt/Telescope Lever4. Multi-Function Turn

Signal Switch

Windshield Wipers OFF

Intermittent - Long Delay

Intermittent -Medium Delay

Intermittent -Short Delay

Low Speed

High Speed

Depressing the button at the end of the lever will activate the windshield washer.


PEDALS

Service Brake Pedal

The service brake pedal (2, Figure 32-1) is a footoperated pedal which applies the service brakes.Service brakes should only be applied when dynamicretarding requires additional braking force to slow thetruck speed quickly. They should also be used tobring the truck to a complete stop once the speed isless than 4.8 kph (3 mph).

Dynamic Retarding

Dynamic retarding is a braking torque (not a brake)produced through electrical generation by the wheel-motors when the truck motion (momentum) is thepropelling force.

For normal truck operation, dynamic retardingshould be used to slow and control truck speed.

Dynamic retarding is available in FORWARD/REVERSE at all truck speeds above 0 kph/mph;however, as the truck speed slows below 4.8 kph (3mph), the available retarding force may not be effec-tive. Use the service brakes to bring the truck to acomplete stop.

Dynamic retarding will not hold a stationary truck onan incline.Use the parking brake or wheel brake lockfor this purpose.

Dynamic retarding is available in NEUTRAL onlywhen truck speed is above 4.8 kph (3 mph).

When dynamic retarding is in operation, engine rpmwill automatically go to an advance retard speed set-ting. This rpm will vary depending on temperature ofseveral electrical system components.

Dynamic retarding will be applied automatically if thespeed of the truck obtains the maximum speed set-ting programmed in the control system software.

When dynamic retarding is activated, an indicatorlight in the overhead display will illuminate. Thegrade/speed retard chart should always be used todetermine safe downhill speeds. Refer to Grade/Speed Retard Chart in this chapter.

Dynamic Retard Pedal

Dynamic retard pedal (3, Figure 32-1) is a foot oper-ated pedal which allows the operator to slow thetruck and maintain a safe productive speed withoutthe use of the service brakes. For normal truck oper-ation, only dynamic retarding should be used to slowand control the speed of the truck. The Grade/SpeedChart (8, Figure 32-1) should always be followed todetermine MAXIMUM safe truck speeds for descend-ing various grades with a loaded truck. Servicebrakes should be applied only when dynamic retard-ing requires additional braking force to slow the truckspeed quickly or to bring the truck to a complete stop.

When dynamic retarding is in operation, the enginerpm will automatically go to an advance rpm retardspeed setting (usually 1250 rpm)*. Dynamic retardingwill be applied automatically, if the speed of the truckreaches the predetermined overspeed retard setting.Dynamic Retarding is available in FORWARD/REVERSE at all truck speeds above 0 kph/mph, butis available in NEUTRAL only when truck speed isabove 4.8 kph (3 mph).


Throttle/Accelerator Pedal

Throttle/accelerator pedal (4, Figure 32-1), andshown below, is a foot-operated pedal which allowsthe operator to control engine rpm depending onpedal depression.

It is used by the operator to request torque from themotors when in forward or reverse. In this mode, thepropulsion system controller commands the correctengine speed for the power required. In NEUTRAL,this pedal controls engine speed directly.

GRADE/SPEED RETARD CHARTGrade/speed retard chart (8, Figure 32-1), andshown below, provides the recommended MAXI-MUM retarding limits at various truck speeds andgrades with a fully loaded truck.

This decal in the truck may differ from the decalbelow due to optional truck equipment such as:wheel motor drive train ratios, retarder grids, tiresizes, etc. Always refer to this decal in the operator'scab and follow these recommendations for truckoperation.

The operator must reference this chart beforedescending any grade with a loaded truck. Properuse of dynamic retarding will maintain a safe speed.

Two speed lists are provided, one for continuousretarding, and the second for short term (approxi-mately three-minute) retarding. Both lists arematched to the truck at maximum Gross VehicleWeight (GVW). The two ratings are guidelines forproper usage of the retard function on downhillgrades.


The "short term" numbers listed on the chart indicatethe combination of speeds and grades which thevehicle can safely negotiate for a short durationbefore system components reach the maximumallowable temperature during retarding. Thesespeeds are faster than the "continuous" values,reflecting the thermal capacity of various systemcomponents. System components can accept heat-ing at a higher-than-continuous rate for a short periodof time. Beyond this short duration of time, the sys-tem would become overheated.

If the vehicle is operated at "short term" grade andspeed limits for a period of time exceeding thermalcapacity, the Propulsion System Controller (PSC)gradually reduces retarding effort from "short term" to"continuous". The "retard @ continuous" indicatorlight will illuminate alerting the operator of the retard-ing reduction and the need for a reduction in speed.The operator must use the service brakes to quicklyslow the truck to maximum "continuous" retardinglimits or less.

Do not LIGHTLY apply the service brakes whenattempting to slow the truck on a downhill grade.Overheating of the brakes will result. FULLYapply the brakes (within safe limits for road con-ditions) in order to quickly slow the truck to max-imum "continuous" retarding limits or less.

NOTE: The "three minute" curve is a MINIMUM; theactual time limit could be greater. Ambienttemperature, barometric pressure and recent motorpower levels can affect this number.

The "short term" rating will successfully accommo-date most downhill loaded hauls. It is necessary todivide haul road grade segment length by allowablespeed to determine actual time on grade. If actualtime on the grade exceeds the allowable limits, thegrade will need to be negotiated at the "continuous"speed.

The "continuous" numbers on the chart indicate thecombination of speeds and grades which the vehiclecan safely negotiate for unlimited time or distanceduring retarding.

DO NOT exceed these recommended MAXIMUMspeeds when descending grades with a loaded truck.


OVERHEAD PANEL AND DISPLAYSThe items listed below are located on the overheadpanel. Refer to Figure 32-1 for the location of eachitem. A brief description of each component is docu-mented below.

Radio Speakers

Radio speakers (9, Figure 32-1) for the AM/FM Ste-reo cassette are located at the far left and right of theoverhead panel.

Warning Alarm Buzzer

Warning alarm buzzer (10, Figure 32-1) will soundwhen activated by any one of several truck functions.Refer to Instrument Panel and Indicator Lights in thissection for a detailed description of functions andindicators that will activate this alarm.

Cab Radio

This panel will normally contain AM/FM Stereo Cas-sette (11, Figure 32-1). Refer to Section 70 for amore complete description of the radio and its func-tions. Individual customers may use this area forother purposes, such as a two-way communicationsradio.

Warning Light Dimmer Control

Warning light dimmer control (12, Figure 32-1) per-mits the operator to adjust the brightness of warningindicator lights (13).

Status/Warning Indicator Light Panel

Panel (13, Figure 32-1) contains an array of indicatorlights to provide the operator with important statusmessages concerning selected truck functions. Referto Instrument Panel and Indicator Lights in this sec-tion for a detailed description of these indicators.

Air Cleaner Vacuum Gauges

Air cleaner vacuum gauges(14, Figure 32-1) provide acontinuous reading of themaximum air cleaner restric-tion reached during operation.The air cleaner(s) should beserviced when the gauge(s)shows the maximum recommended restriction of 635 mm (25 in.) of H2O vacuum.

NOTE: After service, push the reset button on face ofgauge to allow the gauge to return to zero.

Windshield Wipers

Windshield wipers (15, Figure 32-1) are powered byan electric motor. Refer to Steering Wheel And Con-trols in this section for a location and description ofthe windshield wiper and washer controls.


CENTER CONSOLE P-F-N-R Selector Switch

Selector switch (2, Figure 32-3) is mounted on a con-sole to the right of the operator's seat. It is a fourposition switch that controls the park, forward, neu-tral, and reverse motion of the truck. When the selec-tor switch handle is in the center N position, it is inNEUTRAL. When the selector switch is in the P posi-tion, it is in PARK, and the parking brake will also beapplied. The parking brake is spring applied andhydraulically released. It is designed to hold a sta-tionary truck when the engine is off and the keyswitch is turned OFF. The truck must be completelystopped before moving the selector switch to PARK,or damage may occur to parking brake. When thekey switch is ON, and the selector switch is in PARK,the parking brake indicator light (A3, overhead panel,Figure 32-8) will be illuminated.

The selector switch handle must be in PARK tostart the engine.

NOTE: Do not move the P-F-N-R selector switch tothe PARK position at the shovel or dump. With keyswitch ON and engine on. Sudden shock caused byloading or dumping could cause the system's motionsensor to release the park brake.

The operator can select FORWARD drive by movingthe handle to the F position.

The operator can select REVERSE drive by movingthe handle to the R position.

NOTE: The truck must be stopped before theselector handle is moved to a drive position.

FIGURE 32-3. CENTER CONSOLE

1. Center Console 2. P-F-N-R Selector Switch 3. Override/Fault Reset Switch 4. Engine Stop Switch 5. L.H. Window Control Switch 6. R.H. Window Control Switch 7. Hoist Control Lever8. Retarder Speed Control Dial9. RSC Switch

10. Data Store Button11. VHMS Snapshot In Progress Light12. Link Energized Light (Red)13. Service Engine Light (Blue)14. 12V Auxiliary Power Outlets


Override/Fault Reset Switch

Switch (3, Figure32-3) is spring-loaded to the OFFposition. Whenpushed in and held,this switch may beused for several functions.

1. This switch permits the operator to override thebody-up limit switch and move the truck forwardwhen the selector switch is in FORWARD, thedump body is raised, and the brakes arereleased.

Use of the override switch for this purpose isintended for emergency situations only!

2. The push button deactivates the retard pedalfunction when speed of truck is below 4.8 kph (3mph).

3. The override switch is also used to reset anelectric system fault when indicated by a redwarning light. Refer to Overhead Status/Warn-ing Indicators in this section.

Engine Stop Switch

Switch (4, Figure 32-3) is used to stop theengine. Pull the switch up to stop theengine. Push the switch back down toenable engine operation.

Use this switch to stop the engine if the key switchshould fail to operate, or to stop the engine withoutturning off the 24 VDC electrical circuits.

A ground level engine stop switch is also located atthe right front corner of the truck.

L.H. Window Control Switch

Switch (5, Figure 32-3) is spring-loaded to the OFFposition.

• Pushing the front of the switch raises the left sidecab window.

• Pushing the rear of the switch lowers the window.

R.H. Window Control Switch

Switch (6, Figure 32-3) is spring-loaded to the OFFposition.

• Pushing the front of the switch raises the rightside cab window.

• Pushing the rear of the switch lowers the window.

Hoist Control Lever

Hoist control (7, Figure 32-3) is a four position hand-operated lever located between the operator seatand the center console (see illustration below).

Raising The Dump Body 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.)

2. Raise engine rpm to increase hoist speed. 3. Reduce engine rpm as the last stage of the

hoist cylinders begin to extend and then let theengine go to low idle as the last stage reacheshalf-extension.

4. Release hoist lever as the last stage reachesfull extension.

5. After material being dumped clears the body,lower the body to frame.

Refer to Operating Instructions - Dumping, for morecomplete details concerning this control


Move hoist lever forward to DOWN position andrelease. Releasing the lever places hoist controlvalve in the FLOAT position allowing the body toreturn to frame.


Retard Speed Control (RSC) Adjust Dial

Dial (8, Figure 32-3) allows the operator to vary thedownhill truck speed that the retard speed controlsystem will maintain when descending a grade. Thisfunction can be overridden by either the accelerator,retard lever, or retard pedal.

When the dial is rotated counterclockwisetoward this symbol, the truck will descenda grade at lower speeds.

When the dial is rotated clockwise towardthis symbol, the truck speed will increase.

Always refer to the Grade/Speed Retard Chart in theoperator's cab and follow the recommendations fortruck operation. DO NOT exceed these recom-mended MAXIMUM speeds when descendinggrades with a loaded truck.

Throttle pedal position will override RSC setting. Ifoperator depresses throttle pedal to increase truckspeed, dynamic retarding will not come on unlesstruck overspeed setting is reached or foot operatedretard pedal is used. When throttle pedal is releasedand RSC switch is on, dynamic retarding will comeon at, or above, the RSC dialed speed and will adjusttruck speed to, and maintain, the dialed speed.

To adjust RSC control, pull switch (9) ON and startwith dial (8) rotated toward fastest speed while driv-ing truck at desired maximum speed. Relax throttlepedal to let truck coast and turn RSC adjusting dialslowly counterclockwise until dynamic retarding isactivated. Dynamic retarding will now be activatedautomatically anytime the "set" speed is reached, theRSC switch is on, and throttle pedal is released.

With RSC switch on and dial adjusted, the systemwill function as follows: As truck speed increases tothe "set" speed and throttle pedal released, dynamicretarding will apply. As truck speed tries to increase,the amount of retarding effort will automaticallyadjust to keep the selected speed. When truck speeddecreases, the retarding effort is reduced to maintainthe selected speed. If truck speed continues todecrease to approximately 4.8 kph (3 mph) below"set" speed, dynamic retarding will turn off automati-cally. If truck speed must be reduced further, theoperator can turn the adjust dial to a new setting ordepress the foot operated retard pedal.

If the operator depresses the foot operated retardpedal and the retard effort called for is greater thanthat from the automatic system, the foot pedal retardwill override RSC.

Retard Speed Control (RSC) Switch

Switch (9, Figure 32-3) turns the system on and off.Push the knob in for OFF and pull the knob out toturn the system ON.


Data Store Button

Button (10, Figure 32-3) is for use by qualified main-tenance personnel to record in memory a “snap-shot”of the AC drive system. It will also trigger the VHMSsystem to store a snap-shot of the truck operatingsystem. Light (11, Figure 32-3) will stay illuminatedwhile the VHMS system is recording the snap-shot.

VHMS Snapshot In Progress Light

Light (11, Figure 32-3) is an indicator that will illumi-nate while the VHMS system is in the process of tak-ing a snapshot of machine data.

Link Energized Light

Light (12, Figure 32-3) is a red indictor that, when illu-minated, indicates that the AC drive system is ener-gized. No one is permitted to work on the AC drivesystem while this light is illuminated.

Service Engine Light

Light (13, Figure 32-3) is a blue indicator that will illu-minate if a problem is detected by the electronicengine monitoring system.

Electric propulsion and dynamic retarding will still beavailable.

If this light is ON, notify maintenance personnel sothey can diagnose and repair the problem the nexttime the truck is in the shop for repairs or at the nextPM (Preventive Maintenance) interval.

DIAGNOSTIC PORTS

The diagnostic ports shown in Figure 32-4 arelocated on the back wall of the cab next to the D.I.D.Panel.

VHMS Diagnostic Port

Diagnostic port (1, Figure 32-4) is used to downloadtruck operation data from the VHMS controller.

Interface Module (IM) Diagnostic Port

Diagnostic port (2) is used to connect the interfacemodule to a computer for installing software.

Payload Meter Diagnostic Port

Diagnostic port (3) is used to download data from thepayload meter system. Refer to Section 60, PayloadMeter III, for a more complete description of the pay-load meter and its functions.

Truck Control Interface (TCI) Diagnostic Port

Diagnostic port (4) is used to access diagnostic infor-mation for the Truck Control Interface (TCI).

Propulsion System Controller (PSC) Diagnostic Port

Diagnostic port (4) is used to access diagnostic infor-mation for the Propulsion System Controller (PSC).

Engine Diagnostic Port (CENSE)

Diagnostic port (6) is a three pin connector used toaccess diagnostic information for the engine monitor-ing system.

Engine Diagnostic Port (QUANTUM)

Diagnostic port (7) is a nine pin connector used toaccess diagnostic information for the engine controlsystem.

FIGURE 32-4. DIAGNOSTIC PORTS

1. VHMS Diagnostic Port

2. IM Diagnostic Port3. Payload Meter

Diagnostic Port4. TCI Diagnostic Port

5. PSC Diagnostic Port6. Engine Diagnostic

Port (CENSE)7. Engine Diagnostic

Port (QUANTUM)


OPERATOR’S SEAT The operator's seat provides a fully adjustable cush-ioned ride for driver comfort and easy operation.

Adjustment

The following adjustments must be made while sit-ting in the seat.

1. Headrest: (1, Figure 32-5) will move up, down,fore, or aft by moving headrest to desired posi-tion.

2. Armrests: Rotate adjusting knob until the arm-rest is in the desired position.

3. Backrest: Lift backrest adjustment handle (3)to release and select the backrest angle.Release the control handle to set.

4. Seat Belt: The operator must have seat belt (4)buckled in place and properly adjusted when-ever vehicle is in motion.

5. Seat Slope: Lift seat slope lever (5) and hold toadjust the slope of the seat. Release the leverto lock the adjustment.

6. & 7 Air Lumbar Support: Each rocker switch(6 or 7) controls an air pillow. Switch (7) controlsthe lower air pillow and switch (6) controls theupper air pillow. To inflate, press on top of therocker switch and hold for desired support, thenrelease. To deflate, press on the bottom of therocker switch and hold for desired support, thenrelease. Adjust each pillow for desired support.

8.Seat Suspension: Press rocker switch (8) ontop to increase ride firmness. Press on lowerpart of rocker switch to decrease ride firmness.

9.Fore/Aft Location of Seat: Lift fore and aftlever (9) and hold. Bend knees to move seat toa comfortable position. Release the controllever to lock the adjustment.

12. Seat Height: Lift lever (12) and hold to adjustthe height of the seat. Release the lever to lockthe adjustment.

FIGURE 32-5. OPERATOR’S SEAT ADJUSTMENTCONTROLS

1. Headrest 2. Armrest Adjustment 3. Backrest Adjustment4. Seat Belt5. Seat Slope Adjust-

ment6. Upper Air Pillow

Lumbar Support7. Lower Air Pillow

Lumbar Support

8. Seat Firmness 9. Fore and Aft Adjust-

ment10. Mounting Hardware11. Seat Tether

Cap Screw12. Seat Height

Adjustment


HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLSThe heater/air conditioner compartment containsheater/air conditioner controls (6, Figure 32-1) andsome of the heater/air conditioner components, suchas the blower motor assembly and heater coils. Opti-mum cab air climate can be selected by using the fol-lowing controls in various combinations.

Fan Control Knob

Knob (1, Figure 32-6) controls the cab air fan motor.The fan motor is a 3-speed motor: low (setting 1),medium (setting 2), and high (setting 3). Speeds areselected by rotating the control knob clockwise to thedesired position. OFF is full counter-clockwiseposition (setting 0).

Temperature Control Knob

Knob (2, Figure 32-6) allows the operator to select acomfortable temperature.

• Rotating the knob counterclockwise (blue arrow)will select cooler temperatures. Fullcounterclockwise position is the coldest airsetting.

• Rotating the knob clockwise (red arrow) willselect warmer temperatures. Full clockwiseposition is the warmest heater setting.

Directional Control Knob

Knob (3, Figure 32-6) directs heated air to differentareas of the cab.

• The full counterclockwise position directs air tothe floor vents only.

• Turning the knob one position clockwise directsair to both the floor and dash vents.

• Turning the knob one more position clockwisedirects air to the dash vents only.

• Turning the knob one more position clockwisedirects air to the windshield defrost vents only.

• The full clockwise position directs air to both thefloor and windshield defrost vents.

Heater Vents

Each heater/air conditioner vent (4, Figure 32-6) is aflapper type which may be opened or closed orrotated 360° for optimum air flow. There are four(three not shown) across the top of the panel, oneeach in the right and left panel modules, and fourbelow the panel.

FIGURE 32-6. A/C & HEATER CONTROLS


INSTRUMENT PANEL Control Symbols

The operator must understand the function and oper-ation of each instrument and control. Many controlfunctions are identified with international symbolsthat the operator should learn to recognize immedi-ately. This knowledge is essential for proper and safeoperation.

Items that are marked optional do not apply to everytruck.

The following symbols are general indicators andmay appear in multiple locations and combinationson the instrument panel.

Most switches have two LED lights inside them, oneamber and one green in color. The amber is locatedin the top portion of the switch and indicates thatfunction has been activated. The green LED islocated in the lower portion of the switch and indi-cates that function has not been activated.

• To activate a function, push on the top portion ofthe switch. At this time, the amber LED will beilluminated, and the green LED will be OFF.

• To de-activate a function, push on the lowerportion of the switch. At this time, the green LEDwill be illuminated, and the amber LED will beOFF.

NOTE: The green LED light in the hazard lightswitch, head light switch and the ladder light switchwill be illuminated when battery power is connectedto the truck. The LED lights in the other switches willilluminate when the key switch is turned to the ONposition.

This symbol when it appears onan indicator or control identifiesthat this indicator or control isNOT used.

This symbol identifies a rotarycontrol or switch. Rotate the knobclockwise or counterclockwise forfunctions.

This symbol identifies a switchused to test or check a function.Press the switch on the side nearthe symbol to perform the test.


FIGURE 32-7. PANEL GAUGES, INDICATORS, AND CONTROLS1. Key Switch2. Engine Stop Switch with Timer Delay3. Rotating Beacon (Optional)4. Heated Mirrors (Optional)5. AC Drive System Rest Switch6. Wheel Brake Lock Switch7. Hazard Lights Switch8. Heater/Air Conditioner Vents9. Engine Oil Pressure Gauge

10. Right Turn Signal Indicator Light11. Digital Tachometer12. High Beam Headlight Indicator13. Speedometer/Payload Meter Display

14. Left Turn Signal Indicator15. Water Temperature Gauge16. Lamp Check Switch17. Headlight/Panel Illumination Light Switch18. Ladder Light Switch (3-Way)19. Backup Light Switch20. Fog Light Switch21. Payload Meter Mode Switch22. Panel Illumination Lights Dimmer Control23. Hydraulic Oil Temperature Gauge24. Engine Hourmeter25. Fuel Level Gauge


Key Switch

Key switch (1, Figure 32-7) is a three-position (OFF,RUN, START) switch.

Starting

When the switch is rotated one position clockwise, itis in the RUN position and all electrical circuitsexcept START are activated.

1. With the selector switch in PARK, rotate keyswitch fully clockwise to the START position,and hold this position until the engine starts.The START position is spring-loaded to returnto RUN when the key is released. If the engineis equipped with a prelube system, a noticeabledelay will occur before engine cranking begins.

2. After engine has started, place rest switch (5,Figure 32-7) in the OFF position, which will de-activate the rest mode of operation. Refer to thediscussion of rest switch later in this chapter.

Engine Stop Switch with Five Minute Idle TimerDelay

Switch (2, Figure 32-7) is a three-position, rocker type switch withOFF, ON and MOMENTARY posi-tions. When used, the engine isallowed to idle for approximatelyfive minutes before it stops. Thedelayed shutdown feature allowsthe engine to cool down slowly,reducing internal temperatures ascoolant is circulated through theengine.

Operation1. Stop the truck, and reduce engine rpm to low

idle. Place the selector switch in PARK. Placethe rest switch in the ON position to put thedrive system in REST mode of operation. Referto the discussion of the rest switch later in thischapter.

2. Press the top of the engine shutdown switch toselect the ON (center) position. Press the top ofthe switch again to activate the timer delay(MOMENTARY position). Release the switchand allow it to return to the ON position.

When the delay timer has been activated, thetimer delay indicator light (C4, Figure 32-8) inthe overhead status panel will illuminate to indi-cate that the shutdown timing sequence hasstarted. The engine will continue to idle forapproximately five minutes to allow for properengine cool-down before stopping.

3. Turn the key switch counterclockwise to theOFF position to cause the engine to stop whenthe timing sequence is complete. When theengine stops, this will activate the hydraulicbleed-down timer and turn off the 24 VDC elec-tric circuits controlled by the key switch.

NOTE: To cancel the five minute idle timersequence, press the timer delay switch to the OFF(lower) position. If the key switch is in the OFFposition, the engine will stop. If the key switch is inthe ON position, the engine will continue to run.

4. With key switch OFF, and engine stopped, waitat least 90 seconds. Ensure the steering circuitis completely bled down by turning the steeringwheel back and forth several times. No frontwheel movement will occur when hydraulicpressure is relieved.

5. Verify all the link voltage lights turn off withinfive minutes after the engine is shut down. Oneis located on the rear of the center console inthe cab, two others are located in the accesspanel at the left front corner of the electricalcabinet. If the lights remain on, refer to SectionE in the service manual for additional instruc-tions and information.

6. Close and lock all windows. Remove key fromkey switch and lock cab to prevent possibleunauthorized truck operation. Dismount thetruck properly.


Rotating Beacon Light Switch(Optional)

Switch (3, Figure 32-7) controlsthe operation of the rotating bea-con light.

Heated Mirror Switch(Optional)

Switch (4, Figure 32-7) controlsthe operation of the heated mir-rors.

Rest Switch

Switch (5, Figure 32-7) is a rockertype switch with a locking device forthe OFF (lower side pressed in)position. There is no LED light toilluminate when this switch is in theOFF position. A small black tabmust be pushed to the left to unlockthe switch before the top side canbe depressed to switch to the ONposition. When in the ON position,an internal amber lamp will illuminate. The switchshould be activated to de-energize the AC drive sys-tem whenever the engine is to be shutdown orparked for a length of time with the engine running.

The selector switch must be in PARK and the vehiclenot moving to enable this function. This will allow theengine to continue running while the AC drive systemis de-energized.

Activation of the rest switch alone DOES NOTcompletely ensure that the drive system is safeto work on. Refer to Section 20, Safety, for moreinformation on servicing a 830E truck. Check all"link-on", or "link energized", indicator lights toverify the AC drive system is de-engergizedbefore performing any maintenance on the drivesystem. DO NOT activate the rest switch whilethe truck is moving! The truck may unintention-ally enter the “rest” mode after stopping.

An amber (yellow) indicator lightin the overhead panel (B6, Figure32-8) will illuminate when the"rest" state has been requestedand entered.

Wheel Brake Lock Control

Switch (6, Figure 32-7) should beused when the engine is running dur-ing dumping and loading operationsonly. The brake lock switch actuatesthe hydraulic brake system whichlocks the rear wheel service brakesonly. When pulling into the shovel ordump area, stop the truck using thefoot-operated service brake pedal.When the truck is completelystopped and in the loading position, apply the brakelock by pressing on the top of the rocker switch.Move the P-F-N-R lever to NEUTRAL. DO NOTplace the P-F-N-R lever in PARK. To release, pressthe lower part of the rocker switch.

Do not use this switch to stop the truck unlessthe foot-operated treadle valve is inoperative.Use of this switch applies rear service brakes at areduced, unmodulated pressure. Do not use thebrake lock for parking. With the engine stopped,hydraulic pressure will bleed down, allowing thebrakes to release.

Use at shovel and dump only to hold the truck inposition

Hazard Warning Lights

Switch (7, Figure 32-7) flashes allthe turn signal lights. Pressing thetop side of the rocker switch acti-vates these lights. When theselights are on, a red LED light will beilluminated inside the switch. Press-ing on the lower side of the rockerswitch turns these lights off, and agreen LED light will be illuminated.

Cab/Air Conditioner Vents

Vents (8, Figure 32-7) may be directed by the opera-tor to provide the most comfortable cabin air flow.


Engine Oil Pressure Gauge

Gauge (9, Figure 32-7) indicates pres-sure in the engine lubrication systemin pounds per square inch (psi).

Normal operating pressure afterengine warm up should be:

Idle - 138 kPa (20 psi) MinimumRated Speed - 310 - 483 kPa (45 to 70 psi)

Right Turn Signal Indicator

Indicator (10, Figure 32-7) illuminates to indicate thatthe right turn signals are operating when the turn sig-nal lever on the steering column is moved upward.Moving the lever to its center position will turn theindicator off.

Tachometer

Tachometer (11, Figure 32-7) displays engine crank-shaft speed in revolutions per minute (rpm).

Governed rpm

Low Idle - 750 rpm

High Idle - 1910 rpm

Full Load - 1900 rpm

High Beam Indicator

Indicator (12, Figure 32-7) illuminates to indicate thatthe truck headlights are on high beam. To switch theheadlights to high beam, push the turn indicator leveraway from the steering wheel. For low beam, pull thelever toward the steering wheel.

Speedometer/Payload Meter Display

Speedometer/payload meter display (13, Figure 32-7) indicates the truck speed in kilometers per hour(kph) or in miles per hour (mph). The display alsoshows payload meter information. For more informa-tion, see Section 60, Payload Meter III, in this man-ual.

Left Turn Signal Indicator

Indicator (14, Figure 32-7) illuminates to indicate thatthe left turn signals are operating when the turn sig-nal lever on the steering column is moved downward.Moving the lever to its center position will turn theindicator off.

Water Temperature Gauge

Gauge (15, Figure 32-7) indicates thetemperature of the coolant in theengine cooling system. The tempera-ture range after engine warm-up andtruck operating under normal condi-tions should be:

85°-97°C (185°-207°F)

Lamp Test Switch

Switch (16, Figure 32-7) is pro-vided to allow the operator to testthe indicator lamps prior to startingthe engine. To test the lamps andthe warning horn, turn key switch(1, Figure 32-7) to the RUN posi-tion and press the top side of therocker switch for the CHECK posi-tion. All lamps should illuminateexcept those which are for optionalequipment that may not be installed. The warninghorn should also sound. Any lamp bulbs which do notilluminate should be replaced before operating thetruck. Releasing the spring-loaded switch will allowthe switch to return to the OFF position. A green LEDwill illuminate in both switch positions.

Light Switch

The instrument panel lights, clear-ance lights, and the headlights arecontrolled by this three-positionrocker type switch (17, Figure 32-7). OFF is selected by pressing thebottom of the switch. Press the topof the switch until it reaches the firstdetent to select the panel lights,clearance lights and tail lights only.Press the top of the switch againuntil it reaches the second detent to select head-lights, panel lights, clearance lights and tail lights.


Ladder Light Switch

Ladder light switch (18, Figure 32-7)turns the ladder lights on or off.Pressing the top of the rocker switchturns the lights on. Pressing the bot-tom of the switch turns the lights off.A green LED light will illuminate inboth switch positions. Another ladderlight switch is mounted at the rightfront corner of the truck near thebase of ladder.

Manual Backup Switch

Manual backup switch (19, Figure32-7) allows the backup lights to beturned on for added visibility andsafety when the selector switch(see Operator Controls) is not inREVERSE position. When theswitch is in the ON position, themanual back up light indicator (B4,overhead panel, Figure 32-8) will beilluminated.

Fog Lights (Optional)

Fog lights (20, Figure 32-7) areoptional equipment that are useful infoggy conditions and heavy rain.Pressing the top of the rocker switchturns the fog lights on. Pressing thebottom of the switch turns the lightsoff.

Payload Meter Switch

Payload meter switch (21, Figure32-7) is a two-way, momentaryrocker switch. The top position isthe SELECT position. The SELECTposition is used to step through thedifferent displays. The lower posi-tion is the SET position. The SETposition is used to set the operatorID, or clear the load and total toncounters. Refer to Section 60, Payload Meter III, for amore complete description of the payload meter sys-tem and its functions.

Panel Light Dimmer

Panel light dimmer (22, Figure 32-7)is a rheostat which allows the opera-tor to vary the brightness of theinstruments and panel lights.

• Rotating the knob to the full clockwise positionturns the panel lights on to the brightestcondition.

• Rotating the knob counterclockwise continuallydims the lights until OFF position is reached atfull counterclockwise rotation.


Hydraulic Oil Temperature Gauge

Hydraulic oil temperature gauge (23,Figure 32-7) indicates oil tempera-ture in the hydraulic tank. There aretwo colored bands: green and red.

Green indicates normal operation.

As the needle approaches the red zone, minimumengine idle speed will increase to help cool the oil.

Red indicates high oil temperature in the hydraulictank. Continued operation could damage compo-nents in the hydraulic system. There is also a redtemperature warning light in the overhead panel (A1,Figure 32-8) that will illuminate when the temperatureexceeds a certain level (when the needle enters thered zone). If this condition occurs, the operatorshould safely stop the truck, move selector switch toPARK, and operate engine at 1200 - 1500 rpm toreduce system temperature.

If temperature gauge does not move into thegreen range after a few minutes, and the redoverhead indicator light does not go out, stop theengine and notify maintenance personnel imme-diately.

Hourmeter

Hourmeter (24, Figure 32-7) registersthe total number of hours the enginehas been in operation.

Fuel Level Gauge

Fuel level gauge (25, Figure 32-7)indicates how much diesel fuel is inthe fuel tank.

The fuel tank capacity is 4542 liters(1200 gallons).


OVERHEAD STATUS / WARNING INDICATORS

* Brightness for these indicator lamps can beadjusted by using dimmer control (12, Figure 32-1).

FIGURE 32-8. OVERHEAD STATUS / WARNING INDICATOR

Row / Column

Indicator Description

Indicator Color Wire Index

A1* Hydraulic Oil Temp. High Red-24VIM/34TLB1* Low Steering Pressure Red-12F/33AC1 Low Accumulator Press. Red-12F/33KD1 Not UsedE1 Low Brake Pressure Red-12F/33LA2* Low Hydraulic Oil Level Red-12F4/34LLB2* Low Automatic

Lubrication PressureAmber-12MD8/68LLP

C2* Circuit Breaker Tripped Amber-12MD3/31CBD2* Hydraulic Oil Filter Amber-12MD/39E2* Low Fuel Amber-24VIM/38A3* Park Brake Applied Amber-24VIM/52ALB3* Service Brake Applied Amber-12MD/44LC3* Body Up Amber-12MD6/63LD3* Dynamic Retarding Amber-12MD/44DLE3 Stop Engine Red-12M/31MTA4* Starter Failure Amber-21SL/24VIMB4* Manual Back-Up Lights Amber-12MD/47LC4* 5 Min. Shutdown Timer Amber-12MD/23L1D4* Retard Speed Control Amber-12MD/31RE4* Check Engine Amber-12MD7/419

Row / Column

Indicator Description

Indicator Color Wire Index

A5 No Propel/ No Retard Red-12M/75-6P1B5 Propulsion System

WarningAmber-12F/79WI

C5 Propulsion System Temperature

Amber -12F/34TW1

D5 Interface Module Failure Red-24VIM/311MLIE5 Battery Charge System

FailureRed-24VIM/11BCF1

A6 NO PROPEL Red-12M/75NPIB6 Propulsion System @

RestAmber-12M/72PR1

C6* Propulsion System Not Ready

Amber-12MD/72NR1

D6* Reduced Propulsion System

Amber-12MD/72LP1

E6* Retard @ Reduced Level Amber-12MD/76LR1


Status / Warning Indicator Light Symbols

Amber indicator lights alert the operator that the indi-cated truck function requires some precaution whenlighted.

Red indicator lights alert the operator that the indi-cated truck function requires immediate action bythe operator. Safely stop the truck and turn theengine off.

DO NOT OPERATE THE TRUCK WITH A REDWARNING LIGHT ILLUMINATED!

Refer to Figure 32-8 and the descriptions below it forexplanations of the symbols. Location of the symbolsare described by rows (A - E) and columns (1 - 6).

A1. High Hydraulic Oil Temperature

This red warning light indicateshigh oil temperature in thehydraulic tank. Continued opera-tion could damage componentsin the hydraulic system.

The light illuminates at 107°C(225°F)

If this condition occurs, the operator should safelystop the truck, move selector switch to PARK, andoperate engine at 1200 - 1500 rpm to reduce systemtemperature.

If temperature gauge does not move into thegreen range after a few minutes, and the redoverhead indicator light does not go out, stop theengine and notify maintenance personnel imme-diately.

B1. Low Steering Pressure

When the key switch is turnedON, the low steering pressurewarning light will illuminate untilthe steering system hydraulicpressure reaches 15 858 kPa(2300 psi). The warning alarmwill also turn on, and both will remain on, until theaccumulator has been filled with hydraulic oil.

During truck operation, the low steering pressurewarning light and warning horn will turn on if thesteering system hydraulic pressure drops below 15 858 kPa (2300 psi).

• If the light illuminates momentarily (flickers) whileturning the steering wheel while at low truckspeed and low engine rpm, truck operation maycontinue. This may be considered normal.

• If the indicator light illuminates at higher truckspeed and high engine rpm, DO NOT OPERATETHE TRUCK.

If the low steering warning light continues to illu-minate and the alarm continues to sound, lowsteering pressure is indicated. The remainingpressure in the accumulators allows the operatorto control the truck to a stop. Do not attempt fur-ther operation until the malfunction is locatedand corrected.


C1. Low Accumulator Pre-charge Pressure

The low accumulator prechargewarning light, if illuminated, indi-cates low nitrogen precharge forthe steering accumulator(s). Tocheck for proper accumulatornitrogen precharge, the engine must be stopped andthe hydraulic system completely bled down. Turn thekey switch to the RUN position. The warning light willnot illuminate if the accumulators are properlycharged. The warning light will flash if the nitrogenprecharge within the accumulator(s) is below 7585 ±310 kPa (1100 ± 45 psi).

If the low accumulator precharge warning lightflashes, notify maintenance personnel immedi-ately. Do not attempt further operation until theaccumulators have been recharged with nitro-gen. Refer to the shop manual for proper charg-ing instructions. If nitrogen precharge pressureis low, sufficient oil for emergency steering maynot be available.

D1. Not Used

This light is reserved for future use.

E1. Low Brake Pressure

This red indicator light indicates amalfunction within the hydraulicbrake circuit. If this light illumi-nates and the buzzer sounds,stop the truck, shift to PARK,and turn the engine off. Notifymaintenance personnel.

NOTE: Adequate hydraulic fluid is stored to allow theoperator to safely stop the truck.

A2. Low Hydraulic Tank Level

This warning light indicates theoil level in the hydraulic tank isbelow recommended level. Dam-age to hydraulic pumps mayoccur if operation continues.Stop the truck and turn theengine off. Notify maintenance personnel immedi-ately.

B2. Automatic Lubrication Sys-tem Pressure

This amber light will illuminate ifthe automatic lubrication systemfails to reach 13 790 kPa (2,000psi) at the junction block locatedon the rear axle housing within aspecified time after the lube timer initiates a cycle ofgrease. To turn the light off, turn key switch OFF,then back to ON again. Notify maintenance person-nel at earliest opportunity after light comes on.

C2. Circuit Breaker Tripped

This amber light will illuminate ifany of the circuit breakers in therelay circuit control boards aretripped. The relay circuit boardsare located in the electrical con-trol cabinet.

D2. Hydraulic Oil Filter Monitor

This amber light indicates arestriction in the high pressure fil-ter assembly for either the steer-ing or hoist circuit. This light willilluminate before filters start tobypass. Notify maintenance per-sonnel at earliest opportunity after the light illumi-nates.

NOTE: The filter monitor warning light may alsoilluminate after the engine is initially started if the oilis cold. If the light turns off after the oil is warmed,filter maintenance is not required.


E2. Low Fuel

This amber low fuel indicatorlight will illuminate when theusable fuel remaining in the tankis approximately 95 liters (25 gal-lons). A warning buzzer will alsosound.

A3. Parking Brake

This amber parking brake indi-cator will illuminate when theparking brake is applied. Do notattempt to drive the truck withthe parking brake applied.

B3. Service Brake

This amber service brake indi-cator light will illuminate whenthe service brake pedal isapplied or when wheel brakelock is applied. Do not attemptto drive the truck from stoppedposition with the service brakes applied, except asnoted in Section 30, Operating Instructions - StartingOn A Grade With A Loaded Truck.

C3. Body Up

This amber body up indicator,when illuminated, indicates thatthe body is not completely downon the frame. The truck shouldnot be driven until body is downand the light is off.

D3. Dynamic Retarding

This amber dynamic retardingindicator light illuminates when-ever the retarder pedal is oper-ated, RSC is activated, or theautomatic overspeed retardingcircuit is energized. It indicatesthat the dynamic retarding function of the truck isbeing used.

E3. Stop Engine

This red engine monitor warninglight will illuminate if a seriousengine malfunction is detectedin the electronic engine controlsystem.

• Electric propulsion to thewheelmotors will be discontinued.

• Dynamic retarding will still be available if neededto slow or stop the truck.

Stop the truck as quickly as possible in a safearea and shift to PARK. TURN THE ENGINE OFFIMMEDIATELY. Additional engine damage islikely to occur if operation is continued.

Listed below are a few conditions that could causethe stop engine light to illuminate:

• Low Oil Pressure - red warning light willilluminate, but the engine does not stop.

• Low Coolant Level - red warning light willilluminate, but the engine does not stop.

• Low Coolant Pressure - red warning light willilluminate, but the engine does not stop.

• High Coolant Temperature - red warning light willilluminate, but the engine does not stop.

A4. Cranking Motor Failure

This amber indicator will illumi-nate when either starter motor(of two) fails to crank the engine,leaving just one cranking motorto start the engine. With only onecranking motor doing the work oftwo, the motor life will be shortened. If this indicatorilluminates, truck operation may continue, but main-tenance personnel should be alerted as soon as pos-sible.


B4. Manual Backup Lights

This amber indicator will illumi-nate when the manually oper-ated manual backup light switch(19, Figure 32-7) is turned ON.

C4. Engine Shutdown Timer - 5Minute Idle

When the engine shutdown timerswitch has been activated (2,Figure 32-7), this indicator lightwill illuminate to indicate that theshutdown timing sequence hasstarted. Information detailing the operation of thisswitch is outlined earlier in this section.

D4. Retard Speed Control(RSC) Indicator

This amber light is illuminatedwhen the RSC switch mountedon the console is pulled out tothe ON position. The light indi-cates the retarder is active. It isfor feedback only and does not signal a problem.

E4. Check Engine

This amber check engine indica-tor will illuminate if a malfunctionis detected by the engine elec-tronic control system.

If this indicator illuminates, truckoperation may continue, butmaintenance personnel should be alerted as soon aspossible.

A5. No Power

This red “no retard/no propel”indicator light indicates a faulthas occurred which has elimi-nated the retarding and propul-sion capability. A warning buzzerwill also sound.

If this condition occurs, the operator should safelystop the truck, move selector switch to PARK, shut-down the engine, and notify maintenance personnelimmediately.

B5. Propulsion System Warn-ing

When this amber indicator isilluminated, the light indicates a“no propel” or “no retard” eventmay be about to occur. It isintended to provide advancenotice of these events whenpossible. It does not require the operator to stop thetruck, but may suggest that truck operation be appro-priately modified, in case a red alarm does occur.

C5. Propulsion System Tem-perature

This amber AC drive systemtemperature warning light indi-cates the drive system tempera-ture is above a certain level.When this condition occurs, theoperator should consider modifying truck operation inorder to reduce system temperature. The operator isnot required to stop the truck at this time.

D5. Electrical System Failure

This red warning light indicatesthat the VHMS system detecteda failure somewhere in the 24volt electrical system.


E5. Battery Charging SystemFailure

The red battery charging systemlight indicates a problem hasbeen detected in the chargingsystem, and system voltage is ator below 24.0 volts. If this lightilluminates, the operator should safely stop the truck,move selector switch to PARK, shut the engine off,and notify maintenance personnel immediately. Iftruck operation continues, and the battery voltagedrops below 20.0 volts, the propulsion system will notoperate, but retarding will still be available.

A6. No Propel

The red “no propel” light indi-cates a fault has occurred whichhas eliminated the propulsioncapability. If this conditionoccurs, the operator shouldsafely stop the truck, move selec-tor switch to PARK, shut down the engine, and notifymaintenance personnel, immediately.

B6. Propel System @ Rest

The amber “propel system @rest” light is used to indicate thatthe AC drive system is de-ener-gized and propulsion is not avail-able. This light is activated whenthe instrument panel rest switchis turned ON and the AC drive system is de-ener-gized. The three link energized lights (one on rear ofthe center console inside the operator cab, and twoon the deck-mounted control cabinets) should NOTbe illuminated at this time.

C6. Propel System Not Ready

The amber indicator light func-tions during start-up much likethe hour glass icon on a com-puter screen. This light indicatesthe computer is in the processof performing the self-diagnos-tics and set-up functions at start-up. Propulsion willnot be available at this time.

D6. Reduced Propulsion

The amber “reduced propulsion”light is used to indicate that thefull AC drive system performancein propulsion is not available. Atthis time, the only event thatshould activate this light is theuse of “limp home mode”. This mode of operationrequires a technician to enable.

E6. Retard At ContinuousLevel

The amber retard at continuouslevel light indicates that theretarding effort is at the continu-ous level. The operator shouldcontrol the speed of the truck inaccordance to the "continuous" speeds on theGRADE/SPEED RETARD CHART on page 32-4.


VEHICLE HEALTH MONITORING SYSTEM (VHMS)

Operation

This system uses VHMS controller (2, Figure 32-10)to gather data about the operation of the truck fromsensors and other controllers installed on the truck.The data stored in the VHMS controller is collectedby a laptop personal computer (PC) or transmitteddirectly by communications satellite (utilizing the Orb-comm controller). This data is then compiled at theKomatsu computer server. Based on this information,the servicing Komatsu distributor will suggestimprovements and provide information aimed atreducing machine repair costs and downtime.

When the data-store button (1, Figure 32-9) ispressed on the back side of the center console, it willstore a “snapshot” of the Statex III drive system. Itwill also trigger the VHMS system to store a “snap-shot” of the truck operating system. A light (2, Figure32-9) will stay illuminated while the VHMS system isrecording the “snapshot”, which lasts for 7.5 minutes.

The VHMS system is turned on by the truck keyswitch. Immediately after receiving 24V power fromthe key switch, the VHMS controller begins thepower-up initialization sequence. This sequencetakes about three seconds, during which time the redLED digits (4, Figure 32-10) display a circularsequence of flashing LED segments.

During normal truck operation, the red LED digits onthe VHMS controller will count from 00-99 continu-ously.

When the key switch is turned OFF, the VHMS con-troller will remain on while it finishes processing inter-nal data and saves the recent data into permanentmemory. When the data has been safely stored, thetwo digit LED display will turn OFF. This processcould take up to three minutes to complete.

If 24V power is disconnected (using the batterydisconnect switches) from the VHMS controllerbefore it has completed it’s shut down proce-dure, the VHMS controller will lose all data gath-ered since the key switch was last turned ON. Donot disconnect battery power until the VHMScontroller has completed the shut down proce-dure and has turned the LED digits off.

FIGURE 32-9. CENTER CONSOLE, REAR VIEW

1. Data Store Button2. VHMS Snapshot In Progress Light

FIGURE 32-10. VHMS COMPONENT LOCATION1. Orbcomm Controller2. VHMS Controller3. Interface Module

4. Red LED Lights5. Green LED Light


The Orbcomm controller (1, Figure 32-10) transmitsdata through antenna (1, Figure 32-11) mounted ontop of the cab. The antenna coaxial cable is routedthrough protective tube structure (2) to protect it fromdamage. If the antenna or coaxial cable is damaged,replace the parts.

Interface Module

Interface module (3, Figure 32-10) receives datafrom the sensors installed on the truck and sends thisinformation to the VHMS controller. There is a smallgreen LED light on the face of the controller. With thekey switch ON, the light should be blinking. If the lightis continuously illuminated, there is a problem in thecontroller.

When a new interface module controller is installedon the truck, new software has to be installed insidethe controller. IM-Diag connector (1, Figure 32-12) isused to connect the interface module to a laptop PCfor installing software.

Basic Precautions

When using this truck, there is no particular need tooperate the VHMS system.

Never disassemble, repair, or modify the VHMS sys-tem. This may cause failure or fire on the machine orthis system.

Do not touch the system when operating themachine.

Do not pull on the wiring harnesses, connectors. orsensors of this system. This may cause short circuitsor disconnections that lead to failure or fire on themachine or this system.

Do not get water, dirt or oil on the system controllers.

If there is any abnormality with the VHMS system,please consult the servicing Komatsu distributor.

FIGURE 32-11. ORBCOMM ANTENNA1. Orbcomm Antenna 2. Tube Structure

FIGURE 32-12. DIAGNOSTIC PORTS(D.I.D. PANEL AT REAR OF CAB)

1. IM Diagnostic Port2. VHMS Diagnostic Port


FUSE BLOCKSLOCATION AMPS DEVICES(S) PROTECTED CIRCUIT LOCATION

Terminal A Fuses 1-12: 24VDC Key Switch PowerFB1-1 15 A/C, Heater Blower Motor 12H Auxiliary Control Cabinet

FB1-2 10 Windshield Washer / Wiper 63 Auxiliary Control Cabinet

FB1-3 5 Fuel Gauge, Engine Temp Gauge 712G Auxiliary Control Cabinet

FB1-4 10 Cab Key Switch Power 712P Auxiliary Control Cabinet

FB1-5 10 Hoist Limit Solenoid 712H Auxiliary Control Cabinet

FB1-6 15 Turn / Clearance Lights 712T Auxiliary Control Cabinet

FB1-7 10 Engine Options 712E Auxiliary Control Cabinet

FB1-8 10 AID and Indicator Lights 12M Auxiliary Control Cabinet

FB1-9 15 Engine Start Failure 712SF Auxiliary Control Cabinet

FB1-10 10 Engine Shutters 712R Auxiliary Control Cabinet

FB1-11 10 Dome Light Switch 712A Auxiliary Control Cabinet

Terminal B Fuses 13-16: 12VDC Regulated PowerFB1-13 10 Radio Relay 65 Auxiliary Control Cabinet

Terminal C Fuses 17-24: Ground Level Shut Down PwrFB1-17 15 Key Switch Supply 11KS Auxiliary Control Cabinet

FB1-18 15 Payload Meter III Lights 39J Auxiliary Control Cabinet

FB1-19 5 Payload Meter III 39G Auxiliary Control Cabinet

Terminal A Fuses 1-12: 24VDC Battery PowerFB2-1 15 Engine Service Lights 11SL Auxiliary Control Cabinet

FB2-2 15 Dome, Fog, Hour Meter, Ladder Lights 11L Auxiliary Control Cabinet

FB2-3 15 Hazard Lights 46 Auxiliary Control Cabinet

FB2-4 10 Interface Module 11INT Auxiliary Control Cabinet

FB2-5 10 VHMS/ORB Comm Power 85 Auxiliary Control Cabinet

FB2-6 20 Modular Mining Hub 11M Auxiliary Control Cabinet

FB2-7 15 VHMS/Orbcom Battery 11DISP Auxiliary Control Cabinet

FB2-8 15 HID Head Lights 11HDL Auxiliary Control Cabinet

FB2-9 15 Oil Reserve Pump 11ORS Auxiliary Control Cabinet

FB2-10 15 Reserve Control Module 11RCNT Auxiliary Control Cabinet

FB2-11 20 Hydraulic Bleed-down Power 11BD Auxiliary Control Cabinet

Terminal A Fuses 1-12: Drive Control PowerFB3-1 15 Cab Drive System Power 71P Auxiliary Control Cabinet

FB3-2 10 Automatic Lube 68ES Auxiliary Control Cabinet

FB3-3 10 GE Power Interface Module 71IM Auxiliary Control Cabinet

Terminal B Fuses 13-16: 15V From GE to Wheel SpeedFB3-13 10 Right Front Wheel 15RWS Auxiliary Control Cabinet

FB3-14 10 Left Front Wheel 15LWS Auxiliary Control Cabinet

Terminal C Fuses 17-24: 12V Unregulated PowerFB3-17 10 Power Plugs (12 V) 67C Auxiliary Control Cabinet

FB3-18 20 R.H. Window (12 V) 67R Auxiliary Control Cabinet

FB3-19 20 L.H. Window (12 V) 67P Auxiliary Control Cabinet


FUSE BLOCKSLOCATION AMPS DEVICES(S) PROTECTED CIRCUIT LOCATION

Terminal A Fuses 1-12: FB4-1 10 Brake Circuits 71BC Auxiliary Control Cabinet

FB4-2 5 Payload Meter III 712PL Auxiliary Control Cabinet

FB4-3 5 Interface Module 87 Auxiliary Control Cabinet

FB4-4 10 VHMS Module 71VHM Auxiliary Control Cabinet

FB4-5 5 Modular Mining Hub 712MM Auxiliary Control Cabinet

FB4-6 5 Display Module 86 Auxiliary Control Cabinet

FB4-7 15 Bleed-down Circuit 71BD Auxiliary Control Cabinet

FB4-8 10 OP Switch LED Power 71LS Auxiliary Control Cabinet

FB4-9 10 Selector Switch Power 71SS Auxiliary Control Cabinet

Terminal C Fuses 17-24: 15V From GEFB4-17 5 Temperature Gauge 15V Auxiliary Control Cabinet

FB4-18 15 Pedal Voltage 15PV Auxiliary Control Cabinet

FB4-19 5 Engine Interface 15VL Auxiliary Control Cabinet

CIRCUIT BREAKERSAMPS DEVICES(S) PROTECTED CIRCUIT LOCATION

CBA 5 Pay Load Meter III 396 Auxiliary Control Cabinet

CBB 15 Pay Load Meter III 11S Auxiliary Control Cabinet

CB13 12.5 Clearance Lights 46 RB1, Auxiliary Control Cabinet

CB14 15 Turn Signal Flasher 11Z RB1, Auxiliary Control Cabinet

CB15 12.5 Tail Lights 41T RB1, Auxiliary Control Cabinet

CB16 12.5 Retard Lights 44D RB3, Auxiliary Control Cabinet

CB17 12.5 Manual Back-Up Lights 47B RB3, Auxiliary Control Cabinet

CB18 12.5 Stop Lights 44A RB3, Auxiliary Control Cabinet

CB19 15 Backup Lights and Horn 79A RB3, Auxiliary Control Cabinet

CB11 12.5 Backup Horn and Lights 79A RB3, Auxiliary Control Cabinet

CB20 5 Engine Control Power 23D RB4, Auxiliary Control Cabinet

CB21 12.5 Service Lights, Horn, Solenoid 11A RB4, Auxiliary Control Cabinet

CB22 5 Engine Run Relay 439E RB4, Auxiliary Control Cabinet

CB23 12.5 Headlights, Left Low Beam 11DL RB5, Auxiliary Control Cabinet

CB24 12.5 Headlights, Right Low Beam 11DR RB5, Auxiliary Control Cabinet

CB25 12.5 Headlights, Left High Beam 11HL RB5, Auxiliary Control Cabinet

CB26 12.5 Headlights Right High Beam 11HR RB5, Auxiliary Control Cabinet

CB27 12.5 Headlights and Dash Lights 11D RB5, Auxiliary Control Cabinet

CB60 50 11CB2 Battery Control Box

CB61 15 11C1 Battery Control Box


NOTES

OM4048 Lubrication & Service - Section 40Page 40-1

LUBRICATION AND SERVICERecommended preventive maintenance will contrib-ute to the long life and dependability of the truck andits components. The use of proper lubricants and theperformance of checks and adjustments at the rec-ommended intervals is most important.

Lubrication requirements are referenced to the lubekey found in the Lubrication Chart (page 40-3). Fordetailed service requirements for specific compo-nents, refer to the service manual section for thatcomponent (i.e. Section H for suspensions, Section Lfor hydraulic system, etc.).

Refer to the manufacturer's service manual whenservicing any components of the General Electricsystem.

Refer to the engine manufacturer's service manualwhen servicing the engine or any of its components.

The service intervals presented here are in hours ofoperation. These intervals are recommended inlieu of an oil analysis program which may deter-mine different intervals. However, if the truck isbeing operated under extreme conditions, some orall, of the intervals may need to be shortened and theservice performed more frequently.

The 830E truck is equipped with an automatic lubri-cation system. The initial setup for this system pro-vides for nominal amounts of lubricant to bedelivered to each serviced point. The lubricationinjectors can be adjusted to vary the amount of lubri-cant delivered. In addition, the timer for lubricationintervals is normally adjustable. For adjustments tothese devices, refer to Automatic Lubrication Systemlater in this manual.

830E SERVICE CAPACITIES

HYDRAULIC TANK SERVICE

There are two sight gauges on the side of thehydraulic tank. With the engine stopped, key switchOFF, hydraulic system bled down and body down, oilshould be visible in the top sight gauge. If hydraulicoil is not visible in the top sight gauge, follow AddingOil instructions below.

Adding Oil

Keep the system open to the atmosphere only aslong as absolutely necessary to lessen the chancesof system contamination.

Service the tank with clean Type C-4 hydraulic oilonly. All oil being put into the hydraulic tank must befiltered through filters rated at three microns.

1. With the engine stopped, key switch OFF,hydraulic system bled down and body down,check to see that hydraulic oil is visible in thetop sight gauge.

2. If hydraulic oil is not visible in the top sightgauge, remove the tank fill cap. Add clean, fil-tered C-4 hydraulic oil (Lubrication Chart, LubeKey “B”) until oil is visible in the top sight gauge.

3. Install the fill cap. 4. Start the engine. Raise and lower the dump

body three times.5. Repeat Steps 1 through 4 until oil is maintained

in the top sight gauge with engine stopped,body down, and hydraulic system bled down.

WHEEL MOTOR SERVICE

Due to differences in gear ratio and component evo-lution/design, wheel motor service intervals may beunit number and/or mine specific. Because of thewide variety of factors involved, it is necessary toconsult your area Komatsu representative for allwheel motor service intervals and instructions. Gen-eral intervals for oil service and sampling are listed inthe interval charts.

Crankcase:(including 4 oil filters)Komatsu SDA16V160 orSSDA16V160 Engines

Liters U.S.Gallons

280 74

Cooling System:Komatsu SDA16V160 orSSDA16V160 Engine

568 150

Hydraulic System:Refer to “Hydraulic Tank Service”

947 250

Wheel Motor Gear Box(each side)

38 10

Fuel Tank (Diesel Fuel Only) 4542 1200

Lubrication & Service - Section 40 OM4048Page 40-2

COOLANT LEVEL CHECK

Inspect the coolant sight gauge. If coolant cannot beseen in the sight gauge, it is necessary to add cool-ant to the system before truck operation. Refer to theprocedure below for the proper filling procedure.

RADIATOR FILLING PROCEDURE

The cooling system is pressurized due to thermalexpansion of coolant. DO NOT remove the radia-tor cap while the engine and coolant are hot.Severe burns may result.

1. With the engine and coolant at ambient temper-ature, remove the radiator cap.

NOTE: If coolant is added using the Wiggins quick fillsystem, the radiator cap MUST be removed prior toadding coolant.

2. Fill the radiator with the proper coolant mixture(as specified by the engine manufacturer) untilcoolant is visible in the sight gauge.

3. Install the radiator cap.4. Operate the engine for five minutes. Check the

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

repeat Steps 1 through 4. Any excess coolantwill be discharged through the vent hose afterthe engine reaches normal operating tempera-ture.

Engine coolant must always be visible in the sightgauge before truck operation.

RESERVE ENGINE OIL SYSTEM (Optional)The reserve oil tank for the engine is designed to addmore oil capacity to the engine to reduce the frequentservicing of the engine oil. The engine oil level muststill be checked every shift using the dipstick. Ifengine oil level is not correct, check for proper opera-tion of the reserve oil system. Never add oil to theengine unless it has been drained.

If the engine oil has been drained from the oil pan,the new oil must be added to the engine oil panbefore starting. DO NOT use the oil in the reservetank to fill an empty engine with oil. After an oilchange, both the engine and reserve tank must befull of oil before starting the engine.

Reserve Oil Tank Filling Procedure (Remote fill)1. Connect the pressure supply hose from the

new oil supply to the quick coupler on the truck.Open valve on supply hose to apply pressure.

2. Pull out on switch (2, Figure 40-1) to turn thesystem on.

3. Push start switch (3). The VALVE OPEN light(5) should illuminate and the filling process willbegin.

4. When tank is full, the VALVE OPEN light willturn off and FULL light (4) will illuminate.

5. Close the oil supply valve in the fill hose.6. Press and hold start switch (3) for a couple of

seconds.7. Disconnect the new oil supply hose.8. Push switch (2) in to turn system power OFF.

FIGURE 40-1. CONTROL PANEL

COOLING SYSTEMANTI-FREEZE RECOMMENDATIONS

(Ethylene Glycol Permanent Type Anti-Freeze)Percentage of

Anti-FreezeProtection

To:10 + 23° F - 5° C20 + 16° F - 9° C25 + 11° F - 11° C30 + 4° F - 16° C35 - 3° F - 19° C40 - 12° F - 24° C45 - 23° F - 30° C50 - 34° F - 36° C55 - 48° F - 44° C60 - 62° F - 52° C

Use only anti-freeze that is compatible with engine as specified by engine manufacturer.

1. Remote Control Box2. System Switch3. Start Switch

4. “FULL” Light5. “VALVE OPEN”

Light


LUB

RIC

ATIO

N C

HA

RT


10 HOUR (DAILY) INSPECTION

Truck Serial Number______________________ Site Unit Number_______________ Date_______________Hourmeter_____________ Name of Service Technician___________________________________

TASK COMMENTS CHECKED INITIALS1. MACHINE - Inspect the entire machine for leaks,

worn parts, and damage. Repair as necessary.2. FAN DRIVE AND TURBOCHARGERS - Check for

leaks, vibration or unusual noise. Check alternator and fan belt condition and alignment.

3. RADIATOR - Check the coolant level and fill with the proper mixture as shown in the Cooling System Rec-ommendation Chart in this chapter. Refer to the engine manual for proper coolant additives.

4. ENGINE -

a. Check the oil level on the dipstick. Refer tothe engine manual for oil recommendations.(Lube Key “A”).

NOTE: If the truck is equipped with a reserve engineoil tank, the oil should be visible in the center (middle)sight gauge. If not, add oil to the reserve tank until oilis visible in the top sight gauge. Also, with the enginerunning, check operation of the LED indicator light.See below for description of LED light signals. Referto Figure 40-1.

LED Light Signals: • Steady - Pump 1 is withdrawing oil from the

engine sump and bringing down the oil level. • Regular pulsing - Pump 2 is returning oil to the

engine sump and raising the oil level. • Irregular pulsing - Oil is at the correct operating

level.

b. Inspect exhaust piping for integrity.

c. Check for abnormal noises and fluid leaks.

d. Eliminator Filter - Check operating indicator.5. HYDRAULIC TANK - Check the oil level in the tank.

Add oil if necessary. Refer to Hydraulic Tank Service - Adding Oil. Oil should be visible in the top sight glass. - DO NOT overfill. Lube Key “B”.

6. WHEELS AND TIRES -

a. Inspect tires for proper inflation and wear.b. Check for embedded debris in tread and remove.c. Inspect for damaged, loose, or missing wheel

mounting nuts and studs.


10 HOUR (DAILY) INSPECTION (Continued)


TASK COMMENTS CHECKED INITIALS7. COOLING AIR DUCTWORK - Inspect ductwork from

the blower to the rear drive case. Ensure that duct-work is secure, free of damage, and unrestricted.

8. AIR INTAKE PIPING - Check all mounting hardware,joints, and connections. Ensure no air leaks exist andall hardware is properly tightened. Figure 40-2.

9. AIR CLEANERS - Check the air cleaner vacuumgauges in the operator cab, Figure 40-3. The aircleaner(s) must be serviced if the gauge(s) shows thefollowing maximum restriction:

Komatsu SDA16V160 or SSDA16V160 Engines: . . . . . . . . . . . . . . . . . . . . . . . . 25 in. of H2O vacuum.

Refer to Section C in the shop manual for servicinginstructions for the air cleaner elements. Empty the aircleaner dust caps.

NOTE: After service, push the reset button on face ofgauge to allow the gauge to return to zero.

10. CAB AIR FILTER - Under normal operating condi-tions, clean every 250 hours. In extremely dusty con-ditions, service as frequently as required. Clean the filter element with mild soap and water. Rinse com-pletely clean and air dry with a maximum of 275 kPa (40 psi). Reinstall the filter. Refer to Figure 40-4.

FIGURE 40-2. FIGURE 40-3.

FIGURE 40-4. 1. Filter Cover 2. Cab Filter


10 HOUR (DAILY) INSPECTION (Continued)


TASK COMMENTS CHECKED INITIALS11. FUEL FILTERS (Fuel Separators) - Drain water from

the bottom drain valve on each fuel separator.12. AUTOMATIC LUBE SYSTEM -

• Check the grease reservoir; fill as required. LubeKey “D”.

• When filling the reservoir, check the grease filterindicator. Clean or replace the grease filter if theindicator detects a problem.

• Inspect the system and check for properoperation. Ensure the following important areasare receiving adequate amounts of grease. LubeKey “D”.

Steering Linkage

Final Drive Pivot Pin

Rear Suspension Pin Joints - Upper & Lower

Body Hinge Pins - Both Sides

Hoist Cylinders Pins - Upper & Lower

Anti-sway Bar - Both Ends


50 HOUR LUBRICATION AND MAINTENANCE CHECKS

*These checks are required only after the initial 50 hours of operation (such as: the commissioning of a newtruck, or after a new or rebuilt component installation).


TASK COMMENTS CHECKED INITIALS*1. FUEL FILTERS - Change the fuel filters, (fuel

separators).

Refer to engine manufacturer's maintenance manualfor fuel filter replacement instructions.

*2. HYDRAULIC SYSTEM FILTERS - Replace filter ele-ments only, after the initial 50, 100, and 250 hours ofoperation; then at each 500 hours of operation there-after.

*3 FAN DRIVE ASSEMBLY - Check torque for the sixfan mounting cap screws: 237 N·m (175 ft. lbs.). SeeFigure 40-5.

FIGURE 40-5.


100 HOUR LUBRICATION AND MAINTENANCE CHECKS

*These checks are required only after the initial 100 hours of operation (such as: the commissioning of a newtruck, or after a new or rebuilt component installation), check:


TASK COMMENTS CHECKED INITIALS*1. HYDRAULIC SYSTEM FILTERS - Replace filter ele-

ments only, after the initial 100 and 250 hours ofoperation; then at each 500 hours of operation there-after.


250 HOUR LUBRICATION AND MAINTENANCE CHECKSThe 10 hour lubrication and maintenance checks should also be performed at this time.

NOTE: “Lube Key” references are to the lubrication chart.

(CONTINUED NEXT PAGE)


TASK COMMENTS CHECKED INITIALS1. ENGINE - Refer to the engine manufacturer’s Opera-

tion & Maintenance manual for complete specifica-tions regarding engine lube oil specifications.

NOTE: If the engine is equipped with the *Centinel™oil system and/or the Eliminator™ filter system,engine oil and filter change intervals are extendedbeyond 250 hours. Refer to engine Operation &Maintenance manual for specific oil and filter changeintervals.

* The Centinel™ system is a duty-cycle-dependentlubrication management system whereby oil isblended with the fuel and burned and an extension ofoil change intervals can occur.

a. Change engine oil. Lube Key “A”.

b. Replace engine oil filters.

NOTE: When installing spin-on filter elements, followthe instructions as specified by the filter manufacturer.The tightening instructions are normally printed on theoutside of the filter. Do not use a wrench or strap totighten filter elements.

c. If the truck is equipped with a reserve engineoil tank, change the reserve tank oil filter.

d. Check belt tension and condition of eachaccessory belt. Refer to engine Operation &Maintenance manual for specific adjustmentinstructions.

e. Check the torque on the cooling fan mountingcap screws (1, Figure 40-5). Tighten capscrews (2) to 237 N·m (175 ft lbs).


250 HOUR LUBRICATION AND MAINTENANCE (Continued)

TASK COMMENTS CHECKED INITIALS2. COOLING SYSTEM -

a. COOLANT MIXTURE - Check for propercoolant mixture. Add coolant as required.

b. COOLANT FILTERS - Change coolant filters.

c. COOLING SYSTEM HOSES - Check coolingsystem hoses for damage and signs of deteri-oration.

Refer to the engine maintenance manual for coolantfilter replacement instructions and proper coolant mix-ture instructions.

3. FUEL FILTERS - Change the fuel filters (fuel separa-tors). Refer to engine Operation & Maintenance man-ual for specific filter replacement instructions.

4. FUEL TANK - Drain water and sediment from the fueltank. Refer to Shop Manual, Section B, Fuel Tank -Cleaning.

5. STEERING LINKAGE - Check the torque on pinretaining nuts (1, Figure 40-6) on the steering linkage- 712 N·m (525 ft lbs). Check the torque on tie rodretaining nuts (2) - 420 N·m (310 ft lbs).

6. HYDRAULIC PUMP DRIVESHAFT & U-JOINTS -Add one or two applications of grease to each greasefitting. Non - moly grease only. Check that each bear-ing of the cross & bearing assembly is receivinggrease. Replace bearings if any wear is detected.

7. CAB AIR FILTER - Under normal operating condi-tions, clean every 250 hours. In extremely dusty con-ditions, service as frequently as required. Clean thefilter element with mild soap and water. Rinse com-pletely clean and air dry with a maximum of 275 kPa(40 psi). Reinstall the filter. Refer to Figure 40-4.

FIGURE 40-6.


250 HOUR LUBRICATION AND MAINTENANCE (Continued)

*This check is required only after the first 250 hours of operation (such as: the commissioning of a new truck, orafter a new or rebuilt component installation), check:

TASK COMMENTS CHECKED INITIALS8. MOTORIZED WHEEL GEAR CASE - Refer to the

G.E. Planned Maintenance Manual and specificmotorized wheel shop manual. Check for correct oillevel. Lube key “C”.

*9. HYDRAULIC SYSTEM FILTERS - Replace filter ele-ments only after the initial 250 hours of operation;then at each 500 hours of operation thereafter. Checkoil level. Add oil as necessary. Lube Key “B”.

10. BATTERIES - Check the electrolyte level and addwater if necessary.

11. BODY-UP & HOIST LIMIT SWITCHES - Check oper-ation of the switches. Clean the sensing areas of anydirt accumulation and inspect the wiring for any signsof damage.

12. WHEEL MOTOR BLOWER (If equipped) - Greasemotor blower shaft bearings. Lube key “D”.

13. G.E. PREFILTER BLOWER (If equipped) - Add oneto two applications of grease to the grease fitting.Lube key “D”.


500 HOUR LUBRICATION AND MAINTENANCE CHECKSMaintenance requirements for every 10 & 250 hour Lubrication and Maintenance Checks should also be per-formed at this time.



TASK COMMENTS CHECKED INITIALS1. FINAL DRIVE CASE BREATHERS - Remove the

breather elements for the motorized wheels. Clean orreplace the elements.

2. HYDRAULIC SYSTEM FILTERS - Replace the tankbreathers and high pressure filter elements. Checkthe 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 - Lubricate the trea-dle roller and hinge pins with lubricating oil. Lift the boot from the mounting plate and apply a few drops of lubricating oil between the mounting plate and the plunger.

5. HOIST ACTUATOR LINKAGE - Check operation. Clean, lubricate, and adjust as necessary.

6. PARKING BRAKE - Refer to Section J, Parking Brake Maintenance. Perform the recommended inspections.

7. RESERVE ENGINE OIL SYSTEM (OPTION)

a. Check electrical system connections for tight-ness, corrosion and physical damage. Checkthe battery, oil pressure switch, junctionboxes, remote control fill box and the circuitbreakers.

b. Examine all electrical cables over their entirelength for possible damage.

c. Examine all hoses, including those on thereserve tank and the ones leading to andfrom the engine. Check for leaks, cracks orother damage. Check all fittings for tightness,leakage or damage.

8. ACCUMULATOR PRECHARGE - Check all steering and brake system accumulator pre-charge pressures. Refer to shop manual for details.


500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)


TASK COMMENTS CHECKED INITIALS9. WHEEL MOTOR OIL SAMPLING - Refer to Section

G5, Wheel Motor, for oil sampling information.10. WHEEL MOTOR OIL (Initial 500 hours only) -

Change or filter wheel motor gear oil only after initial500 hours or operation. Wheel motor gear oil must befiltered or changed every 2500 hours of operationthereafter.

11. FRONT WHEELS - Check front wheel bearing pre-load 500 hours after truck commissioning (and at 500hours after each rebuild) and every 10,000 hoursthereafter. Refer to Section G in the shop manual forbearing preload adjustment procedures.

12. VHMS DATA DOWNLOAD - Using a laptop PC withthe VHMS Technical Analysis Tool Box program, per-form a data download from the VHMS controller.Send the data to WebCARE using the FTP feature.Refer to Section D in the shop manual for moredetailed instructions.


1000 HOURS LUBRICATION AND MAINTENANCE CHECKSMaintenance for every 10, 250, & 500 hour Lubrication and Maintenance Checks should also be performed at thistime.



TASK COMMENTS CHECKED INITIALS1. HYDRAULIC TANK - Drain the hydraulic tank and

clean the inlet strainer. Refill the tank with new oil;approximate capacity 901 l (238 gal). Use Lube Key“B”.

NOTE: Oil change interval can be extended to 2,500hours if oil is sampled at every 250 hour intervals andno abnormalities are detected.

2. RADIATOR - Clean the cooling system with a qualitycleaning compound. Flush with water. Refill the sys-tem with anti-freeze and water solution. Check theCooling System Recommendation Chart in this sec-tion for the correct mixture. Refer to the engine manu-facturer’s Operation and Maintenance Manual for thecorrect additive mixture.

3. FUEL TANK - Remove the breather and clean in sol-vent. Dry with pressurized air and reinstall.

4. OPERATOR'S SEAT - Apply grease to the slide rails. Lube Key “D”.

5. AUTOMATIC BRAKE APPLICATION - Ensure the brakes are automatically applied when brake pres-sure decreases below the specified limit. Refer to the appropriate Shop Manual, Section J, Brake Check-out Procedure.

6. FRONT ENGINE MOUNT TRUNION - Add one or two applications of grease at fitting. Lube key “D”.

7. AUTOMATIC LUBE SYSTEM PUMP - Check pump housing oil level. Refill to bottom of level plug with SAE 10W-30 motor oil.

8. ELIMINATOR FILTER - Clean and check centrifuge. Refer to engine manufacture’s Operation & Mainte-nance Manual. (Service interval is dependent on duty cycle, oil quality, etc.)


2500 HOUR MAINTENANCE CHECKSMaintenance for every 10, 250, & 500 hour Lubrication and Maintenance Checks should also be performed at thistime.


5000 HOUR MAINTENANCE CHECKSMaintenance for every 10, 250, 500 1,000 & 2,500 hour Lubrication and Maintenance Checks should also be per-formed at this time.



TASK COMMENTS CHECKED INITIALS1. WHEEL MOTOR GEAR OIL - Wheel motor gear oil

must be replaced every 2500 hours of operation.Refer to G.E. Motorized Wheel Service & Mainte-nance manual.

2. FRONT WHEELS - Drain oil and refill to proper level.Lube key “E”.


TASK COMMENTS CHECKED INITIALS1. AIR CLEANERS - Clean the Donaclone tubes in the

pre-cleaner section of the air filter. Use low pressurecold water or low pressure air to clean the tubes.Refer to Section C, Air Cleaners.

NOTE: Do not use a hot pressure washer or highpressure air to clean the tubes. Hot water/high pres-sure causes the pre-cleaner tubes to distort.


10,000 HOUR MAINTENANCE CHECKSMaintenance for every 10, 250, 500, 1,000, 2,500 & 5000 hour Lubrication and Maintenance Checks should alsobe performed at this time.



TASK COMMENTS CHECKED INITIALS1. WHEEL MOTORS - Clean the area around the

grease ports to prevent dirt or other contaminatesfrom entering. Remove the six grease port plugs oneach wheel motor. Grease the inboard and outboardwheel hub bearings with one 14 oz. cartridge pereach grease port.

2. FRONT WHEELS - Drain oil and completely disas-semble and check all parts for wear or damage. Referto Section “G” of the service manual for disassemblyand assembly procedures. Refill with oil. Check the oillevel at the oil level plug on wheel hub. Lube key “E”.Check bearing preload at the first 500 hours aftereach rebuild.

OM4209 Automatic Lubrication System - Section 4242-1

AUTOMATIC LUBRICATION SYSTEM

GENERAL DESCRIPTIONThe automatic lubrication system is a pressurized lubri-cant delivery system which delivers a controlledamount of lubricant to designated lube points. The sys-tem is controlled by an electronic timer which signals asolenoid valve to operate a hydraulic motor poweredgrease pump. Hydraulic oil for pump operation is sup-plied by the truck steering circuit.

Grease output is proportional to the hydraulic motorinput flow. A pump control manifold, mounted on top ofthe hydraulic motor, controls input flow and pressure. A24VDC Solenoid mounted on the manifold turns thepump on and off.

The pump is driven by the rotary motion of the hydrau-lic motor, which is then converted to reciprocatingmotion through an eccentric crank mechanism. Thereciprocating action causes the pump cylinder to moveup and down. The pump is a positive displacement,double-acting type as grease output occurs on both theup and the down stroke

During the down stroke, the pump cylinder is extendedinto the grease. Through the combination of shovelaction and vacuum generated in the pump cylinderchamber, the grease is forced into the pump cylinder.Simultaneously, grease is discharged through the out-let of the pump. The volume of grease during intake istwice the amount of grease output during one cycle.During the upstroke, the inlet check valve closes. Onehalf the grease taken in during the previous stroke istransferred through the outlet check and discharged tothe outlet port.

Over-pressurizing of the system, modifying parts,using incompatible chemicals and fluids, or usingworn or damaged parts, may result in equipmentdamage and/or serious personal injury.

• DO NOT exceed the stated maximum work-ing pressure of the pump, or of the lowest rated component in the system.

• Do not alter or modify any part of this sys-tem unless approved by factory authoriza-tion.

• Do not attempt to repair or disassemble the equipment while the system is pressurized.

• Make sure all fluid connections are securely tightened before using this equipment.

• Always read and follow the fluid manufac-turer's recommendations regarding fluid compatibility, and the use of protective clothing and equipment.

• Check all equipment regularly and repair, or replace, worn or damaged parts immedi-ately.

This equipment generates very high grease pres-sure. Extreme caution must be used when operat-ing this equipment as material leaks from loose orruptured components can inject fluid through theskin and into the body causing serious bodilyinjury including possible need for amputation. Ade-quate protection is recommended to preventsplashing 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 asimple cut. Tell attending physician exactly whatfluid was injected.

FIGURE 42-1. PUMP & RESERVOIR COMPONENTS1. Hose From Filter2. Outlet to Injectors3. Hydraulic Motor4. Pressure Reducing

Valve5. Solenoid Valve6. Test Switch

7. Vent Valve8. Pressure Gauge9. Pump Assembly

10. 1Flow Control Valve11. Pressure Switch12. Grease Reservoir13. Vent Hose

Section 42 - Automatic Lubrication System OM420942-2

FIGURE 42-2. AUTOMATIC LUBRICATION SYSTEM INSTALLATION

1. L.H. Suspension, Bottom Bearing2. L.H. Hoist Cylinder, Top Bearing3. L.H. Hoist Cylinder, Bottom Bearing4. L.H. Anti-Sway Bar Bearing5. L.H. Suspension, Top Bearing6. L.H. Body Pivot Pin7. R.H. Body Pivot Pin8. Grease Supply From Pump9. R.H. Suspension, Bottom Bearing

10. R.H. Hoist Cylinder, Top Bearing11. R.H. Hoist Cylinder, Bottom Bearing12. Rear Axle Pivot Pin

13. R.H. Anti-Sway Bar Bearing14. R.H. Suspension, Top Bearing15. Truck Frame16. Vent Hose17. Pipe Plug (Oil Level)18. Pressure Switch, N.O., 17 237 kPa (2500 psi)19. Grease Pump20. Vent Valve21. Filter22. Grease Supply to Injectors23. Injectors24. Pressure Switch, N.O., 13 790 kPa (2000 psi)

NOTE: The above illustration shows the standard location for the lube pump and reservoir(right platform). This assembly may be located on the left platform on some models.


SYSTEM COMPONENTS

FilterA filter assembly (21, Figure 42-2) mounted on the

grease reservoir filters the grease prior to refilling the reservoir from the shop supply. A bypass indicator

alerts service personnel when the filter requires replacement.

Hydraulic Motor and Pump

Rotary hydraulic pump (3 & 9, Figure 42-1) is a fullyhydraulically operated grease pump. An integratedpump control manifold is incorporated with the motor tocontrol input flow and pressure.

NOTE: The pump crankcase oil level must bemaintained to the level of the pipe plug (17, Figure 42-2). If necessary, refill with 10W-30 motor oil.

Hydraulic oil supply inlet pressure must notexceed 20 685 kPa (3000 psi). Exceeding the ratedpressure may result in damage to the system com-ponents and personal injury.

Grease Reservoir

The reservoir (12, Figure 42-1) has an approximatecapacity of 41 kg (90 lbs.) of grease. When the greasesupply is replenished by filling the system at the ser-vice center, the grease is passed through the filter toremove contaminants before it flows into the reservoir.

Pressure Reducing Valve

The pressure reducing valve (4, Figure 42-1), locatedon the manifold reduces the hydraulic supply pressure(from the truck steering circuit) to a suitable operatingpressure of 2241-2413 kPa (325-350 psi) for thehydraulic motor used to drive the lubricant pump.

Flow Control Valve

The flow control valve (10, Figure 42-1) mounted onthe manifold, controls the amount of oil flow to thehydraulic motor. The flow control valve has beenfactory adjusted and the setting should not be dis-turbed.

Solenoid Valve

The solenoid valve (5, Figure 42-1), when energized,allows oil to flow to the hydraulic motor.

Vent Valve

With the vent valve (7, Figure 42-1) closed, the pumpcontinues to operate until maximum grease pressure isachieved. As this occurs, the vent valve opens andallows the grease pressure to drop to zero, so theinjectors can recharge for their next output cycle.

Lubrication Cycle Timer

The solid state lubrication cycle timer provides a 24VDC timed-interval signal to energize the solenoidvalve (3, Figure 42-3) providing oil flow to operate thegrease pump motor. This timer is mounted in the Elec-trical Interface Cabinet.

Pump Cutoff Pressure Switch

Pressure switch (18, Figure 42-2) is a normally openswitch set at 17 237 kPa (2500 psi). This switch de-energizes the pump solenoid relay when the greaseline pressure reaches the switch pressure setting, turn-ing off the motor and pump.

Grease Pressure Failure Switch

Pressure switch (24, Figure 42-2) is a normally openswitch set at 13 789 kPa (2000 psi). This switch moni-tors grease pressure in the injector bank on the rearaxle housing. If the proper pressure is not sensedwithin 60 seconds (switch contacts do not close) awarning lamp circuit to notify the operator a problemexists in the lube system.

Pressure Gauge

The pressure gauge (8, Figure 42-1) monitors hydrau-lic oil pressure to the inlet of the hydraulic motor.

Injectors

Each injector (23, Figure 42-2) delivers a controlledamount of pressurized lubricant to a designated lubepoint. Refer to Figure 42-2 for locations.


SYSTEM OPERATION

Normal Operation:1. During truck operation, the lubrication cycle timer

will energize the system at a preset time interval.2. The timer provides 24 VDC to energize the pump

solenoid valve (3, Figure 42-3), allowing hydraulicoil provided by the truck steering pump circuit toflow to the pump motor and initiate a pumpingcycle.

3. The hydraulic oil pressure from the steering circuitis reduced to 2241-2413 kPa (325-350 psi) by thepressure reducing valve (4) before entering themotor. In addition, the amount of oil supplied tothe pump is limited by the flow control valve (6).Pump pressure can be read using the gauge (5)mounted on the manifold.

4. With oil flowing into the hydraulic motor, thegrease pump will operate, pumping grease fromthe reservoir to the injectors (13), through a checkvalve (10) and to the vent valve (11).

5. During this period, the injectors will meter theappropriate amount of grease to each lubricationpoint.

6. When grease pressure reaches pressure switch(18, Figure 42-2) setting, the switch contacts willclose and energize the relay RB7-K5, removingpower from the hydraulic motor/pump solenoidand the pump will stop. The relay will remainenergized until grease pressure drops (pressureswitch opens again) and the timer turns off.

7. After the pump solenoid valve is de-energized,hydraulic pressure in the manifold drops and thevent valve (11, Figure 42-3) will open, releasinggrease pressure in the lines to the injector banks.When this occurs, the injectors are then able torecharge for the next lubrication cycle.

8. The system will remain at rest until the lubricationcycle timer turns on and initiates a new greasecycle.

9. During the normal lubrication cycle, if greasepressure fails to reach 13790 kPa (2000 psi) atthe pressure switch located on the rear axle hous-ing, an amber indicator light will illuminate on theoverhead panel.

FIGURE 42-3. HYDRAULIC SCHEMATIC

1. Hydraulic Oil Return2. Hydraulic Oil Supply3. Pump Solenoid Valve4. Pressure Reducing Valve5. Motor Pressure Gauge

6. Flow Control Valve7. Hydraulic Motor8. Grease Pump9. Pressure Switch (N.O.)

10. Check Valve

11. Vent Valve12. Orifice13. Injector Bank


GENERAL INSTRUCTIONS

LUBRICANT REQUIRED FOR SYSTEMGrease requirements will depend on ambient tempera-tures encountered during truck operation:

• Above 32°C (90°F) - Use NLGI No. 2 multipur-pose grease (MPG).

• -32° - 32°C (-25° - 90°F) - Use NLGI No. 1 mul-tipurpose grease (MPG).

• Below -32°C (-25°F) - Refer to local supplier for extreme cold weather lubricant requirements.

System Priming

The system must be full of grease and free of air pock-ets to function properly. After maintenance, if the pri-mary or secondary lubrication lines were replaced, itwill be necessary to prime the system to eject allentrapped air.

1. Fill lube reservoir with lubricant, if necessary.2. To purge air from the main supply line, remove

the main supply line at the grease canister. Con-nect an external grease supply to the line.

3. Remove plugs from each injector group insequence (right front, left front, and rear axle).

4. Using the external grease source, pump greaseuntil grease appears at the group of injectors andre-install the pipe plug. Repeat for remaininginjector groups.

5. Remove the caps from each injector and connectan external grease supply to the zerk on the injec-tor and pump until grease appears at the far endof the individual grease hose or the joint beinggreased.

Filter Assembly

The filter assembly element (5, Figure 42-4) must bereplaced if the bypass indicator (2) shows excessiveelement restriction.

FIGURE 42-4. FILTER ASSEMBLY

1. Housing2. Bypass Indicator3. O-Ring4. Backup Ring5. Element

6. Spring7. Bowl8. O-Ring9. Plug


LUBRICANT PUMP

Pump Housing Oil Level

The pump housing must be filled to the proper levelwith SAE 10W-30 motor oil. Oil level should bechecked at 1000 hour intervals. To add oil, removepipe plug (4, Figure 42-5) and fill housing to bottom ofplug hole.

Pump Pressure Control

High pressure hydraulic fluid from the truck steeringsystem is reduced to 2240 - 2413 kPa (325 - 350 psi)by the pressure reducing valve located on the manifoldon top of the pump motor. This pressure can be readon the gauge installed on the manifold and should bechecked occasionally to verify pressure is within theabove limits.

Pressure Control Valve Adjustment1. With the truck engine on, activate the test switch

(2, Figure 42-5) to start the hydraulic motor andpump.

2. Loosen the locknut on the pressure control (1,Figure 42-5) by turning the nut counterclockwise.

3. Turn the valve stem counterclockwise until it nolonger turns. (The valve stem will unscrew until itreaches the stop - it will not come off.)

NOTE: This is the minimum pressure setting, which isapproximately 1172 kPa (170 psi).

4. With the pump stalled against pressure, turn thepressure control valve stem clockwise until 2240 -2413 kPa (325 - 350 psi) is attained on the mani-fold pressure gauge (2).

5. Tighten the locknut to lock the stem in position.

Note: The flow control valve (5) is factory adjusted to9.5 lpm (2.5 gpm). Do not change this setting.

FIGURE 42-5. PUMP CONTROLS

1. Pump Pressure Control2. Test Switch3. Pressure Gauge

4. Oil Level Plug5. Flow Control Valve


INJECTORS (SL-1 Series “H”))

Injector Specifications• Each lube injector services only one grease

point. In case of pump malfunction, each injec-tor is equipped with a covered grease fitting to allow the use of external lubricating equipment.

• Injector output volume: Maximum output = . . . . . . 1.31 cc (0.08 in3).Minimum output = . . . . . . 0.13 cc (0.008 in3).

• Operating Pressure:Minimum - . . . . . . . . . 12 755 kPa (1850 psi)Maximum - . . . . . . . . . 24 133 kPa (3500 psi)Recommended - . . . . 17 238 kPa (2500 psi)

• Maximum Vent Pressure - (Recharge) . . . . . . . . . . . . . . . . . . . 4 137 kPa (600 psi)

Injector Adjustment

The injectors may be adjusted to supply from 0.13 -1.31 cc (0.008 - 0.08 in3) of lubricant per injectioncycle. The injector piston travel distance determinesthe amount of lubricant supplied. This travel is in turncontrolled by an adjusting screw in the top of the injec-tor housing.

Turn the adjusting screw (1, Figure 42-6) counterclock-wise to increase lubricant amount delivered and clock-wise to decrease the lubricant amount.

When the injector is not pressurized, maximum injectordelivery volume is attained by turning the adjustingscrew (1) fully counterclockwise until the indicating pin(8) just touches the adjusting screw. At the maximumdelivery point, about 9.7 mm (0.38 inch) adjustingscrew threads should be showing. Decrease the deliv-ered lubricant amount by turning the adjusting screwclockwise to limit injector piston travel. If only half thelubricant is needed, turn the adjusting screw to thepoint where about 4.8 mm (0.19 inch) threads areshowing. The injector will be set at minimum deliverypoint with about 0.22 mm (0.009 inch) thread showing.

NOTE: The above information concerns adjustment ofinjector delivery volume. The timer adjustment shouldalso be changed, if overall lubricant delivery is too littleor too much. Injector output should NOT be adjusted toless than one-fourth capacity.

FIGURE 42-6. TYPE SL-1 INJECTOR

1. Adjusting Screw2. Locknut3. Piston Stop Plug4. Gasket5. Washer6. Viton O-Ring7. Injector Body Assy.8. Piston Assembly9. Fitting Assembly

10. Plunger Spring

11. Spring Seat12. Plunger13. Viton Packing14. Inlet Disc15. Viton Packing16. Washer17. Gasket18. Adapter Bolt19. Adapter20. Viton Packing

NOTE: The piston assembly (8) has a visibleindicator pin at the top of the assembly to verifyinjector operation.


INJECTOR OPERATION

STAGE 1.

The injector piston (2) is in its normalor “rest” position. The dischargechamber (3) is filled with lubricant fromthe previous cycle. Under the pressureof incoming lubricant (6), the slidevalve (5) is about to open the passage(4) leading to the measuring chamber(1) above the injector piston (2).

STAGE 2.

When the slide valve (5) uncovers thepassage (4), lubricant (6) is admittedto the measuring chamber (1) abovethe injector piston (2) which forces lu-bricant from the discharge chamber(3) through the outlet port (7) to thebearing.

STAGE 3.

As the injector piston (2) completes itsstroke, it pushes the slide valve (5)past the passage (4), cutting off furtheradmission of lubricant (6) to the pas-sage (4) and measuring chamber (1).The injector piston (2) and slide valve(5) remain in this position until lubri-cant pressure in the supply line (6) isvented.

STAGE 4.

After venting, the injector spring ex-pands, causing the slide valve (5) tomove, so that the passage (4) anddischarge chamber (3) are connectedby a valve port (8). Further expansionof the spring causes the piston tomove upward, forcing the lubricant inthe measuring chamber (1) throughthe passage (4) and valve port (8) torefill the discharge chamber (3).

Injector is now ready for the nextcycle.


SYSTEM CHECKOUTTo check system operation (not including timer), pro-ceed as follows:

1. Start the engine. 2. Actuate the test switch at the reservoir/pump

assembly.3. The motor and pump should operate until the sys-

tem attains 17 237 kPa (2500 psi). 4. Once the required pressure is achieved, the

pump motor should turn off and the systemshould vent.

5. Check for pump, hose or injector damage or leak-age with the system under pressure.

6. After checking system, stop the engine. Observ-ing normal precautions regarding high voltagepresent in the propulsion system before attempt-ing to repair lube system.

Lubrication Controller Check

Pressing the manual lube button on the enclosurecover will initiate a lube event. (See Figure 42-7).

Lubrication Controller Operation

The time between lube events is determined by thesetting of the rotary switch, which selects the numeralsetting, and the dip switch, which selects the units ineither minutes or hours.

Lubrication Controller Components

Mode switch (2, Figure 42-7) consists of 4 dipswitches. The first dip switch controls the maximumamount of “on time”, either 30 seconds or 120 seconds.

The second dip switch controls the mode, either timermode or controller mode. When the switch is set to thetimer mode, the amount of time that the pump is on willbe determined by the setting of the dip switch (30 sec-onds or 120 seconds). When the switch is set to thecontroller mode, a pressure switch must be installed inthe lube supply line. The pressure switch will detectsupply line pressure, and will reset the timer at a setpressure. If the pump fails to reach the set pressurewithin the dip switch setting (30 seconds or 120 sec-onds), the controller will initiate an alarm.

The third dip switch is for selecting the units for the “offtime” to be used in conjunction with off time switch (1).Hours or minutes may be selected.

The fourth dip switch is used to select “memory off” or“memory on”. When the switch is set to “memory off”, alube cycle will occur each time power is turned on. Thelube cycle will start at the beginning of the on time set-ting.

When the switch is set to “memory on”, the controllerwill function as follows:

1. When power is turned off during ‘off time’(between cycles), the lube cycle will resume at thepoint of interruption after power is restored. Inother words, the controller will remember its posi-tion in the cycle.

2. When power is turned off during ‘on time’ (duringa cycle), the controller will reset to the beginningof the lube cycle after power is restored.

Off time switch (1) is used to select units of time. Possi-ble time intervals are: 0.5, 1, 2, 4, 8, 15, 24 or 30. Themode switch determines whether the off time units willbe minutes or hours.

Cover (3) contains three LED windows and a manuallube switch. The LED’s indicate system operation andstatus. When power is on, a green LED will illuminate.When the pump is on, another green LED will illumi-nate. A red LED will illuminate when an alarm conditionoccurs.

Lubrication Controller Adjustment

The lubrication controller is factory adjusted to the fol-lowing switch settings:

dip switch 1 . . . . . . . . . . . . . . . . . . . . . . . 120 seconds

dip switch 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . timer

dip switch 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . minutes

dip switch 4 . . . . . . . . . . . . . . . . . . . . . . . . .memory off

Rotary Switch. . . . . . . . . . . . . . . . . . . . . . . . 15 minutes


FIGURE 42-7. LUBRICATION CYCLE TIMER

1. Off Time Switch2. Mode Switch

3. Cover


SYSTEM TROUBLESHOOTING CHARTIf the following procedures do not correct the problem, contact a factory authorized service center.

TROUBLE POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION

Pump Does Not Operate

Lube system not grounded.

Electrical power loss.

Timer malfunction.Solenoid valve malfunctioning.Relay malfunctioningMotor or pump malfunction.

Correct grounding connections to pump assembly and truck chassis.Locate cause of power loss and repair. 24 VDC power required. Ensure key switch is ON.Replace timer assemblyReplace the solenoid valve assemblyReplace relayRepair or replace motor and/or pump assembly. (Refer to Service Manual for rebuild instructions.)

NOTE: On initial startup of the lube system, the timing capacitor will not contain a charge, therefore the first timing cycle will be about double in length compared to the normal interval. Subsequent timer cycles should be as specified.

Pump Will Not PrimeLow lubricant supply. Dirt in reservoir, pump inlet clogged, filter

clogged.

Pump Will Not Build Pressure

Air trapped in lubricant supply line.Lubricant supply line leaking.

Vent valve leaking.Pump worn or scored.

Prime system to remove trapped air.Check lines and connections to repair leakage.Clean or replace vent valve.Repair or replace pump assembly. (Refer to Service Manual for rebuild instructions.)

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 (pres-sure release) the indicator stem will again move out into the adjusting yoke.Malfunctioning injector - usually indicated by the pump building pressure and then venting.All injectors inoperative - pump build up not sufficient to cycle injec-tors.

Replace individual injector assembly.

Service and/or replace pump assembly. (Refer to Service Manual for rebuild instructions.)

Pressure Gauge Does Not Register Pressure

No system pressure to the pump motor.No 24 VDC signal at pump sole-noid.Pressure reducing valve set too low.24V Relay (RB7K8 or RB7K5) may be defective.

Check hydraulic hose from steering sys-tem.Determine problem in 24 VDC electric system.Refer to “Pressure Control Valve Adjust-ment”.Replace relay.


TROUBLE POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION

Pump Pressure Builds Very Slowly Or Not At All

No signal at solenoid.

Check timer.

Controller Does Not Operate.

No electric power to controller.Turn on electric power to pump. “POWER” LED should light, “PUMP ON” LED should light when “MANUAL LUBE” is pressed.

“PUMP ON” LED Lights, But Load Connected To Terminals 3 & 4 Will Not

Energize

Printed circuit board failure. Remove and replace.

Load Connected To Terminals 3 & 4

Energized, But “PUMP ON” LED Does Not Light

Printed circuit board failure or key-pad failure.

Remove and replace.

Bearing Points Excessively Lubricated

Controller memory mode is to OFF. Switch controller memory mode to ON.

Injector output adjustment setting too high.

Readjust to lower setting.

Bearing Points Are Not Sufficiently Lubricated

Timer/controller cycle time setting too low.

Set to longer cycle time or reevaluate lube requirements.

Injector output adjustment setting too low.

Readjust injector output setting.

Timer/controller cycle time setting does not deliver lubricant often enough.

Set to shorter cycle time or reevaluate lube requirements.

System too large for pump output. Calculate system requirements per plan-ning manual.


PREVENTATIVE MAINTENANCE PROCEDURESUse the following maintenance procedures to ensureproper system operation.

Daily Lubrication System Inspection1. Check grease reservoir level.

Inspect grease level height after each shift ofoperation. Grease usage should be consistentfrom day-to-day operations.

• Lack of lubricant usage would indicate an inop-erative system. Excessive usage would indicate a broken supply line.

2. Check filter bypass indicator when filling reser-voir. Replace element if bypassing.

3. Check all grease hoses from the SL-1 Injectors tothe lubrication points.

a. Repair or replace all damaged feed line hoses.

b. Ensure that all air is purged and all new feedline hoses are filled with grease before sendingthe truck back into service.

4. Inspect key lubrication points for a bead of lubri-cant around seal. If a lubrication point appearsdry, troubleshoot and repair problem.

250 Hour Inspection1. Check all grease hoses from the SL-1 Injectors to

the lubrication points (see, Figure 42-2).

a. Repair or replace all worn / broken hoses.

b. Ensure that all air is purged and all new feedline hoses are filled with grease before sendingthe truck back into service.

2. Check all grease supply line hoses from the pumpto the SL-1 injectors.

a. Repair or replace all worn / broken supplylines.

b. Ensure that all air is purged and all new supplyline hoses are filled with grease before sendingthe truck back into service.

3. Check grease reservoir level.

a. Fill reservoir if low. Check filter bypass indica-tor when filling reservoir. Replace element ifbypassing.

b. Check reservoir for contaminants. Clean, ifrequired.

c. Check that all filler plugs, covers and breathervents on the reservoir are intact and free ofcontaminants.

4. Inspect all bearing points for a bead of lubricantaround the bearing seal.It is good practice to manually lube each bearingpoint at the grease fitting provided on each Injec-tor. This will indicate if there are any frozen orplugged bearings, and will help flush the bearingsof contaminants.

5. System Checkout

a. Remove all SL-1 injector cover caps to allowvisual inspection of the injector cycle indicatorpins during system operation.

b. Start truck engine.

c. Actuate the lube system test switch (6, Figure42-1). The hydraulic motor and grease pumpshould operate.

d. With the grease under pressure, check eachSL-1 injector assembly. The cycle indicator pin should be retractedinside the injector body.

e. When the system attains 17 237 kPa (2500psi), the pump should shut off and the pressurein the system should drop to zero, venting backto the grease reservoir.

f. With the system vented, check all of the SL-1injector indicator pins; all of the pins should bevisible. Replace or repair injectors, if defective.

g. Reinstall all injector cover caps.

h. Check timer operation.

Note: With engine on, lube system should activatewithin five minutes. The system should build 13790 -17237 kPa (2000 - 2500 psi) within 25-40 seconds.

i. If the system is working properly, the machineis ready for operation.

j. If the system is malfunctioning, refer to thetroubleshooting chart.

1000 Hour Inspection1. Check pump housing oil level. Refill to bottom of

level plug with SAE 10W-30 motor oil if necessary


NOTES:

OM5040 Specifications - Section 50Component Description Page 50-1

MAJOR COMPONENT DESCRIPTION

Truck And Engine

The 830E-AC Dump Truck is an off-highway, reardump truck with AC Electric Drive. The gross vehicleweight is 385 852 kg (850,650 lbs.). The engine is aKomatsu SDA16V160 rated @ 1865 kW (2500 HP).

Alternator (GTA-41)

The diesel engine drives an in-line alternator at enginespeed. The alternator produces AC current which isrectified to DC within the main control cabinet. The rec-tified DC power is converted back to AC by groups ofdevices called "inverters", also within the main controlcabinet. Each inverter consists of six "phase modules"under the control of a "gate drive unit" (GDU). TheGDU controls the operation of each phase module.

Cooling air for the control / power group and wheelmotors, as well as the alternator itself, is provided bydual fans mounted on the alternator shaft.

AC Induction Traction Motorized Wheels

The alternator output supplies electrical energy to thetwo wheel motors attached to the rear axle housing.The motorized wheels use three-phase AC inductionmotors with full-wave AC power.

The two wheel motors convert electrical energy back tomechanical energy through built-in gear trains withinthe wheel motor assembly. The direction of the wheelmotors is controlled by a forward or reverse handselector switch located on the center console.

Suspension

HYDRAIR®II suspension cylinders located at eachwheel provide a smooth and comfortable ride for theoperator and dampens shock loads to the chassis dur-ing loading and operation.

Operator's Cab

The operator cab has been engineered for operatorcomfort and to allow for efficient and safe operation ofthe truck. The cab provides wide visibility, with an inte-gral 4-post ROPS/FOPS structure, and an advancedanalog operator environment. It includes a tintedsafety-glass windshield and power-operated side win-dows, a deluxe interior with a fully adjustable seat withlumbar support, a fully adjustable tilt/telescope steeringwheel, controls mounted within easy reach of the oper-ator, and an analog instrument panel which providesthe operator with all instruments and gauges which arenecessary to control and/or monitor the truck's operat-ing systems.

Power Steering

The truck is equipped with a full time power steeringsystem which provides positive steering control withminimum operator effort. The system includes nitro-gen-charged accumulators which automatically provideemergency power if the steering hydraulic pressure isreduced below an established minimum.

Dynamic Retarding

The dynamic retarding is used to slow the truck duringnormal operation or control speed coming down agrade. The dynamic retarding ability of the electric sys-tem is controlled by the operator through the activationof the retarder pedal in the operators cab and by set-ting the RSC (Retarder Speed Control). DynamicRetarding is automatically activated, if the truck speedgoes to a preset overspeed setting.

Brake System

The braking system consists of an all hydraulic actua-tion system. Depressing the brake pedal actuateswheel-speed single disc front brakes and armature-speed dual disc rear brakes. The brakes can also beactivated by operating a switch on the instrumentpanel. The brakes will be applied automatically if sys-tem pressure decreases below a preset minimum.

The parking brake is intregal with the service brake cal-iper, and is spring-applied and hydraulically-released.The park brake is applied by moving the P-F-N-Rselector lever to the PARK position.

Specification - Section 50 OM5040Page 50-2 Component Descriptions

830E-AC MAJOR COMPONENTS

OM5040 Specifications - Section 50Component Description Page 50-3

SPECIFICATIONSThese specifications are for the standard Komatsu830E-AC Truck. Customer Options may change thislisting.

ENGINE

Komatsu SDA16V160No. of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16Operating Cycle. . . . . . . . . . . . . . . . . . . . . . . . 4-StrokeRated Brake HP. . . .1865 kW (2500 HP) @ 1900 RPMFlywheel HP . . . . . .1761 kW (2360 HP) @ 1900 RPM

Weight* (Wet) . . . . . . . . . 9,608 kg (21,182 pounds)* Weight does not include Radiator, Sub-frame, or Alternator

AC ELECTRIC DRIVE SYSTEM

(AC/DC Current)

Alternator . . . . . . . . . . . . . . General Electric GTA - 41Dual Impeller, In-Line Blower. .255 m³/ min (9,000 cfm)Motorized Wheels . . . . . GEB25 AC Induction Traction

MotorsStandard Gear Ratio*. . . . . . . . . . . . . . . . . 31.875:1Maximum Speed . . . . . . . . . . . . 64.5 km/h (40 mph)

*NOTE: Wheel motor application depends upon GVW, haul road grade and length, rolling resistance, and other parameters. Komatsu & G.E. must analyze each job condition to assure proper application.

DYNAMIC RETARDINGElectric Dynamic Retarding . . . . . . . . . . . . . . StandardMaximum Rating . . . . . . . . . . . . . . 2983 kW (4000 HP)

BATTERY ELECTRIC SYSTEMBatteries . 4 x 8D 1450 CCA, 12 volt, in series/parallel, and 2 x 30H 800CCA, 220-ampere-hour

batteries, bumper mounted with disconnect switch

Alternator . . . . . . . . . . . . 24 Volt, 260 Ampere OutputLighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 VoltCranking Motors (2). . . . . . . . . . . . . . . . . . . . . . 24 Volt

SERVICE CAPACITIES. . . . . . . . . . . . . . . . . . . . . . . . . . . Liters . . . (Gallons)Crankcase * . . . . . . . . . . . . . . . . . . . 280 . . . . . . . . .74 * Includes Lube Oil FiltersCooling System . . . . . . . . . . . . . . . . 568 . . . . . . (150)Fuel . . . . . . . . . . . . . . . . . . . . . . . . 4542 . . . . . (1200)Hydraulic System. . . . . . . . . . . . . . . 946 . . . . . . (250)Wheel Motor Gear Box (each) . . . . . . 38 . . . . . . . (10)

HYDRAULIC SYSTEMSHoist . . . . . . . . . . . . . . . . . . . . . . Tandem Gear Pump

851 lpm (225 gpm) @ 1900 rpm and 17 240 kPa (2,500 psi)

Steering/Brake Pump: . Pressure Compensated PistonRated @ . . . . . . . . . . . 246 lpm (65 gpm) @ 1900 rpm

and 18 961 kPa (2750 psi)Relief Pressure-Hoist. . . . . . . . . 17 240 kPa (2500 psi)Relief Pressure-Steering/Brake . 27 580 kPa (4000 psi)Hoist Cylinders (2) . . . . . . . . . . . . . . 3-Stage HydraulicTank (Vertical/Cylindrical) . . . . . . . . . Non-PressurizedFiltration. . . . . . . . . . . . . . In-line replaceable elements

Suction. . . . . . . . . . . . . .Single, Full Flow, 100 MeshHoist & Steering Filters ..............Beta 12 Rating =200

Dual In-Line, High Pressure

SERVICE BRAKESActuation . . . . . . . . . . . . . . . . . . . . . . . . . .All HydraulicFront . . . . . . . . . . . . . . . . . . Wheel Speed, Single Disc

Inboard Mounted . . . . . . . . . . . . . . . . . . . 3 CalipersDisc Diameter, O.D. . . . . . . . . . 1213 mm (47.75 in.)

Rear . . . . . . . . . . . . . . . . . Armature Speed, Dual DiscDisc Diameter, O.D. . . . . . . . . . . .635 mm (25.00 in.)

Emergency Brake- . .Automatically Applied (Standard)Wheel Brake Lock . . . . . . . . Manual Switch on Panel. . . . . . . . . . . . . . . . . . . . . . . . . (Loading and Dumping)

PARKING BRAKEEach Rear Wheel . . . . . . . . . . . . . . . . Intregal Caliper. . . . . . . . . . . . . Spring Applied, Hydraulically Released

STEERINGTurning Circle (SAE) . . . . . . . . . . . . . . . 28.4 m (93 ft.)

Twin hydraulic cylinders with accumulator assist to pro-vide constant rate steering. Emergency power steering automatically provided by accumulators.

Specification - Section 50 OM5040Page 50-4 Component Descriptions

STANDARD DUMP BODY CAPACITIES AND DIMENSIONSStandard, Heaped @ 2:1 (SAE) . . . .147 m3 (193 yd3)

Struck. . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 m3 (153 yd3)Loading Height Empty . . . . . . . . . . 6.61 m (21 ft. 8 in.)Dumping Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°Non-heated Body w/Exhaust Mufflers . . . . . . Standard*OPTIONAL capacity dump bodies are available.

TIRESRadial Tires (standard) . . . . . . . . . . . . . . . . . 40.00 R57Optional Tires . . . . . . . . . . . . . . . . . . . . . . . . 46/90 R57Rock Service, Deep Tread . . . . . . . . . . . . . . . TubelessRims, standard 5 piece . . . Rated to 827 kPa (120 psi)

WEIGHT DISTRIBUTIONEmpty Vehicle . . . . . . . . . . . Kilograms. . . (Pounds)Front Axle . . . . . . . . . . . . . . . . . 82 747. . . (182,426)Rear Axle . . . . . . . . . . . . . . . . . . 82 902. . . (182,768)Total (100% Fuel) . . . . . . . . . . . 165 649. . . (365,194)Standard Komatsu Body. . . . . . . 27 669. . . . (61,000)Standard tire weight . . . . . . . . . . 21 081. . . . (46,476)

Loaded Vehicle . . . . . . . . . . Kilograms. . . (Pounds)Front Axle . . . . . . . . . . . . . . . . . 127 330. . . (280,715)Rear Axle . . . . . . . . . . . . . . . . . 258 522. . . (569,935)Total . . . . . . . . . . . . . . . . . . . . . 385 852. . . (850,650)Nominal Payload* (242 U.S. Ton) 220 199. . (485,456)

*Nominal payload is defined by Komatsu America Cor-poration’s payload policy documentation. In general,the nominal payload must be adjusted for the specificvehicle configuration and site application. The figuresabove are provided for basic product description pur-poses. Please contact your Komatsu distributor forspecific application requirements.

OVERALL TRUCK DIMENSIONS(Empty with Standard Body)Length . . . . . . . . . . . . . . . . . . . . . . . . . . 14.4 m (47 ft. 3 in.)Width . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.32 m (24 ft. 0 in.)Height with Canopy . . . . . . . . . . . . . . . . 6.96 m (22 ft. 10 in.)Height with Dump Body Up . . . . . . . . . . 13.52 m (44 ft. 4 in.)Turning Circle (on front track) . . . . . . . . 28.4 m (93 ft. 0 in.)

OM6009 2/05 Payload Meter III - Section 60Page 60-1

PAYLOAD METER III™

INDEX

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-3Data Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-3Data Gathering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-3

COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-4System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-4Suspension Pressure Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-4Inclinometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-4Operator Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-4Operator Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-5Speed Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-5Body-Up Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-5Brake Lock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-5Payload Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-5Communications Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-5key switch Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-6Payload Meter Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-6Load Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-6Wiring and Termination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-7TCI Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-7

OPERATOR’S DISPLAY AND SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-8Reading the Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-8Reading the Load Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-8Using the Operator ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-8Using the Load and Ton Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-8Total Ton Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-8Total Load Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-9Clearing the Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-9Viewing Live Sensor Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-9Other Display Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-9

PAYLOAD OPERATION & CALCULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10Description of Haul Cycle States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10Haul Cycle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10Load Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-11Carry Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-11Measurement Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-11

SOURCES FOR PAYLOAD ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-11Payload Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-11Loading Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-12Pressure Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-12Swingloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-12Speed and Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-12

HAUL CYCLE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-12Haul Cycle Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-13Haul Cycle Warning Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-14

Payload Meter III - Section 60 OM6009 2/05Page 60-2

M: Haul Cycle Too Long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-15N: Sensor Input Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-15Frame Torque Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-15Sprung Weight Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-15Maximum Speed Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-15Alarm Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-15Fault Code Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-16

PC SOFTWARE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-17PC Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-17System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-17Installing the PLMIII Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-17

DOWNLOADING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-18PLM III SYSTEM CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-19

Starting Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-19Displayed Payload Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-19Time Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-19Connection Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-19Connecting to the Payload Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20Configure the Payload Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20Setting the Date and Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20Setting the Truck Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-21Setting the Gauge Display Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-21Setting the Frame Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-21Setting the Truck Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-21Setting the Komatsu Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-21Setting the Komatsu Customer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-21Clean Truck Tare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-22Inclinometer Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-22

DATA ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-23Creating a Query . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-23Sorting on Truck Unit Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-23Sorting on Truck Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-23Sorting on Date Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-24Sorting on Time Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-24Payload Detail Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-25Creating Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-25Summary - one page report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-26Detailed - multi-page report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-26Creating Graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-27Exporting Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-27CSV Export . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-27Compressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-28Importing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-29Deleting Haul Cycle Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-29Viewing Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30Deleting Alarm Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30


INTRODUCTIONPayload Meter III (PLMIII) measures, displays andrecords the weight of material being carried by an off-highway truck. The system generally consists of apayload meter, a gauge display, deck-mountedlights, and sensors. The primary sensors are foursuspension pressures and an inclinometer. Otherinputs include a body up signal, brake lock signal,and speed.

Data Summary

5208 haul cycles can be stored in memory. The fol-lowing information is recorded for each haul cycle:

• Payload

• Operator ID number (0000-9999)

• Distance traveled loaded and empty

• The amount of time spent empty run/stop,loading, loaded run/stop, and dumping

• Maximum speed loaded and empty with time ofday

• Average speed loaded and empty

• Empty carry-back load

• Haul-cycle, loading, dumping start time of day.

• Peak positive and peak negative frame torquewith time of day

• Peak sprung load with time of day

• Tire ton-mph for each front and average per reartires

The payload meter stores lifetime data that cannot beerased. This data includes:

• Top 5 maximum payloads and time stamps.

• Top 5 positive and negative frame torque andtime stamps

• Top 5 maximum speeds and time stamps

Data GatheringWindows 95/98/NT software is available to down-load, store and view payload and fault information.The PC software will download an entire truck fleetinto one Paradox database file. Users can query thedatabase by date, time, truck type and truck numberto produce reports, graphs and export the data. Thesoftware can export the data in '.CSV' format that canbe easily imported into most spreadsheet applica-tions. The Windows software is not compatible withthe Payload Meter II system.

It is important that each payload meter be configuredfor each truck using the PC software. The informationfor frame serial number and truck number is used bythe database program to organize the payload data.In addition, the payload meter must be configured tomake calculations for the proper truck model.Improper configuration can lead to data loss andinaccurate payload calculations.


COMPONENT DESCRIPTION

System Diagram

Suspension Pressure Sensors

PLMIII uses a two-wire pressure sensor. The rangefor the pressure sensor is 4000 psi (281 kg/cm2) andthe overload limit is 10,000 psi (700 kg/cm2). Onewire to the sensor is the supply voltage and the otheris the signal. The 0-4000 psi range is converted intoan electrical current between 4-20 ma. The supplyvoltage for the sensor is nominally +18vdc. Eachpressure sensor has an 118 in. (3000 mm) length ofcable. The cable is specially shielded and reinforcedto provide mechanical strength and electronic noiseimmunity.

Inclinometer

The inclinometer is used to increase the accuracy ofload calculations on an incline. The inclinometeruses three wires. For the sensor, red is the +18vdcsupply voltage, black is ground and the white is thesignal. The incline signal is a voltage between 1 and4 volts. Zero degrees of incline is represented by2.6vdc on the signal line. The voltage signal will bedecreased by 0.103vdc for every degree of nose upincline.

Operator Display

The speedometer/display gauge is used as a speed-ometer and payload display. The top display is usedfor speed and can display metric (km/h) or English(mph) units. Grounding terminal #4 on the back ofthe speedometer will switch the meter to display met-ric units. Leaving terminal #4 unconnected will causethe gauge to display English units. The speedometercan be adjusted using a calibration potentiometer inthe back just like existing speedometers.

The payload meter uses the lower display for pay-load information. The normal display mode showsthe current payload. The display can be changed toshow the load and total tons counter or the OperatorID. Using the operator switch on the dash panel, thecurrent suspension pressures and incline can be dis-played. The units for display are set using the PCsoftware. Payloads can be displayed in short tons,long tons or metric tons.


Operator Switch

The payload operator switch is used to set, view andclear the total load counter and total ton counter. It isalso used to enter the operator ID number (0-9999).This switch can also be used to view the suspensionpressures and inclinometer. The payload meter oper-ator switch is located on the dashboard. It is a two-way momentary switch. The top position is theSELECT position. The SELECT position is used stepthrough the different displays. The lower position isthe SET position. The SET position is used to set theoperator ID or clear the load and total ton counters.Normally the inputs from the switch to the payloadmeter are open circuit. The switch momentarily con-nects the circuit to ground.

Speed Input

PLMIII uses a speed signal to calculate speed, dis-tance, and other performance data. This input is criti-cal to the proper operation of the system. PLMIIIreceives this signal from the speedometer/operatordisplay on the dashboard. The same signal displayedto the operator is used by the system. Distance cal-culations are made based on the rolling radius of thetires for a particular truck.

Body-Up Switch

The body-up input signal is received from a magneticswitch located on the inside of the truck frame, for-ward the pivot pin of the truck body. This is the sameswitch typically used for input to the drive system.When the body is down, the switch closes and com-pletes the circuit to 71-control power. 24vdc indicatesthe body is down. Open circuit indicates that thebody is up.

Brake Lock Switch

The brake lock is used to lock the rear brakes on thetruck. It is necessary for the accurate calculation ofswingloads during the loading process. Without thebrake lock applied, the payload meter will not calcu-late swingloads during the loading process. Withoutthe brake lock, the payload meter will assume thatthe truck was loaded using a continuous loader andflag the haul cycle record. All other functions will benormal regardless of brake lock usage. The brakelock input comes from the switch located on the dashpanel. The brake lock switch connects the circuit toground. Open circuit indicates brake lock off. Groundindicates brake lock on.

Payload Meter

The payload meter is housed in a black aluminumhousing. There is a small window on the face of theunit. Status and active alarm codes can be viewedthrough the window. During normal operation, a two-digit display flashes 0 back and forth. Active faultcodes will be displayed for two seconds. Thesecodes are typically viewed using the laptop computerconnected to the serial communications port.

There is one 40-pin connector on the payload meter.A jack-screw is used to hold the payload meter andwire harness connector housings together. Thisscrew requires a 4mm or 5/32 hex wrench. The cor-rect tightening torque for this screw is 25 lb-in. Fourbolts hold the payload meter housing to its mountingbracket in the cab.

The circuit board inside the payload meter housing ismade from multi-layer, dual-sided surface-mountelectronics. There are no field serviceable compo-nents inside. The electronics are designed to with-stand the harsh operating environment of the miningindustry. Opening the payload meter housing willresult in voiding the warranty.

Communications Ports

The payload meter has two RS232 serial communi-cations ports and two CAN ports. Connections for thetwo serial ports are available inside the payloadmeter junction box. The two CAN ports are availablefor future electronics systems.

Serial port #1 is used to communicate with the dash-board display. It is also used to connect to the laptopcomputer. The display gauge will remain blank whenthe PC is using the serial port. This port initially oper-ates with serial settings at 9600,8,N,1. These set-tings change automatically to increase thecommunications rate when the PC is using the port.This serial port uses a 3-wire hardware connection.

Serial port #2 is used to communicate to other on-board electronics like Modular Mining's Dispatch®system or the scoreboard from Komatsu. This portuses a 3-wire hardware connection. Connections tothis serial port need to be approved by Komatsu.Several protocol options are available and detailedtechnical information is available depending onlicensing.


Key Switch Input

PLMIII monitors the status of the key switch. 24vdcindicates that the key switch is on, open indicates thekey switch is off. The payload meter does not receiveits electrical power from the key switch circuit. Thepayload meter will remain on for several secondsafter key switch is removed. When the key switchpower is removed, payload meter performs a seriesof internal memory operations before turning itselfoff. To allow for these operations, the key switchshould be turned off for at least 15 seconds beforeturning the key switch back on. The payload meterwill automatically reset itself without error if notenough time is given for these operations. The dis-play may blink briefly.

Payload Meter Power

The payload meter receives its power from the bat-tery circuit on the truck. Removing battery powerfrom the payload meter before removing key switchand waiting 15 seconds may result in lost haul cycledata. The payload meter turns itself off approximately15 seconds after the key switch power is removed.Some haul cycle data will be lost if battery power isremoved before waiting 15 seconds. The payloadmeter system operates at a nominal voltage of 24vdcat 1 to 2 amps depending on options. The payloadmeter is designed to turn itself off if the supply volt-age rises above 36vdc. The payload meter is alsoprotected by a 5 amp circuit breaker located in thejunction box.

Power to the load lights comes from the same batterycircuit. The load lights are powered through a relay.The key switch circuit controls the relay. The loadlights are also protected by a 15 amp circuit breakerin the junction box.

Load Lights

PLMIII uses load lights to indicate to the shovel oper-ator the approximate weight of the material in thetruck. The load lights are illuminated only when thebrake lock is applied. The lights are controlled by thepayload meter through a series of relays in the junc-tion box. The payload meter controls the relays with24vdc outputs. A 24vdc signal from the payloadmeter powers the relay coil and connects batterypower to the load light. When the relay is not pow-ered by the payload meter, a pre-warm resistor con-nects the load light to a reduced voltage. This circuitpre-warms the load light filaments and reduces theinrush current when the light is fully illuminated. Thislengthens the operating life of the load lights.

The load lights progressively indicate to the shoveloperator the approximate weight of the material inthe truck.

A flashing green light indicates the next swingloadwill make the measured load greater than 50% ofrated load. A solid green light indicates that the cur-rent load is greater than 50% of rated capacity.

A flashing amber light indicates the next swingloadwill make the measured load greater than 90% ofrated load. A solid amber light indicates that the cur-rent load is greater than 90% of rated capacity.

A flashing red light indicates the next swingload willmake the measured load greater than 105% of ratedload. A solid red light indicates that the current load isgreater than 105% of rated capacity.

The optimal loading target is a solid green and amberlights with a flashing red light. This indicates that theload is between 90% and 105% of rated load for thetruck and the next swingload will load the truck over105%.


Wiring and Termination

Most of the PLMIII truck connections use a heavy-duty cable. This yellow multi-conductor cable uses a16awg, finely stranded wire designed for continuousmotion operations. The conductors are protected bya foil and braided shield for electronic noise immunityand physical strength. This wire is typically termi-nated with a #10 ring terminal. Most connections forthe PLMIII system are made in the payload meterjunction box.

TCI Outputs

The GE drive system on the 930E requires informa-tion from the payload meter regarding the loadedcondition of the truck. There are three outputs fromthe payload meter to GE to indicate the relative loadin the truck. 24 vdc on the 73MSL circuit indicatesthat the load is 70% of rated load. 24 vdc on the73FSL circuit indicates the truck is 100% loaded. The73OSL circuit is not currently used.


OPERATOR’S DISPLAY AND SWITCH

Reading the Speedometer

The top window of the speedometer/display gauge isthe speedometer section. The display shows thespeed indicated by the frequency being received bythe gauge. This can be adjusted using the potentiom-eter on the back of the gauge. In addition, the unitsfor the display can be changed. Terminal #4 controlsthe displayed units. If #4 is grounded, the display willbe metric. If terminal #4 is left open, the display willbe in English units.

Reading the Load Display

The lower display on the speedometer/display gaugeis used for payload information. The SELECT posi-tion on the operator switch allows the user to scrollthrough a number of useful displays. The order forthe displays is as follows:

• PL= Payload

• Id= Operator ID

• tL= Total Shift Tons

• LC= Shift Load Counter

• LF= Left Front Suspension Pressure

• rF= Right Front Suspension Pressure

• Lr= Left Rear Suspension Pressure

• rr= Right Rear Suspension Pressure

• In= Inclinometer

The display holds the displayed information until theSELECT switch is pressed again. The suspensionpressures, inclinometer, and payload displays arebased on current sensor inputs.

Communications to the display use the same seriallink as the download connection. Whenever anothercomputer is connected to serial port #1 to downloador configure the system, the lower display will blank.This is not the same connection used by mine dis-patch systems.

Using the Operator ID

The current operator ID number is recorded witheach haul cycle. The number can be between 0 and9999.

To set the Operator ID:

1. Press the “SELECT” switch until Id= is dis-played.

2. Hold the “SET” button until 0000 is displayed.The first digit should be flashing.

3. Press the “SET” button again to change thedigit.

4. Press the “SELECT” button once to adjust thesecond digit.

5. Use the “SET” button again to change the digit.6. Press the “SELECT” button once to adjust the

third digit. 7. Use the “SET” button again to change the digit.8. Press the “SELECT” button once to adjust the

fourth digit. 9. Use the “SET” button again to change the digit

10. Press the “SELECT” button one more time toenter the ID.

If no buttons are pressed for 30 seconds, the displaywill return to normal operation. The number beingentered will be lost and the ID number returns to theprevious ID number.

Using the Load and Ton Counter

PLMIII allows the truck operator to monitor and trackthe total tons hauled and the number of haul cyclesduring the shift. This display can be cleared at thebeginning of each shift to allow the operator to recordhow many loads and tons have been hauled duringthe shift.

Total Ton Counter

The total ton counter records the number of tonshauled since the last time it was cleared. This displayis in 100’s of tons. For example, if the display shows

432 the total tons is 43,200. This display can becleared at the beginning of each shift to allow theoperator to record how many tons have been hauledduring the shift. The units are selected using the PCsoftware.

• To view the total ton counter press and releasethe “SELECT” switch until tL= is displayed onthe gauge.


Total Load Counter

The total load counter records the number of loadshauled since the last time it was cleared. This displaycan be cleared at the beginning of each shift to allowthe operator to record how many loads have beenhauled during the shift.

• To view the total load counter press and releasethe “SELECT” switch until LC= is displayed onthe gauge.

Clearing the Counters

Clearing the total ton counter or total load counterclears both records.

To clear the total ton and total load counter:

1. Press the “SELECT” switch until tL= or

LC= is displayed.

2. Hold the “SET” button until the display clears.

Viewing Live Sensor Data

The display can also be used to quickly show the cur-rent readings from the four suspension pressure sen-sors and the inclinometer. This can be used duringregularly scheduled service periods to check thestate of the suspensions. These displays are live andwill update as the values change.

The live displays cannot be cleared and the SET but-ton will have no effect.

The units for the display are controlled by the config-uration of the payload meter. If the payload meter isset to display metric units, the pressures will be dis-played in tenths of kg/cm2. For example, if the dis-

play 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). Multi-ply by 14.2 to convert kg/cm2 to psi. (example -- 1kg/cm2 x 14.2 = 14.2 psi). There is no way to detect theunits setting for the gauge without the PC software.

The inclinometer displays whole degrees of incline.Positive incline is truck nose up. The gauge willquickly display the type of information shown every10 seconds. For example, if the left-front pressure is

being displayed, Lf= will flash on the display every

minute. Only the payload display, PL= does notdisplay this information.

• Left Front Pressure - To display the pressure inthe left-front suspension, press and release the“SELECT” switch until Lf= is displayed.

• Right Front Pressure - To display the pressure inthe right-front suspension, press and release the“SELECT” switch until rf= is displayed.

• Left Rear Pressure - To display the pressure inthe left-rear suspension, press and release the“SELECT” switch until Lr= is displayed.

• Right Rear Pressure - To display the pressure inthe right-rear suspension, press and release the“SELECT” switch until rr= is displayed.

• Inclinometer - To display the truck incline, pressand release the “SELECT” switch until In= isdisplayed.

Other Display Messages

On startup of the payload meter system, the gaugedisplay will scroll the truck type that the PLMIII is con-figured for. For example, on a 930E, the gauge will

scroll, ----930E---.

If the PLMIII encounters memory problems, it will dis-

play ER88 where 88 is the specific memoryerror. In this very rare circumstance, the systemshould be turned off for 30 seconds and restarted.


PAYLOAD OPERATION & CALCULATION

Description of Haul Cycle States

The typical haul cycle can be broken down into eightdistinct stages or states. Each state requires the pay-load meter to make different calculations and storedifferent data.

“States" or stages of a typical haul cycle

1. Tare Zone

2. Empty

3. Loading

4. Maneuvering

5. Final Zone

6. Hauling

7. Dumping

8. After Dump

Haul Cycle Description

A new haul cycle is started after the load has beendumped from the previous cycle. The payload meterwill stay in the after_dump state for 10 seconds toconfirm that the load has actually been dumped. Ifthe current payload is less than 20% of rated load,the payload meter will switch to the tare_zone andbegin calculating a new empty tare. If, after dumping,the payload has not dropped below 20% of ratedload the meter will return to the maneuvering or haul-ing states. In this case, the false_body_up flag will berecorded in the haul cycle record.

While in the tare_zone state, and moving faster than5 km/h (3 mph), the payload meter calculates theempty sprung weight of the truck. This tare value willbe subtracted from the loaded sprung weight to cal-culate the final payload. The payload meter willswitch from the tare_zone or empty to the loadingstate if swingloads are detected. By raising the dumpbody while in the empty state the payload meter canbe manually switched back to the tare_zone to calcu-late a new tare.

From the empty state, the payload meter will switchto the loading state through one of two means. If thebrake lock is applied, the payload meter will be ana-lyzing the suspension pressures to detect a swing-load. If a swingload is detected, the meter will switchto the loading state. The minimum size for swingloaddetection is 10% of rated load. Swingload detectionusually takes 4-6 seconds. The second method toswitch from empty to loading is through continuousloading. This can happen if the brake lock is not usedduring loading. If the load increases above 50% ofrated load for 10 seconds without the brake lock

applied, the meter will switch to loading and recordthe continuous_loading flag in the haul cycle.

The payload meter switches from loading to maneu-vering as soon as the truck begins moving. Themaneuvering zone is 160m and is designed to allowthe operator to reposition the truck under the shovel.More payload can be added anytime within themaneuvering zone. Once the truck travels 160m (0.1miles) the payload meter switches to the final_zoneand begins calculating payload. If the body is raisedwhile the payload meter is in the maneuvering state,the no_final_load flag will be recorded in the haulcycle record, no payload will be calculated, and themeter will switch to the dumping state.

While in the final_zone moving faster than 5 km/h (3mph), the payload meter calculates the loadedsprung weight of the truck. The same advanced algo-rithm is used to calculate the empty and loadedsprung weights. The payload meter will switch fromthe final_zone to the dumping state if the Body-Upsignal is received. If the truck has moved for lessthan 1 minute in the final_zone, the payload meterwill calculate the final payload using an averagingtechnique which may be less accurate. If this hap-pens, the average_load flag will be recorded in thehaul cycle.

The payload meter switches to the dumping statewhen the dump body rises. The payload meter willswitch from dumping to after_dump when the dumpbody comes back down.

From the after_dump, the payload meter will switchto one of three states:

1. If the average payload is greater than 20% ofrated load and no final payload has been calcu-lated, the payload meter will return to themaneuvering state. After the truck travels 160m(0.1 mile) the meter will switch to the final_zoneand attempt to calculate the payload again. Thefalse_body_up flag will be recorded in the haulcycle record.

2. If the average payload is greater than 20% ofrated load and the final payload has been calcu-lated, the payload meter will switch back to thehauling state. The false_body_up flag will berecorded in the haul cycle record.

3. If the average payload is less than 20% of ratedload, the payload meter will switch to thetare_zone and begin to calculate a new emptytare.


Load Calculation

The final load calculation is different from the lastswingload calculation. The accuracy of the swingload calculation depends on loading conditions andthe position of the truck during loading. The last swin-gload calculation is not the value recorded in memoryas the final load. The final load is determined by aseries of calculations made while the truck is travel-ing to the dump site.

Carry Back

Carry back is calculated as the difference betweenthe current truck tare and the clean truck tare. Theclean truck tare is calculated using the PC software.When the suspensions are serviced or changes aremade that may affect the sprung weight of the truck,a new clean truck tare should be calculated.

Measurement Accuracy

Payload measurements are typically repeatablewithin 1%. Accuracy for a particular scale testdepends on specific combinations of pressure sen-sors and payload meters as well as the specifics ofeach scale test. Comparisons from different scaletests are often made without considering the differ-ences introduced by the specific installation andoperation of the scales for each test. In addition,each pressure sensor and payload meter introducesit's own non-linearity. Each truck becomes an individ-ual combination of sensors and payload meter.Errors from these sources can introduce up to a ±7%bias in the payload meter calculations for a specificscale test, for an individual truck.

Because the PLMIII calculates a new empty tare foreach payload, a detailed scale test must weigh thetrucks empty and loaded for each haul cycle. Using asimple average of 2 or 3 empty truck weights as anempty tare for the entire scale test will introduce sig-nificant error when comparing scale weights toPLMIII weights.

SOURCES FOR PAYLOAD ERROR

Payload Error

The number one source of error in payload calcula-tion is improperly serviced suspensions. The payloadmeter calculates payload by measuring differences inthe sprung weight of the truck when it is empty andwhen it is loaded. The sprung weight is the weight ofthe truck supported by the suspensions. The onlymethod for determining sprung weight is by measur-ing the pressure of the nitrogen gas in the suspen-sions. If the suspensions are not properlymaintained, the payload meter cannot determine anaccurate value for payload. The two critical factorsare proper oil height and proper nitrogen charge.

If the suspensions are overcharged, the payloadmeter will not be able to determine the empty sprungweight of the truck. The suspension cylinder must beable to travel up and down as the truck drives empty.The pressure in an overcharged suspension canpush the suspension rod to full extension. In thiscase, the pressure inside the cylinder does not accu-rately represent the force necessary to support thatportion of the truck.

If the suspensions are undercharged, the payloadmeter will not be able to determine the loaded sprungweight of the truck. The suspension cylinder must beable to travel up and down as the truck drives loaded.If the pressure in an undercharged suspension can-not support the load, the suspension will collapseand make metal-to-metal contact. In this case, thepressure inside the cylinder does not accurately rep-resent the force necessary to support that portion ofthe truck.

Low oil height can also introduce errors by not cor-rectly supporting a loaded truck. This is why the cor-rect oil height and nitrogen charge are the mostcritical factors in the measurement of payload. If thesuspensions are not properly maintained, accuratepayload measurement is not possible. In addition,suspension maintenance is very important to the lifeof the truck.


Loading Conditions

The final load calculation of the PLMIII system is notsensitive to loading conditions. The final load is cal-culated as the truck travels away from the shovel.Variations in road conditions and slope are compen-sated for in the complex calculations performed bythe payload meter.

Pressure Sensors

Small variations in sensors can also contribute topayload calculation error. Every pressure sensor isslightly different. The accuracy differences of individ-ual sensors along the range from 0 to 4000 psi canadd or subtract from payload measurements. This isalso true of the sensor input circuitry within individualpayload meters. These differences can stack up 7%in extreme cases. These errors will be consistent andrepeatable for specific combinations of payloadmeters and sensors on a particular truck.

Swingloads

Swingload calculations can be affected by conditionsat the loading site. Parking the truck against the bermor large debris can cause the payload meter to inac-curately calculate individual swingloads. While thePLMIII system uses an advanced calculation algo-rithms to determine swingloads, loading site condi-tions can affect the accuracy.

Speed and Distance

The payload meter receives the same speed signalas the speedometer. This signal is a frequency thatrepresents the speed of the truck. The payload meteruses this frequency to calculate speeds and dis-tances. The meter assumes a single value for therolling radius of the tire. The rolling radius maychange at difference speeds by growing larger athigher speeds. The actual rolling radius of the tire willalso change between a loaded and empty truck. Thepayload meter does not compensate for thesechanges.

NOTE: Earlier 730E & 830E models are subject toincorrect speed data due to electrical interference.The incorrect speeds are generated while the truck isstopped. An attenuator was added to newerproduction models to prevent this error fromoccurring. A kit was released to update older PLMIIIsystems with the attenuator. Consult your areaservice representative for details.

HAUL CYCLE DATAPLMIII records and stores data in its on-board flashmemory. This memory does not require a separatebattery. The data is available through the downloadsoftware.

PLMIII can store 5208 payload records. When thememory is full, the payload meter will erase the old-est 745 payload records and continue recording.

PLMIII can store 512 alarm records in memory.When the memory is full, the payload meter willerase the oldest 312 alarm records and continuerecording.

All data is calculated and stored in metric units withinthe payload meter. The data is downloaded andstored in metric units within the Paradox database onthe PC. The analysis program converts units for dis-plays, graphs and reports.

The units noted in the Table 1 are the actual unitsstored in the data file. The value for the haul cyclestart time is the number of seconds since January 1,1970 to the start of the haul cycle. All other eventtimes are referenced in seconds since the haul cyclestart time. The PC download and analysis programconverts these numbers into dates and times forgraphs and reports.


Haul Cycle Data

The following information is recorded for each haul cycle:

Table 1: HAUL CYCLE DATAData Unit RemarkTruck # alpha-

numericUp to 22 characters can be stored in this field to identify the truck. Typically this field will be justthe 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 metertransitions from dumping to empty state after the previous haul cycle, download program convertsseconds 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 onpage 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 toloading state

Dump start time seconds Number of seconds from the start of the haul cycle to the time when the meter switches fromloaded 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 fromthe operator’s seat.

Peak frame torque time seconds Number of seconds from the start of the haul cycle to the peak torque, download program convertsto time for display

Peak negative frame torque ton-meter Negative frame torque is measured as the frame twists in the counter-clockwise direction asviewed 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 convertsto 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 systemand should be ignored


Haul Cycle Warning Flags

The payload meter expects haul cycles to progress ina particular way. When something unexpected takesplace, the system records a warning flag. Severalevents within the haul cycle can cause a warning flagto be generated. Each one indicates an unusualoccurrence during the haul cycle. They do not neces-sarily indicate a problem with the payload meter orpayload calculation.

A: Continuous Loading

This message is generated when the truck is loadedover 50% full without the payload meter sensingswingloads. This indicates that a continuous loadingoperation was used to load the truck. It may also indi-cate that the payload meter did not receive the brakelock input while the truck was being loaded. Theremay be a problem with the wiring or the brake lockwas not used. The payload meter will not measureswingloads unless the brake lock is used during theloading process.

B: Loading to Dumping Transition

This message is generated when the payload metersenses a body up input during the loading process.This message is usually accompanied by ano_final_load flag.

C: No Final Load

This message is generated when the payload meteris unable to determine the final payload in the truck.Typically, this means that the payload meterswitched from a loaded state to the dumping statebefore the load could be accurately measured.

D: Maneuvering to Dumping Transition

This message is generated when the payload metersenses a body-up input during the maneuvering orrepositioning process indicating that the operator hasdumped the load. It may also be generated if thebody-up signal is not properly reaching the payloadmeter and the weight in the truck falls dramaticallywhile the truck is maneuvering or repositioning.

E: Average Load or Tare Used

This message indicates that the recorded payloadmay not be as accurate as a typical final load calcula-tion. Typically, this is recorded when loading beginsbefore an accurate tare is calculated or the load isdumped before the load can be accurately mea-sured.

F: Final Zone to Dumping Transition

This message is generated when the payload metersenses a body-up while it is calculating the final pay-load indicating that the operator has dumped theload. It may also be generated if the body-up signal isnot properly reaching the payload meter and theweight in the truck falls dramatically while the truck iscalculating the final payload.

H: False Body Up

This message indicates that the body was raised dur-ing the haul cycle without the load being dumped.The body-up signal indicated that the truck wasdumping, but the weight of the truck did not fall below20% of the rated load.

I: Body Up Signal Failed

This message indicates that the load was dumpedwithout a body-up signal being received by the pay-load meter. The weight of the truck fell below 20%,but the payload meter did not receive a body-up sig-nal from the sensor.

J: Speed Sensor Failed

This message indicates that the payload metersensed the truck loading and dumping withoutreceiving a speed signal.

K: New Tare Not Calculated

The payload meter was not able to accurately calcu-late a new empty sprung weight for the truck to useas the tare value for the haul cycle. The tare valuefrom the last haul cycle was used to calculate pay-load.

L: Incomplete Haul Cycle

The payload meter did not have proper data to startthe haul cycle with after powering up. When thePLMIII powers off, it records the data from the haulcycle in progress into memory. This flag indicatesthat this data was not recorded the last time the pay-load meter was shut down. This can happen whenthe main battery disconnect is used to shut the truckdown instead of the key switch. A haul cycle with thiswarning flag should not be considered accurate. Haulcycles with this warning are displayed in red on thePayload Summary window and are not included inthe summary statistics for reports or display.


M: Haul Cycle Too Long

The haul_cycle_too_long flag indicates that the haulcycle took longer than 18.2 hours to complete. Thetimes stored for particular events may not be accu-rate. This does not affect the payload calculation.

N: Sensor Input Error

An alarm was set for one of the 5 critical sensorinputs during the haul cycle. The five critical sensorsare the four pressure sensors and the inclinometer.Without these inputs, the payload meter cannot cal-culate payload. A haul cycle with this warning flagshould not be considered accurate. Haul cycles withthis warning are displayed in red on the PayloadSummary window and are not included in the sum-mary statistics for reports or display.

Frame Torque Data

Payload meter records the top 5 peak positive andnegative frame torque values and the time theyoccurred. The frame torque is a measure of the twist-ing action along the centerline of the truck. Positiveframe torque is measured when the suspensionforces on the front of the truck act to twist the framein the clockwise direction as viewed from the opera-tor's seat. Negative frame torque is measured whenthe forces from the suspensions act in the oppositedirection.

For example, if the left front and right rear pressurerises as the right front and left rear pressure drops,the truck frame experiences a twisting motion alongthe longitudinal centerline. In this case, the payloadmeter will record a positive frame torque.

The 5 highest values in the positive and negativedirection are stored in permanent memory within thepayload meter.

Sprung Weight Data

The payload meter is constantly monitoring the livepayload calculation. This value naturally rises andfalls for a loaded truck depending on road and drivingconditions. The payload meter records the top 5highest payload calculations and the time theyoccurred. This information is stored in permanentmemory inside the meter.

Maximum Speed Data

The payload meter records the top 5 highest speedsand the time they occurred. This information is storedin permanent memory inside the meter.

Alarm Records

The payload meter stores alarm records to give ser-vice personnel a working history of the system. Allcodes are viewed using the PC connected to thepayload meter. Active codes are also displayed onthe two-digit display on the meter itself. Each codehas a specific cause and should lead to an investiga-tion for correction. Some failures can be overcomeby the payload meter. Haul cycle data will indicate ifan alarm condition was present during the cycle. Fail-ures with the suspension or inclinometer sensorscannot be overcome.


Fault Code Data

Table 2: Fault Code Name Description

1 Left front pressure high Input current > 22 ma

2 Left front pressure low Input current < 2 ma

3 Right front pressure high Input current > 22 ma

4 Right front pressure low Input current < 2 ma

5 Left rear pressure high Input current > 22 ma

6 Left rear pressure low Input current < 2 ma

7 Right rear pressure high Input current > 22 ma

8 Right rear pressure low Input current < 2 ma

9 Inclinometer high Input voltage < 0.565 vdc

10 Inclinometer low Input voltage > 5.08 vdc

11 Speed input failure Not Used

12 Brake lock input failure Not Used

13 Body-up input failure Payload meter detected dumping activity without receiving a body up signal

16 Memory write failure Indicates possible memory problem at power start up. Cycle power and recheck.

17 Memory read failure Indicates possible memory problem at power start up. Cycle power and recheck.

18 Rear right suspension flat Payload meter detected an undercharged suspension condition on the rear right suspension.

19 Rear left suspension flat Payload meter detected an undercharged suspension condition on the rear left suspension.

20 Time change Payload meter time was changed by more than 10 minutes. The Alarm Set time indicatesoriginal time. The Alarm Clear time indicates the new time.

21 Tare value reset The user manually forced the payload meter to reset the haul cycle empty (tare) sprungweight. This forced the meter into the tare_zone state and lost all data for the previous haulcycle.

22 Excessive carryback The payload meter detected an empty carryback load in excess of the user-defined carrybackthreshold on two consecutive haul cycles.

26 User switch fault - SELECT Select switch on for more than 2 minutes, may indicate short to ground

27 User switch fault - SET Set switch on for more than 2 minutes, may indicate short to ground


PC SOFTWARE OVERVIEW

PC Overview

The PC software has several basic functions:

• Configure the PLMIII system on the truck.

• Troubleshoot and check the PLMIII system.

• Download data from the PLMIII system.

• Analyze data from the payload systems.

Configuration, troubleshooting and downloadingrequire a serial connection to the payload meter onthe truck. Analysis can be done at any time without aconnection to the payload meter.

Payload data is downloaded from several trucks intoone database on the PC. The database can be que-ried to look at the entire fleet, one truck or truckmodel. The data can be graphed, reported, importedor exported. The export feature can take payloaddata and save it in a format that spreadsheet pro-grams like Excel or word processing programs caneasily import.

System Configuration

PLMIII needs to be configured for operation when itis first installed on the truck. This process requiresseveral steps and uses the laptop computer to makethe necessary settings. The setup procedure can bebroken down into several steps:

• Connecting the laptop to the PLMIII system.

• Starting communications

• Setting the time & date

• Setting the truck type

• Setting the truck ID

• Setting the speedometer/display gauge units

Installing the PLMIII Software

The CD ROM containing the Payload Data Manage-ment (PDM) Software will automatically begin instal-lation when it is inserted into the drive on the PC. Ifthis does not happen, the software can be installedby running the Setup.exe program on the CD ROM.

The minimum PC requirements for running the soft-ware is a Pentium 133Mhz with 64 MB of ram and atleast 300 MB of free hard drive space available. Forimproved performance, the recommended PC wouldbe a Celeron, AMD K6-2 or better processor with 128MB of ram running at 400 Mhz. The PDM Softwareuses a powerful database to manipulate the largeamounts of data gathered from the PLMIII system.Using a more powerful computer and added memoryto run the software can result in a significantimprovement in performance. The software is writtento use a minimum 800x600 screen resolution.


DOWNLOADING DATAPLMIII records many types of data. The PLMIII PCsoftware is designed to download the data from awhole truck fleet. Instead of creating one data file foreach truck, the PC software combines all the datafrom many trucks into one database on the harddrive of the computer. The software then allowsusers to query the database to create custom reportsand graphs. Data for individual trucks or groups oftrucks can be easily analyzed. This same data canbe exported for use in other software applications likeword processors and spreadsheet applications.

As the database grows, performance of the PC soft-ware for analysis will slow down. It may be helpful toperiodically export data. For example, query thedatabase to show the oldest quarter, month, or halfyear and print out a summary report. Then export thedata to a compressed format and save the file in asecure location. Once the data is exported, deletethe entire query results from the database. If neces-sary, the data can easily be imported back into themain database for analysis at a future date. Remov-ing this older data will improve performance.

The PC software downloads the data from the pay-load meter into a single Paradox database. The datafrom all the trucks is added to the same database.Downloading the payload meter can take severalminutes. The data is added to the database on thelaptop used to download.

To move the data to another computer, a query mustbe run to isolate the particular data for export. Do notpress the operator switch on the dashboard whiledownloading

To download the payload meter:

1. Connect to the payload meter and start the PCsoftware.

2. From the main menu, select "Connect to Pay-load Meter". The PC will request the latest sta-tus information from the payload meter. Thenumber of haul cycles and alarms will be dis-played.

3. Select the " Begin Download" button. The PCwill request the payload and alarm data fromthe payload meter and save it into the data-base. This may take several minutes. Aprogress bar at the bottom will show theapproximate time left.


PLM III SYSTEM CONFIGURATION

Starting Communications

The PDM software allows users to download andconfigure the system.

Before connecting to the payload meter, select"Change Program Options" and confirm that the pro-gram has selected the correct laptop serial port. Mostlaptops use Comm 1 for serial communications. Theunits displayed for reports and graphs by the PC soft-ware can be set on this form. Click “Done” to returnto the main menu.

From the main menu, click the "Connect to PayloadMeter" button. The PC will try to connect to the pay-load meter and request basic information from thesystem. In the event of communications trouble, thePC will try 3 times to connect before "timing-out".This may take several seconds.

Displayed Payload Units

Three options are available for the display of units inthe PC software, reports, and graphs:

Short Tons: Payload is displayed in short tons, dis-tances and speeds will be displayed in Miles

Metric Tons: Payload is displayed in metric tons, dis-tances and speeds are displayed in Kilometers

Long Tons: Payload is displayed in long tons, dis-tances 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

The connection screen displays basic system infor-mation to the user.

• Frame S/N should agree with the truck serialnumber from the serial plate located on the truckframe.

• Truck Number is an ID number assigned to thetruck by the mine.

• The Payload Meter Date / Time values comefrom the payload meter at the moment ofconnection.

• Number of Haul Cycle Records is the number ofhaul cycles records stored in memory andavailable for download.

• Number of Active Alarms shows how manyalarms are currently active in the system at thetime of connection. If there are active alarms, the"Display Active Alarms" button is available.

• Number of Inactive Alarms shows how manyalarms have been recorded in memory and areavailable for download.

• PLM Software Version displays the currentversion of software in the payload meter.

The information on the connection menu comes fromthe configuration of the payload system on the truck.


There are also many configuration and downloadoptions available from this screen. The ConnectionMenu is updated only when the connection is firstmade. It does not update automatically. To viewchanges made while connected, the user must closethe window and reconnect to the payload meter.

The connection menu is displayed after a serial con-nection has been established and the PC softwarehas connected to the payload meter.

Connecting to the Payload Meter

Communications to the PLMIII requires a laptopcomputer running the PDM software. The softwareconnects to the payload meter through the meter'sserial port #1. This is the same port used by thespeedometer/display gauge. When the laptop isusing the serial port, the lower display on the opera-tor gauge on the dashboard will be blank. This doesnot affect the operation of the speedometer.

• Connect the laptop to the system using theEF9160 communications harness. The downloadconnector is typically located on the housingmounted in the cab to the back wall. The PLMIIIsystem uses the same connection as thePayload Meter II system.

Configure the Payload Meter

Configuration of the payload meter requires a serialconnection to the PLMIII system. Clicking the "Con-figure Payload Meter" button will bring up the TruckConfiguration screen and menu. This screen displaysthe latest configuration information stored on thepayload meter.

When changes are made to the configuration, the"Save Changes" button must be pressed to save thechanges into the payload meter. To confirm thechanges, exit to the main menu and re-connect to thepayload meter.

Setting the Date and Time

The time shown on the form is the time transmittedfrom the payload when the connection was firstestablished.

The date and time are maintained by a special chipon the PLMIII circuit board. The memory for this chipis maintained by a very large capacitor when thepower is removed from the payload meter. This willmaintain the date and time settings for approximately30 days. After this time, it is possible for the payloadmeter to lose the date and time setting. It is recom-mended that the system be powered every 20 daysto maintain the date and time. If the date and time islost, simply reset the information using this proce-dure. It takes approximately 90 minutes to rechargethe capacitor.

Changing the date and time will affect the haul cyclein progress and may produce unexpected results inthe statistical information for that one haul cycle.

To change the time:

1. Click on the digit that needs to be changed.2. Use the up/down arrows to change or type in

the correct value.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.


Setting the Truck Type

1. From the Truck Configuration screen, use thepull-down menu to select the truck type that thepayload meter is installed on.

2. Press the "Save Changes" button to programthe change into the meter.

Setting the Gauge Display Units

The payload meter speedometer / display gauge dis-plays the speed on the upper display. The units forthe speed display are selected using a jumper on therear of the case.

The payload units on the lower display can bechanged from metric to short tons or long tons usingthe Truck Configuration screen. This selection alsoswitches between metric (kg/cm2) and psi (lbs/in2)for the live display of pressure on the gauge.

1. From the Truck Configuration screen, select thepayload units to be used on the lower display ofthe speedometer/display gauge.

2. Press the "Save Changes" button to programthe change into the payload meter.

Setting the Frame Serial Number

The frame serial number is located on the platemounted to the truck frame. The plate is outboard onthe lower right rail facing the right front tire. It is veryimportant to enter the correct frame serial number.This number is one of the key fields used within thehaul cycle database. The field will hold 20 alpha-numeric characters.

1. On the Truck Configuration screen, enter thetruck frame serial number in the appropriatefield.


Setting the Truck Number

Most mining operations assign a number to eachpiece of equipment for quick identification. This num-ber or name can be entered in the Truck Numberfield. It is very important to enter a unique truck num-ber for each truck using the PLMIII system. Thisnumber is one of the key fields used within the haulcycle database. The field will hold 20 alpha-numericcharacters.

1. On the Truck Configuration screen, enter thetruck number in the appropriate field.


Setting the Komatsu Distributor

This field in the haul cycle record can hold the nameof the Komatsu distributor that helped install the sys-tem. Komatsu also assigns a distributor number toeach distributor. This number is used on all warrantyclaims. This Komatsu distributor number can also beput into this field. The field will hold 20 alpha-numericcharacters.

1. On the Truck Configuration screen, enter thedistributor name or number in the appropriatefield.


Setting the Komatsu Customer

This field in the haul cycle record can hold the nameof the mine or operation where the truck is in service.Komatsu also assigns a customer number to eachcustomer. This number is used on all warrantyclaims. This Komatsu customer number can also beput into this field. The field will hold 20 alpha-numericcharacters.

1. On the Truck Configuration screen, enter thecustomer name or number in the appropriatefield.



Clean Truck Tare

The payload meter uses the clean truck tare value tocalculate carry-back load for each haul cycle. Thecarry-back stored in the haul cycle record is the newempty tare minus the clean truck tare.

This procedure should be performed after service tothe suspensions or when significant changes aremade to the sprung weight of the truck. Before per-forming this procedure, be sure the suspensions areproperly filled with oil and charged. It is critical to pay-load measurement that the proper oil height and gaspressure be used.

Once the clean tare process is started, the payloadmeter will begin to calculate the clean empty sprungweight of the truck. This calculation continues whilethe truck drives to the next loading site. Once theprocedure is started, there is no reason to continueto monitor the process with the PC. The truck doesnot need to be moving to start this procedure.

1. After cleaning debris from the truck and check-ing to see that the suspensions are properlyserviced, use the PLMIII software to connect tothe payload meter.

2. From the "Truck Configuration" screen, select"Clean Truck Tare".

3. Be sure to follow the screen instructions.

Inclinometer Calibration

The inclinometer calibration procedure is designed tocompensate for variations in the mounting attitude ofthe inclinometer. The inclinometer input is critical tothe payload calculation.

This procedure should be performed on relatively flatground. Often the maintenance area is an ideal loca-tion for this procedure.

1. After cleaning debris from the truck and check-ing to see that the suspensions are properlyserviced, use the PLMIII software to connect tothe payload meter.

2. From the "Truck Configuration" screen, select"Inclinometer".

3. With the truck stopped and the brake lock on,press the “Start” button. This instructs the pay-load meter to sample the inclinometer once.

4. Turn the truck around. Drive the truck aroundand park in the exact same spot as before, fac-ing the other direction.

5. With the truck stopped and the brake lock on,press the “Start” button. This instructs the pay-load meter to sample the inclinometer again.The payload meter will average the two sam-ples to determine the average offset.

6. Be sure to follow the screen instructions.


DATA ANALYSIS

The data analysis tools allow the user to monitor theperformance of the payload systems across the fleet.Analysis begins when the "View Payload Data" but-ton is pressed. This starts an "all trucks, all dates, alltimes" query of the database and displays the resultsin the Payload Summary Form.

The user can change the query by changing thedates, times, or trucks to include in the query for dis-play.

Haul cycles in the data grid box at the bottom can bedouble-clicked to display the detailed results of thathaul.

Creating a Query

The program defaults to show all trucks, all types, alldates and all times for the initial query. The displaycan be narrowed by selecting which trucks or typesto view and for what dates and times.

The query items are added in the "AND" condition. Ifthe user selects a truck # and date range, the querywill sort the data for that truck number AND the daterange.

Sorting on Truck Unit Number

The truck unit number is the truck unit numberentered into the payload meter when it was config-ured at installation. The query can be set to look forall trucks or one particular truck number. When theprogram begins, it searches through the database forall the unique truck numbers and creates a list toselect from.

Choosing one particular truck number will limit thedata in the displays, summaries and reports to theone selected truck. To create reports for truck num-ber 374, select 374 from the pull-down menu and hitthe "Query Database and Display" button.

Sorting on Truck Type

The truck type is the size of the truck from the familyof Komatsu trucks. This allows the user to quicklyview results from different types of trucks on theproperty. For example, a separate report can be gen-erated for 830E and 930E trucks.

PAYLOAD SUMMARY FORM


Sorting on Date Range

The default query starts in 1995 and runs through thecurrent date on the PC. To narrow the range to aspecific date, change the “From” and “To” dates.For example, to view the haul cycle reports fromtruck 374 for the month of July, 2000:

1. Select truck 374 from the Truck Unit pull-downmenu.

2. Change the “From” date to July 1, 2000.

3. Change the “To” date to July 31, 2000. 4. Press the "Query Database and Display" to

view the results.

Sorting on Time Range

The time range sorts the times of the day for validdates. Changing the time range to 6:00AM to 6:00PMwill limit the payloads displayed to the loads thatoccurred between those times for each day of thedate range. Times are entered in 24:00 format. Toview the haul cycle reports from the first shift for truck374 from January 5, 2000 to January 8, 2000:

1. Select truck 374 from the Truck Unit pull-downmenu.

2. Change the “From” date to July 1, 2000.

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" toview the results.

This query will display haul cycles from January 5 toJanuary 8, from 6:00 AM to 6:00 PM.

The shift times selected can extend the query pastthe original date. If the dates set for the query areJanuary 5 to January 8 and the times were changedto query the 6:00 PM (18:00) to 6:00 AM (06:00) shift,the results would extend into the morning of the 9th.This can been seen in the following example:

Date: 1/5/00 to 1/8/00Daily Shift Time: 6:00 to 18:00

0:00

6:00

18:00

24:00

12:00

Jan 5, 2000 Jan 9, 2000Jan 8, 2000Jan 7, 2000Jan 6, 2000Time

Date

Query : Haul Cycles Included in the Query


Payload Detail Screen

The Payload Detail screen gives the details for anyindividual haul cycle. From the “Payload Summary”screen, double-click on any haul cycle to display thedetail.

Creating Reports

Reports can be generated and viewed on the screenor printed. These reports are generated from thequery displayed on the Payload Summary Screen.From the example in "Sorting on Time Range", thereport printed would only contain data from truck 374during the month of July 2000, from 8:00 AM to 5:00PM.

It is important to carefully select the query data andpress the "Query Database & Display" button beforeprinting a report.

0:00

6:00

18:00

24:00

12:00

Jan 5, 2000 Jan 9, 2000Jan 8, 2000Jan 7, 2000Jan 6, 2000Time

Date

Query : Date: 1/5/00 to 1/8/00Daily Shift Time: 18:00 to 6:00 Haul Cycles Included in the Query


NOTE: Some haul cycles may contain the SensorInput warning flag. This indicates that one of the fourpressure sensors or inclinometer was not functioningproperly during the haul cycle. Haul cycles with thiswarning are displayed in red on the PayloadSummary window and are not included in thesummary statistics for reports or display.

Summary - one page report

A summary of the queried data can be printed onto 1page. 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 andfollows with pages of data for each haul cycle. Thedetailed report prints date, time, payload, cycletimes, and cycle distances, speeds and the numberof swing loads.


Creating Graphs

The PLMIII software can generate graphs thatquickly summarize payload data. These graphs canbe customized for printing. Just like the reports, thegraphs are generated from the query displayed onthe “Payload Summary” screen. From the "Sorting onTime Range" example, the graph that is printedwould only contain data from truck 374 during themonth of July 2000, from 8:00 AM to 5:00 PM.

It is important to carefully select the query data andpress the "Query Database & Display" button beforecreating a graph.

1. From the Payload Summary Screen select the“Graph” button at the bottom. The HistogramSetup screen will display

2. Enter the "Lowest Value". This will be the low-est payload on the graph. Any payloads lessthan 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 valuewill be summed in the last bar.

4. Enter the "Incremental Change". This will deter-mine the number of bars and the distancebetween them. The program limits the numberof bars to 20. This allows graphs to fit on thescreen and print onto 1 page.

5. Press the “Create Graph” button.

The graph will be displayed based on the query set-tings from the Payload Summary screen. The graphcan be customized and printed.

Exporting Data

The data from the database can be exported for usewith other software applications. The data is selectedfrom the currently displayed query. The exporteddata can be put into a ".CSV" file or a compressed".zip" file.

• The “.CSV” format allows data to be easilyimported into spreadsheet applications and wordprocessing applications.

• The “.Zip” format allows data to be transferredfrom one computer to the PDM Softwaredatabase on another computer. This offers acompact way to transfer data from one computerto another.

CSV Export

CSV stands for Comma Separated Value. This is anASCII text file format that allows spreadsheet appli-cations like Excel and Lotus 123 to import data eas-ily. To export the data into a ".csv" file, press the"Export" button at the bottom of the payload sum-mary screen and select "To CSV". The program willrequest a filename and location for the file.


.

Two sets of data are exported. At the top of the filewill be the haul cycle data. The columns, left to rightare:

• Truck number• Haul cycle start date• Haul cycle start time• Payload• Swingloads• Operator ID• Warning Flags• Carry Back• Total Haul Cycle time• Empty Running Time• Empty stop time• Loading time• Loaded running time• Loaded stopped time• Dumping time• Loading start time• Dumping start time• Loaded haul distance• Empty haul distance• Loaded maximum speed• Time when loaded maximum speed occurred• Empty maximum speed• Time when loaded maximum speed occurred• Maximum + frame torque• Time when the maximum + frame torque

occurred• Maximum - frame torque• Time when the maximum - frame torque

occurred• Maximum sprung weight calculation• Time when the maximum sprung weight

calculation occurred• Left Front Tire-kilometer-hour• Right Front Tire-kilometer-hour• Average Rear Tire-kilometer-hour• Frame serial number

• Reserved 1-5, 7-10: These values are internalcalculations used in the continued developmentof PLMIII and should be ignored.

• Reserved 6: This value is the payload estimateat the shovel just before the truck begins tomove.

The second series of data below the haul cycle datais the alarms. The alarm columns, left to right are:

• The alarm type• The date the alarm was set• The time the alarm was set• Alarm description• The date the alarm was cleared• The time the alarm was cleared

Compressed

This export function allows the data from one laptopto be transferred to another computer. This can beuseful when a service laptop is used to downloadmultiple machines and transfer the data to a centralcomputer for analysis. This can also be used to copyhaul data from a particular truck onto a diskette foranalysis.

The file format is a compressed binary form of thedisplayed query. The file can only be imported byanother computer running the PDM Software.


To export data in ZIP format:

1. Confirm that the data displayed is the querydata that needs to be exported.

2. From the payload summary screen, press the"EXPORT" button and select "To ZIP".

3. The program will ask for a filename and loca-tion.

Importing Data

This import function allows the data from one laptopto be transferred to another computer. This can beuseful when a service laptop is used to downloadmultiple machines and transfer the data to a centralcomputer for analysis. This can also be used to copyhaul data from a particular truck from a diskette into adatabase for analysis.

To import data, press the "IMPORT" button at thebottom of the “Payload Summary” screen. The pro-gram will ask for a ".zip" file to import, locate the fileand press "Open". The program will only import ".zip"files created by another computer running the PDMSoftware.

Deleting Haul Cycle Records

To delete haul cycle records from the main database,press the "Delete" button at the bottom of the “Pay-load Summary” screen. The program will display asummary of the records from the displayed query. Todelete a record, select one at a time and press the"Delete" button. It is recommended that records beexported to a zip file for archival purposes beforedeletion. Multiple records may be selected by holdingdown the Shift key. Pressing the "Delete All" buttonwill select all the records from the current query anddelete them.

NOTE: There is no recovery for records that havebeen deleted from the main database. It is highlyrecommended that all records be exported andarchived in a compressed file format for futurereference before being deleted.


Viewing AlarmsFrom the Payload Summary screen, click the“Alarms” button to display the alarm screen. Thealarms are sorted by the query settings from the Pay-load Summary screen. Alarms can be displayed asActive or Inactive.

Deleting Alarm Records

To delete alarm records from the main database,press the "Delete" button at the bottom of the “AlarmDisplay” screen. The program will display a summaryof the alarms from the query. To delete an alarm,select one at a time and press the "Delete" button. Itis recommended that the query data be exported to a“.zip” file for archival purposes before deletion. Multi-ple records may be selected by holding down theShift key. Pressing the "Delete All" button will selectall the alarms from the current query and deletethem.

NOTE: There is no recovery for alarms that havebeen deleted from the main database. It is highlyrecommended that all records be exported andarchived in a compressed file format for futurereference before being deleted.


NOTES


NOTES

PORTIONS OF THIS PRODUCT RELATING TO PAYLOAD MEASURING SYSTEMS ARE MANUFACTURED UNDER LICENSE FROM

L.G. HAGENBUCH holder of U.S. Patent Numbers 4,831,539 and 4,839,835

OM7004 4/05 Radio / Cassette Player - Section 70Page 70-1

RADIO / CASSETTE PLAYER

GENERAL RECEIVER FUNCTIONS

Turning The Power On And Off1. Turn the key switch to ON.2. Press PWR (1, Figure 70-1) to turn the receiver

on and off. Pushing ON/AUDIO (6) also turnsthe receiver power on.

Display

With the receiver off, the clock will be displayed.Momentarily pressing DSP/TM SET (9) with thereceiver on will allow the operator to toggle betweendisplays.

• When the receiver is in AM, FM1, FM2, or WX,the display will toggle between the frequency andthe clock.

• When the receiver is in an active satellite modeand the provider is transmitting the availableinformation, the display will toggle between theclock, frequency, station name, artist, song titleand music type.

• When the receiver is in the cassette mode, thedisplay will toggle between TP SIDE 1 or TPSIDE 2, and the clock.

Setting The Default Display1. Press and hold DSPL/TM (9) for 2 seconds

until the hour digits flash.

2. Press push-button 6/FF (15) to change thedefault display.

After five seconds of inactivity has elapsed, theselected default will display.

Adjusting Display Brightness1. Press and hold DIM (14) until DIM appears on

the display.

2. Rotate ON/AUDIO knob (6) clockwise or coun-terclockwise until the desired brightness isobtained.

FIGURE 70-1. RADIO / CASSETTE PLAYER

Radio / Cassette Player - Section 70 OM7004 4/05Page 70-2

SETTING THE TIME1. Turn the key switch ON. 2. Press and hold DSPL/TM SET (9, Figure 70-1)

for two seconds. When the number displayflashes, time set mode is active.

3. Press TUNE / SEEK (7 & 8) to change thehour setting.

4. Press the DSPL/TM button to switch to minutes.The minute digits will flash when in this mode.

5. Press TUNE / SEEK to change the minutesetting.

After five seconds of inactivity, the display will returnto the default mode. The clock will now display thecorrect time of day.

OPERATING THE RADIO

BAND

Press BAND (2, Figure 70-1) to switch between FM1,FM2, AM, and WX Weather (US) and Satellite (XM1,XM2 or SR1, SR2). If a separate satellite receiver isnot connected to your radio and operational, the sat-ellite bands will not appear in the display.

TUNE/SEEK

TUNE (7) / SEEK (8) allows you to move up ordown in frequency to other stations. There are twomodes of operation for finding other stations, manualtuning and seek mode.

Press and hold both TUNE (8) and BAND (2) for 2seconds to toggle between the two modes. The dis-play will read either MANUAL or SEEK to indicate themode the receiver is in.

Manual Tuning

Press TUNE (8) to tune to the next higher fre-quency. Press SEEK (7) to tune to the next lowerfrequency. Holding either of the buttons for morethan 0.5 seconds will activate fast tuning forincreased speed.

When in satellite mode, press and release either theTUNE or the SEEK buttons to navigate to the

next channel. Pressing and holding either of the twobuttons for more than 0.5 seconds will increase thecycle speed through the channels. The increasecycle speed is approximately 10 channels per sec-ond.

SEEK Mode

Hold either the TUNE or SEEK buttons for morethan 0.5 seconds to enter the seek mode. SEEK willappear on the display when this mode is activated. Inthis mode, the radio will scroll through stations andstop on the next station with a strong signal.

If the receiver can not find a strong enough signalafter two band cycles, the seek mode will discontinueand the receiver will return to the initial starting point.

When in satellite mode, press TUNE or SEEK tonavigate through the channels. Pressing and holdingeither of the two buttons for more than two secondswill increase the cycle speed through the channels.The increase cycle speed is approximately 10 chan-nels per second.

SCAN

Press SCAN button (10) to scan all stations on thecurrent band. When a strong frequency is found, thereceiver will pause on that station for about 5 sec-onds and then continue scanning. Scan will appearon the display along with the frequency when thismode is active. To stop scanning, press the SCANbutton again.

AUTO

AUTO (12) allows the receiver to store the 6 stron-gest stations onto push-buttons 1 through 6. PressAUTO until AUTO and AS appear on the display. Thepresets on the current band only will now be pro-grammed with the six strongest frequencies. Presetson the other inactive bands will not be changed.Pressing AUTO again will delete the stations anddefault to the original preset stations.

NOTE: The AUTO function is not functional on thesatellite band.


ADJUSTING THE RECEIVER SETTINGSVOLUME: Rotate ON/AUDIO (6, Figure 70-1) knobclockwise to increase the volume and counter-clock-wise to decrease the volume. VOL will be displayedalong with the volume level.

BASS: Push and release ON/AUDIO (6) knob untilBASS and the current bass level is displayed. Rotatethe knob clockwise to increase the bass and counter-clockwise to decrease the bass.

TREBLE: Push and release ON/AUDIO (6) knob untilTREB and the current treble level is displayed.Rotate the knob clockwise to increase the treble andcounter-clockwise to decrease the treble.

FADE: Push and release ON/AUDIO (6) knob untilFADE and the current level is displayed. Rotate theknob clockwise to move the sound to the front speak-ers and counter-clockwise to move the sound to therear speakers.

BALANCE: Push and release ON/AUDIO (6) knobuntil BAL and the present level is displayed. Rotatethe knob clockwise to move the sound to the rightspeakers and counter-clockwise to move the soundto the left speakers.

SPEAKER: Push and release ON/AUDIO (6) knobuntil SPKR and the current setting is displayed.Rotate the ON/AUDIO knob to select 2-speaker or 4-speaker operation. When 2-speaker operation active,the rear speakers are muted and the FADE optionwill not appear on the menu.

PROGRAMMING PRESET STATIONSPresets are stations that are stored on each of the 6push-buttons. After a station has been programmedinto one of the preset buttons, pushing the presetprovides a quick return to that station. The six but-tons can each store a preset channel per band.

NOTE: The receiver is equipped with two FM radiobands: FM1 and FM2. The two bands are identical.However, each one allows the operator to set 6preset channels for a total of 12 FM presets.

Perform the following steps to program the presets:

1. Turn the receiver on.2. Select the band and the desired station.3. Press and hold one of the six push-buttons for

at least two seconds. During the two secondperiod, receiver output will be muted and thepush-button number will not show on the dis-play. When the station has been committed tomemory, the audio and the preset icon willreturn.

OPERATION OF THE WEATHERBAND (U.S.)NOAA - weather radio is a service of the NationalWeather Service. It provides continuous broadcastsof the latest weather information directly from theNational Weather Service offices. Taped weathermessages are repeated every four to six minutes andare routinely revised every one to three hours, ormore frequently if needed. Most of the stations oper-ate 24 hours, daily.

The weather for the area you are in may be found onone of seven stations. When in the Weatherbandmode, the display will show the WX icon and CHAN #to indicate the channel. The channel may beadjusted through the TUNE /SEEK buttons, andmay be preset as in the radio mode. The frequency associated with each channel is asfollows:

1. 162.550 MHz 5. 162.450 MHz 2. 162.400 MHz 6. 162.500 MHz 3. 162.475 MHz 7. 162.525 MHz 4. 162.425 MHz

The National Weather Service operates approxi-mately 372 stations. Close to 90 percent of thenation's population is within the listening range of aNOAA weather radio broadcast.


SATELLITE RADIOTo use the satellite radio function on your radio, asubscription must be ordered from a provider. Thereare currently two providers in the U.S.: XM and SiriusSatellite Radio. When a subscription is ordered, youwill need to get an additional receiver and antennafrom your provider.

To activate the external satellite receiver, you mustsupply the provider with your Electronic Serial Num-ber (ESN). To find the ESN, first install the satellitereceiver per the instructions from the your provider.Next, follow the instructions below.

XM Satellite Radio:

1. Turn both the radio and the satellite receiver on.Press the BAND button on the radio and selecteither XM1 or XM2.

2. Tune your satellite receiver to channel 0 to seethe ESN display.

Record the ESN.

The display will return to the default setting after5 seconds.

Sirius Satellite Radio:

1. Turn the radio on and with the display showingthe clock, press and hold the DSPL/TM SETbutton until the hours segment is flashing.

2. Press the BAND button and the ESN will be dis-played.

Record the ESN.

The display will return to the default setting after5 seconds.

NOTE: Only one satellite receiver can be installedand connected to your receiver at one time.

Obstructions in the satellite signal may impair yoursatellite radio reception. Contact your provider forsatellite radio reception problems.

Operating Satellite Radio1. Use the BAND button to select the proper satel-

lite radio band. (XM1, XM2, SR1, SR2)

2. Use the TUNE and SEEK buttons to navi-gate through the channels.

Program Type Search (PTY)

XM and Sirius both allow you to search by musictype. Program Type Search (PTY) allows you to per-form a music search by type. Perform the followingsteps in order to do a PTY search.

1. Press SCAN and push-button 1 at the sametime. PTY will appear on the display.

2. Continue to press push-button 1 until thedesired genre of programming is displayed.

3. Once the desired genre has been selected,press the TUNE and SEEK buttons to scrollthrough the different channels in that genre.Station names will appear on the display asyour scroll.

You may also scan through the channels usingthe scan feature. Press the SCAN button tobegin scanning the channels. Press the SCANbutton again to stop at the desired channel.


CASSETTE PLAYER The cassette player that the radio is equipped withworks best with cassettes that range from 30 to 90minutes long. Cassettes that are longer than 90 min-utes have thinner tape, and do not work well in thismodel cassette player. It is also important to only use cassettes that are ingood condition. Cassettes that are dirty, damaged, orhave been exposed to excessive heat and/or sunlightcould cause damage to the cassette player and pos-sible failure.The cassette player is equipped with automaticequalization and metal tape sensing functions. An Mwill appear on the display when a metal tape issensed.Cleaning the cassette player is a recommendedmaintenance item. It should be performed at 35 hour(cassette play) intervals. Failure to clean the cassetteplayer may diminish sound quality and cause cas-sette player failure.

Playing A Cassette1. Turn the receiver ON.2. Insert a cassette into the player. The cassette

icon will appear on the display. The tape willbegin to play when the icon appears.

Press button (3, Figure 70-1) to changefrom the radio to a cassette. TP SIDE 1 or TPSIDE 2 will appear on the display depending onwhich side of the cassette is currently beingplayed. If a cassette is not loaded in the player,NO TAPE will appear on the display.

NOTE: A tape may be inserted when the receiver isoff by pressing the eject button and inserting the tapewithin 25 seconds.

Cassette Functions

The 4/REV button (17) rewinds the cassette. Thecassette will continue to rewind until the button ispressed again, or until the cassette reaches the endof the tape. <REW will appear on the display as thecassette is rewinding.

The 6/FF button (15) fast forwards the cassette. Thecassette will continue to fast forward until the buttonis pressed again, or until the cassette reaches theend of the tape. FWD> will appear on the display asthe cassette is fast forwarding.

Press Eject (5) to remove the cassette from theplayer. When the eject button is held, it acts as a stopbutton.

The button (4) causes the cassette player toreverse directions and play the opposite side of thecassette. Pressing the button a second time willreverse the cassette back to the original side.

NOTE: The cassette will automatically flip to theopposite side when the end of the tape is reached.

Progrommable Eject Default

The cassette player has been pre-programmed toreturn to the radio after a tape has been ejected. Thisdefault may be changed to an “eject audio mute”mode. This mode will mute the radio after a cassettehas been ejected. When this occurs, “NO TAPE” willappear on the display and the radio will remainmuted until BAND (2) is pressed. Pressing this buttonwill enable the radio.

Perform the following steps to change the ejectdefault mode:

1. Press and hold DSP/TM SET (9, Figure 70-1)for at least 2 seconds until the hour digits flash.

2. Press button (3) to toggle between“P.PLAY” and “EJMUTE”. After 5 seconds ofinactivity, the receiver will return to the defaultdisplay.


Bad Tape Detect

If the receiver detects a bad cassette, “BAD TAPE”will appear on the display and the tape will beejected. If this occurs, the cassette should beremoved from the player and should not be re-inserted.

To use a cleaning tape or a CD adapter in the cas-sette player, the bad tape detector must be turnedoff. Perform the following steps to disable this mode:

1. Turn off receiver and turn key switch to OFF.

2. Press and hold button (3) for 5 seconds.“BAD TAPE DETECT OFF” will appear on thedisplay. When this is displayed, the detectorhas been disabled.

Repeat this procedure to reactivate the badtape detector. “BAD TAPE DETECT ON” willappear on the display after the detector hasbeen activated.

Cleaning The Cassette Player

After 35 hours of cassette play, the display will readTP CLEAN for five seconds. This indicates that it istime to clean the cassette player.

1. Turn key switch to ON and turn off receiver.2. Disable BAD TAPE DETECT mode. Press and

hold button (3, Figure 70-1) for five sec-onds. “BAD TAPE DETECT OFF” will appearon the display. When this is displayed, thedetector has been disabled.

3. Turn the receiver on.4. Insert a wet-type, non-abrasive, scrubbing cas-

sette cleaner. Follow the instructions providedwith the cleaner.

5. Reset the clean tape timer. With the receiveron, press and hold the eject button for five sec-onds. TP CLEAN will appear on the display andthe tape icon will flash after three seconds haselapsed. After five seconds CLN RST willappear on the display. When this occurs, theclean tape timer will be reset to zero hours. Ifthe button was released before CLN RST wasdisplayed, the timer will not be reset.

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