CEAM012100

Operation & Maintenance

Manual

930E-2
DUMP TRUCK

SERIAL NUMBERS A30300 thru A30303

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

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

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

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

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

CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust, some of its constituents, and certain vehicle
components contain or emit chemicals known to the State of California to
cause cancer, birth defects or other reproductive harm.

CALIFORNIA
Proposition 65 Warning
Battery posts, terminals and related accessories contain lead and lead
compounds, chemicals known to the State of California to cause cancer
and birth defects or other reproductive harm. Wash hands after handling.
NOTES
 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.

CEHQ000700 - Komatsu America International Company 12/99

 INFORMATION IMPORTANTE SUR LE MOTEUR AVERTISSEMENT
CE MOTEUR EST CONFORME AUX NORMES AMÉRICAINES DEL’EPA (ANNÉE DU DES BLESSURES PEUVENT RÉSULTER ET LA GARANTIE
MODÈLE) ET DE LA CALIFORNIE POUR LES MOTEURS LARGES NON-ROUTIERS A IGNI- S’ANNULER SI LES RPM DU TAUX D’ESSENCE OU L’ALTITUDE
TION PAR COMPRESSION. CE MOTEUR EST CERTIFIÉ POUR OPERATION À ESSENCE EXCÈDENT LES VALEURS MAXIMALES PUBLIÉES POUR CE
DIÉSEL. MODÈLE ET SON APPLICATION.

IMPORTANT ENGINE INFORMATION

THIS ENGINE CONFORMS TO YYYY MODEL YEAR U.S. EPA REGULATION AND THE CALIFORNIA
REGULATIONS LARGE NON ROAD COMPRESSION IGNITION ENGINES. THIS ENGINE IS CERTI-
FIED TO OPERATE ON DIESEL FUEL.
MODÈLE DU MOTEUR WARNING NO. SÉRIE
INJURY MAY RESULT AND WARRANTY IS VOIDED IF FUEL RATE RPM OR ALTITUDES EXCEED
PUBLISHED MAXIMUM VALUES FOR THIS MODEL AND APPLICATION.
FAMILLE DU MOTEUR ENGINE MODEL SERIAL NO. DÉPLACEMENT

SYSTÈME DE ENGINE FAMILY DISPLACEMENT LITERS

CONTROLE DES
ÉMISSIONS D’ÉCHAPPEMENT EXHAUST EMISSION
FIRING ORDER 1-5-3-6-2-4 LITRES
CONTROL SYSTEM
ADV. LOAD OUTPUT Kw ( HP) RPM
CHARGE DE SORTIE ADV. SÉQUENCE DE MISE À FEU
VALVE LASH IN. EX. FUEL RATE mm3/STROKE mm3/BATTEMENT
PORTÉE DE VALVE À FROID COLD (mm) AT ADV.
(mm) TAUX D’ESSENCE À ADV.

VITESSE STATIQUE IDLE SPEED RPM FAMILY EMISSION LIMIT

INITIAL INJECTION DEG. BTDC DATE OF MANUFACTURE LIMITE D’ÉMISSION DE
TIMING LA FAMILLE

RÉGLAGE DE L’ALLUMAGE - _____________________________________________ KOMATSU LTD.

INJECTION INITIALE MADE IN JAPAN DATE
DE FABRICATION

DEG. BTDC
KOMATSU LTÉE
FABRIQUÉ AU JAPON

ENGINE DATAPLATE - ENGLISH / FRENCH

OM1037 Introduction - Section 10
Page 10-1

FOREWORD

This manual is written for use by the operator and/or the service technician and is designed to help these persons
to become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently.
All operators and maintenance personnel should read and understand the materials in this manual before operat-
ing the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings and
cautions should be understood and followed when operating or accomplishing repairs on the truck.

The first section is an Introduction to the manual and contains a Table of Contents to locate specific areas of inter-
est. Other sections include Safety, Operation, Maintenance, Specifications, and Optional Equipment.
The illustrations used in this manual are TYPICAL of the component shown and may not be an exact reproduction
of what is found on the truck.

A product identification plate is located on the frame in front of the right side front wheel and designates the Truck
Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle
Weight) rating.

The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 930E).
The three numbers represent the basic truck model.
The letter “M”, when present, designates a Mechanical drive system;
The letter “E”, when present, designates an Electrical wheel motor drive system.

The Product Identification Number (vehicle serial number) contains information which will identify the original man-
ufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service
parts and/or warranty consideration.

The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other compo-
nents. The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle
Weight (GVW) GVW is TOTAL WEIGHT: the Empty Vehicle Weight + the fuel & lubricants + the payload.
To determine allowable payload: Service all lubricants for proper level and fill fuel tank of empty truck (which
includes all accessories, body liners, tailgates, etc.) and then weigh truck. Record this value and subtract from the
GVW rating. The result is the allowable payload.
NOTE: Accumulations of mud, frozen material, etc. become a part of the GVW and reduces allowable payload. To
maximize payload and to keep from exceeding the GVW rating, these accumulations should be removed as often
as practical.
Exceeding the allowable payload will reduce expected life of truck components.
Introduction - Section 10 OM1037
Page 10-2

ALERTS PAGE

This “ALERT” symbol is used with the signal words,

“CAUTION”, “DANGER”, and “WARNING” in this manual
to alert the reader to hazards arising from improper oper-
ating and maintenance practices.

“DANGER” identifies a specific potential hazard

WHICH WILL RESULT
in either INJURY OR DEATH
if proper precautions are not taken.

“WARNING” identifies a specific potential hazard

WHICH WILL RESULT
in either INJURY OR DEATH
if proper precautions are not taken.

“CAUTION” is used for general reminders

of proper safety practices
OR
to direct the reader’s attention to avoid unsafe
or improper practices which may result
in damage to the equipment.
OM1037 Introduction - Section 10
Page 10-3

TABLE OF CONTENTS

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

FOREWARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1
“Alerts” Page - a description of DANGER, WARNING, and CAUTION symbols. . . . . . . . . . . . . . . .10-2
TABLE OF CONTENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-3
Truck Model Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10
ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11

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

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1
Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1
Clothing And Personal Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1
Unauthorized Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1
Leaving The Operator’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-2
Mounting And Dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-2
Fire Prevention For Fuel And Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-2
Precautions When Handling At High Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-3
Asbestos Dust Hazard Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-3
Prevention Of Injury By Work Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-3
Fire Extinguisher And First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-3
Precautions When Using ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-4
Precautions For Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-4
PRECAUTIONS DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-5
Safety Is Thinking Ahead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-5
Safety At The Worksite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-5
Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-5
Preparing For Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-5
Ventilation In Enclosed Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-5
In Operator’s Cab - Before Starting The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-6
Mirrors, Windows, And Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-6
OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-6
When Starting The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-6
Truck Operation - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-6
Check When Traveling In Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-7
Traveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-7
Traveling On Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-8
Ensure Good Visibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-8
Operate Carefully On Snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-8
Avoid Damage To Dump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-8
Driving Near High Voltage Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-8
Introduction - Section 10 OM1037
Page 10-4

TABLE OF CONTENTS

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

When Dumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-9

Working On Loose Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-9
When Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-9
Parking The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-9
TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-9
WORKING NEAR BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10
Battery Hazard Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10
Starting With Booster Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10
PRECAUTIONS FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11
BEFORE PERFORMING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11
Warning Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11
Proper Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11
Stopping The Engine Before Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11
Securing The Dump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11
DURING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12
Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12
Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12
Working Under The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12
Keep The Machine Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12
Rules To Follow When Adding Fuel Or Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12
Radiator Water Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-13
Use Of Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-13
Precautions With The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-13
Handling High Pressure Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-13
Precautions With High Pressure Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-13
Precautions When Performing Maintenance Near High Temperature Or High Pressure . . . . 20-14
Rotating Fan And Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-14
Waste Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-14
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-15
Handling Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-15
Storing Tires After Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-15
ADDITIONAL JOB SITE RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-16
WHEN REPAIRS ARE NECESSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-17
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-18
Preliminary Procedures Before Welding or Performing Maintenance . . . . . . . . . . . . . . . . . . 20-18
Normal Engine Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-18
Engine Shutdown Procedure Before Welding or Performing Maintenance . . . . . . . . . . . . . . 20-19

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

OM1037 Introduction - Section 10
Page 10-5

TABLE OF CONTENTS

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

OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-1

PREPARING FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-1
Safety Is Thinking Ahead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-1
At The Truck - Ground Level Walk Around Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-1
ENGINE START-UP SAFETY PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-4
Cold Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-5
AFTER ENGINE HAS STARTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-5
MACHINE OPERATION SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-6
MACHINE OPERATION ON THE HAUL ROAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-6
STARTING ON A GRADE WITH A LOADED TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-7
PASSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-7
LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-7
DUMPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-8
Raising The Dump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-8
Lowering The Dump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-8
TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-10
SAFE PARKING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-10
NORMAL ENGINE SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-10
DELAYED ENGINE SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11
SUDDEN LOSS OF ENGINE POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-12
RESERVE ENGINE OIL SYSTEM (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-13

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

STEERING WHEEL AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-2
Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-2
Telescope Lock Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-2
Tilt Wheel Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-2
Turn Signal/Headlight Dimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-2
DYNAMIC RETARDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-2
Retarder Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-3
Dynamic Retarder/Service Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-3
Accelerator (Throttle) Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-3
Starting on a Grade With a Loaded Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-3
GRADE/SPEED RETARD CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-4
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-5
OVERHEAD PANEL AND DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-5
CENTER CONSOLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-6
F-N-R Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-6
Hoist Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-7
Raising The Dump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-7
Lowering The Dump Body: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-7
Introduction - Section 10 OM1037
Page 10-6

TABLE OF CONTENTS

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

Ash Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-7

Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-7
L.H. Window Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-7
R.H. Window Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-7
Engine Shutdown Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-7
Override/Fault Reset Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-8
Retard Speed Control (RSC) Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-8
Retard Speed Control (RSC) Adjust Dial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-8
PSC Download Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-9
Engine Diagnostics Download Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-9
TCI Download Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-9
Passenger Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-9
Engine Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-9
Modular Mining System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-9
Payload Meter And Download Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-9
OPERATOR COMFORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-10
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-10
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-10
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS . . . . . . . . . . . . . . . . . . . . . 32-11
Heater/Air Conditioner Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-11
Defroster Vent Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-11
Heater Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-11
Temperature Control Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-11
Fan Control Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-11
Heater/Air Conditioner Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-11
INSTRUMENT PANEL AND INDICATOR LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-13
CONTROL SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-13
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-13
PANEL GAUGES, INDICATORS, AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-15
Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-15
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-15
Engine Shutdown Switch with 5 Minute Idle Timer Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-15
Fog Lights (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-16
Ladder Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-16
Manual Backup Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-16
Panel Illumination Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-16
Cab/Air Conditioner Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-16
Rotating Beacon Light Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-16
Heated Mirror Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-16
OM1037 Introduction - Section 10
Page 10-7

TABLE OF CONTENTS

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

Wheel Brake Lock Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-17

Parking Brake Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-17
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-17
Right Turn Signal Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-18
High Beam Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-18
Left Turn Signal Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-18
Speedometer/Payload Meter Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-18
Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-18
Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-18
Water Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-18
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-18
AC Drive System Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-19
Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-19
Hydraulic Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-19
Rest Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-19
Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-20
Windshield Wiper and Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-20
Panel Light Dimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-20
Payload Meter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-20
OVERHEAD STATUS / WARNING INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-21
STATUS / WARNING INDICATOR LIGHT SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-22
Hazard Warning Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-28
Lamp Test Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-28
Link-On Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-28

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

930E SERVICE CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-1
HYDRAULIC TANK SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-1
Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-1
WHEEL MOTOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-1
COOLANT LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-2
RADIATOR FILLING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-2
RESERVE ENGINE OIL SYSTEM (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-2
Reserve Oil Tank Filling Procedure (Remote fill) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-2
LUBRICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-3
10 HOUR (DAILY) INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-4
50 HOUR LUBRICATION AND MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-7
100 HOUR LUBRICATION AND MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-8
250 HOUR LUBRICATION AND MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-9
500 HOUR LUBRICATION AND MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-12
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . .40-13
2500 HOUR MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-14
5000 HOUR MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-14
Introduction - Section 10 OM1037
Page 10-8

TABLE OF CONTENTS

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

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

GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-1
SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-3
System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-4
Normal Operation: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-4
Pressure Failure Detection Circuits: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-5
GENERAL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-6
Required Lubricant For System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-6
System Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-6
Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-6
LUBRICANT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-7
Pump Housing Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-7
Pump Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-7
Pressure Control Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-7
INJECTOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-8
INJECTORS (SL-1 Series “H”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-9
Injector Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-9
Injector Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-9
SYSTEM CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-10
Lubrication Cycle Timer Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-10
Lubrication Cycle Timer Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-10
SYSTEM TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-11
Preventative Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-14
Daily Lubrication System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-14
250 Hour Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-14
1000 Hour Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-14

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

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

RADIO, AM / FM STEREO CASSETTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-1

SETTING THE TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-1
GENERAL RECEIVER FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-1
Turning The Power On And Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-1
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-1
Setting The Default Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-2
Adjusting Display Brightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-2
OM1037 Introduction - Section 10
Page 10-9

TABLE OF CONTENTS

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

OPERATING THE RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-2

BAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-2
TUNE/SEEK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-2
Manual Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-2
SEEK Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-2
SCAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-2
AUTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-2
ADJUSTING THE RECEIVER SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-3
PROGRAMMING PRESET STATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-3
OPERATION OF THE WEATHERBAND (U.S.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-3
SATELLITE RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-4
Operating Satellite Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-4
Program Type Search (PTY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-4
CASSETTE PLAYER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-5
Playing A Cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-5
Cassette Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-5
PROGRAMMABLE EJECT DEFAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-5
Bad Tape Detect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-6
CASSETTE PLAYER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-6
Introduction - Section 10 OM1037
Page 10-10

TRUCK MODEL ILLUSTRATION

KOMATSU MODEL 930E Dump Truck

OM1037 Introduction - Section 10
Page 10-11

ABOUT THIS MANUAL

This manual is written for use by the operator and/or the service technician. It is designed to help these persons
learn how to operate the truck and its systems in order to keep it operating safely and efficiently. All operators and
maintenance personnel should read and understand the materials in this manual before operating the truck or per-
forming maintenance and/or operational checks on the truck. All safety notices, warnings, and cautions should be
understood and followed when operating or performing repairs on the truck.
The front cover of this manual includes a form number. This form number should be referenced when ordering
additional copies of this manual, or for any other correspondence regarding the coverage in this manual.
Direct all inquiries to:
Komatsu America Corp.
Datakom, Peoria Technical Publications
P.O. Box 240
Peoria, IL 61650-0240
(309)-672-7072 - FAX

This first section is an Introduction to the manual and contains the Table of Contents to locate specific areas of
interest. 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
subject might generally be included. Then, go to that section of the Table of Contents to find a subject description
that most closely describes the specific area of interest to find a page number and go to that page. Section num-
bers and page numbers are located at the top, outside corner of the page.
At the top, inside corner of the page is a document (module) number. If there is ever a question regarding the infor-
mation in a particular section, refer to the document (module) number, the manual form number, and use the
address shown above to correspond. If there is a date (month/year) behind the document (module) number, that
indicates the latest revision date of that page.
The illustrations used in this manual are TYPICAL of the component shown and may not be an exact reproduction
of what is found on the truck.
This manual shows dimensioning of U.S. standard and metric (SI) units throughout. All references to “right”, “left”,
“front”, or “rear” are made with respect to the operator's normal seated position, unless specifically stated other-
wise.
When assembly instructions are provided without references to torque values, standard torque values should be
assumed. Standard torque requirements are shown in torque charts on the following pages of this section, and in
the General Information section of the truck service manual. Individual torques when provided in the text are in bold
face type, such as 100 ft.lbs. (135 N.m) torque. All torque specifications have ±10% tolerance unless otherwise
specified.
Introduction - Section 10 OM1037
Page 10-12

NOTES
OM1200 Standard Charts and Tables - Section 12
Page 12-1

STANDARD CHARTS AND TABLES

This manual provides dual dimensioning for most spec- EFFECT OF SPECIAL LUBRICANTS
ifications. U.S. standard units are specified first, with On Fasteners and Standard Torque Values
metric (SI) units in parentheses. References through- KOMATSU engineering department does NOT recom-
out the manual to standard torques or other standard mend the use of special “friction-reducing” lubricants
values will be to one of the following Charts or Tables. such as, “Copper Coat”, “Never Seize”, and other simi-
For values not shown in any of the charts or tables, lar products on the threads of standard fasteners
standard conversion factors for most commonly used where “standard torque” values are applied.
measurements are provided in TABLE XIII, page 12-6.
The use of special “friction-reducing” lubricants will sig-
nificantly alter the clamping force being applied to fas-
INDEX OF TABLES
teners during the tightening process.
TABLE I . . . . . . . Standard Torque Chart (SAE) . . 12-9
TABLE II . Standard Torque, 12-Point, Grade 9 . 12-10 If special “friction-reducing” lubricants are used with the
TABLE III . . Standard Metric Assembly Torque . 12-10 “Standard Torque” values listed below in Table I (and in
TABLE IV . . . . . . JIC Swivel Nuts Torque Chart . 12-11 Komatsu shop manuals), excessive stress and possi-
TABLE V . . . . . . . . .Pipe Thread Torque Chart . 12-11 ble breakage of the fasteners may result.
TABLE VI . . . . . . . . O-Ring Boss Torque Chart . 12-11 Where Torque Tables specify “Lubricated Threads” for
TABLEVII . . . . O-Ring Face Seal Torque Chart . 12-11 the Standard Torque values listed, these standard
TABLE VIII . Torque Conversions (ft.lbs. - N.m) . 12-12 torque values are to be used with simple lithium
TABLE IX . . Torque Conversions (ft.lbs. - kg.m) . 12-12 base chassis grease (multi-purpose EP NLGI) or a
TABLE X . . . Pressure Conversions (psi - kPa) . 12-12 rust- preventive grease (see list, page 12-10) on the
TABLE XI . . Pressure Conversions (psi - MPa) . 12-12 threads and seats, unless specified otherwise.
TABLE XII . . . . . . . .Temperature Conversions . 12-13 NOTE: Always be sure threads of fasteners and tapped
TABLE XIII . . . Common Conversion Multipliers . 12-14 holes are free of burrs and other imperfections before
assembling.
Standard torque values are not to be used when
“Turn-of-the-Nut” tightening procedures are rec-
ommended.

TABLE I. -STANDARD TORQUE CHART

SAE HEX HEAD CAPSCREW AND NUT ASSEMBLY
Grade 5 (LUBRICATED THREADS) Grade 8
TOLERANCES ±10%
Cap- TORQUE - TORQUE - Cap- TORQUE - TORQUE -
screw GRADE 5 GRADE 8 screw GRADE 5 GRADE 8
Thread Thread
Size ft. lbs. kg.m N.m ft. lbs. kg.m N.m Size ft. lbs. kg.m N.m ft. lbs. kg.m N.m

1/4-20 7 0.97 9.5 10 1.38 13.6 3/4-16 235 32.5 319 335 46.3 454
1/4-28 8 1.11 10.8 11 1.52 14.9 7/8-9 350 48.4 475 500 69.2 678
5/16-18 15 2.07 20.3 21 2.90 28 7/8-14 375 51.9 508 530 73.3 719
5/16-24 16 2.21 22 22 3.04 30 1.0-8 525 72.6 712 750 103.7 1017
3/8-16 25 3.46 34 35 4.84 47 1.0-12 560 77.4 759 790 109.3 1071
3/8-24 30 4.15 41 40 5.5 54 1.0-14 570 78.8 773 800 110.6 1085
7/16-14 40 5.5 54 58 8.0 79 1 1/8-7 650 89.9 881 1050 145 1424
7/16-20 45 6.2 61 62 8.57 84 1 1/8-12 700 96.8 949 1140 158 1546
1/2-13 65 9 88 90 12.4 122 1 1/4-7 910 125.9 1234 1480 205 2007
1/2-20 70 9.7 95 95 13.1 129 1 1/4-12 975 134.8 1322 1580 219 2142
9/16-12 90 12.4 122 125 17.3 169 1 3/8-6 1200 166 1627 1940 268 2630
9/16-18 95 13.1 129 135 18.7 183 1 3/8-12 1310 181 1776 2120 293 2874
5/8-11 125 17.3 169 175 24.2 237 1 1/2-6 1580 219 2142 2560 354 3471
5/8-18 135 18.7 183 190 26.2 258 1 1/2-12 1700 235 2305 2770 383 3756
3/4-10 220 30.4 298 310 42.8 420
1 ft. lbs. = 0.138 kg.m = 1.356 N.m
Standard Charts and Tables - Section 12 OM1200
Page 12-2

Standard Assembly Torques For 12-Point, Grade 9, Standard Metric Assembly Torque For Class 10.9
Capscrews (SAE) Capscrews & Class 10 Nuts
The following specifications apply to required assembly The following specifications apply to required assembly
torques for all 12-Point, Grade 9 (170,000 psi minimum torques for all metric Class 10.9 finished hexagon head
tensile), Capscrews. capscrews and Class 10 nuts.
• Capscrew threads and seats SHALL be lubri- • Capscrew threads and seats SHALL NOT be
cated when assembled. lubricated when assembled. These specifications
Unless instructions specifically recommend otherwise, are based on all capscrews, nuts, and hardened
these standard torque values are to be used with washers being phosphate and oil coated.
simple lithium base chassis grease (multi-purpose EP NOTE: If zinc-plated hardware is used, each piece
NLGI) or a rust- preventive grease (see list, this page) must be lubricated with a Rust Preventive Grease or
on the threads. Lithium-base grease to achieve the same clamping
forces provided below.
• Torques are calculated to give a clamping force of
approximately 75% of proof load. • Torques are calculated to give a clamping force of
approximately 75% of proof load.
• The maximum torque tolerance shall be ±10% of
the torque value shown. • The maximum torque tolerance shall be within
±10% of the torque value shown.
TABLE II. - STANDARD ASSEMBLY TORQUE TABLE III. - STANDARD METRIC ASSEMBLY TORQUE
for 12-Point, Grade 9 Capscrews
CAPSCREW TORQUE TORQUE TORQUE
CAPSCREW TORQUE TORQUE TORQUE SIZE* N.m ft.lbs. kg.m
SIZE* ft. lbs. N.m kg.m
M6 x1 12 9 1.22
0.250 - 20 12 16 1.7
M8 x 1.25 30 22 3.06
0.312 - 18 24 33 3.3
M10 x 1.5 55 40 5.61
0.375 - 16 42 57 5.8
M12 x 1.75 95 70 9.69
0.438 -14 70 95 9.7
M14 x 2 155 114 15.81
0.500 -13 105 142 14.5
M16 x 2 240 177 24.48
0.562 - 12 150 203 20.7
M20 x 2.25 465 343 47.43
0.625 - 11 205 278 28.3
M24 x 3 800 590 81.6
0.750 - 10 360 488 49.7
M30 x 3.5 1600 1180 163.2
0.875 - 9 575 780 79.4
M36 x 4 2750 2028 280.5
1.000 - 8 860 1166 119
* Shank Diameter (mm) - Threads per millimeter
1.000 - 12 915 1240 126
This table represents standard values only. Do not use these val-
1.125 - 7 1230 1670 170 ues to replace torque values which are specified in assembly
1.125 - 12 1330 1800 184 instructions.

1.250 - 7 1715 2325 237

Suggested* Sources for Rust Preventive Grease:
1.250 - 12 1840 2495 254
1.375 - 6 2270 3080 313
• AMERICAN ANTI-RUST GREASE #3-X from
Standard Oil Company (also American Oil Co.)
1.375 - 12 2475 3355 342
1.500 - 6 2980 4040 411
• GULF NORUST #3 from Gulf Oil Company.
1.500 - 12 3225 4375 445 • MOBILARMA 355, Product No. 66705 from Mobil
* Shank Diameter (in.) - Threads per inch Oil Corporation.
This table represents standard values only. Do not use these val- • RUST BAN 326 from Humble Oil Company.
ues to replace torque values which are specified in assembly
instructions.
• RUSTOLENE B GREASE from Sinclair Oil Co.
• RUST PREVENTIVE GREASE - CODE 312 from
the Southwest Grease and Oil Company.
NOTE: This list represents the current Engineering
approved sources for use in Komatsu manufacture. It is
not exclusive. Other products may meet the same
specifications of this list.
OM1200 Standard Charts and Tables - Section 12
Page 12-3

TABLE IV. TABLE VI.

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

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

TABLE V. TABLE VII.

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

PIPE WITH WITHOUT SIZE TUBE SIZE THREADS TORQUE

SIZE THREAD SEALANT SEALANT CODE (O.D.) UNF-2B FT. LBS.
CODE SIZE FT. LBS. FT. LBS.
–4 0.250 0.438 – 20 11 ±1
–2 0.125 – 27 15 ±3 20 ±5
–6 0.375 0.562 – 18 18 ±2
–4 0.250 – 18 20 ±5 25 ±5 –8 0.500 0.750 – 16 35 ±4
–6 0.375 – 18 25 ±5 35 ±5
– 10 0.625 0.875 – 14 51 ±5
–8 0.500 – 14 35 ±5 45 ±5
– 12 0.750 1.062 – 12 71 ±7
– 12 0.750 – 14 45 ±5 55 ±5 – 16 1.000 1.312 – 12 98 ±6
– 16 1.000 – 11.50 55 ±5 65 ±5
– 20 1.250 1.625 – 12 132 ±7
– 20 1.250 – 11.50 70 ±5 80 ±5
– 24 1.500 1.875 – 12 165 ±15
– 24 1.500 – 11.50 80 ±5 95 ±10
– 32 2.000 – 11.50 95 ±10 120 ±10
Standard Charts and Tables - Section 12 OM1200
Page 12-4

TABLE VIII. TORQUE CONVERSIONS

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

FT.
LBS. 0 1 2 3 4 5 6 7 8 9
0 (N.m) 1.36 2.71 4.07 5.42 6.78 8.14 9.49 10.85 12.20
10 13.56 14.91 16.27 17.63 18.98 20.34 21.69 23.05 24.40 25.76
20 27.12 28.47 29.83 31.18 32.54 33.90 35.25 36.61 37.96 39.32
30 40.67 42.03 43.39 44.74 46.10 47.45 48.81 50.17 51.52 52.87
40 54.23 55.59 56.94 58.30 59.66 60.01 62.37 63.72 65.08 66.44
50 67.79 69.15 70.50 71.86 73.21 74.57 75.93 77.28 78.64 80.00
60 81.35 82.70 84.06 85.42 86.77 88.13 89.48 90.84 92.20 93.55
70 94.91 96.26 97.62 98.97 100.33 101.69 103.04 104.40 105.75 107.11
80 108.47 109.82 111.18 112.53 113.89 115.24 116.60 117.96 119.31 120.67
90 122.03 123.38 124.74 126.09 127.45 128.80 130.16 131.51 132.87 134.23
See NOTE on page 12-5 regarding table usage

TABLE IX. TORQUE CONVERSIONS

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

FT.
LBS. 0 1 2 3 4 5 6 7 8 9
0 (kg.m) 0.138 0.277 0.415 0.553 0.692 0.830 0.968 1.106 1.245
10 1.38 1.52 1.66 1.80 1.94 2.07 2.21 2.35 2.49 2.63
20 2.77 2.90 3.04 3.18 3.32 3.46 3.60 3.73 3.87 4.01
30 4.15 4.29 4.43 4.56 4.70 4.84 4.98 5.12 5.26 5.39
40 5.53 5.67 5.81 5.95 6.09 6.22 6.36 6.50 6.64 6.78
50 6.92 7.05 7.19 7.33 7.47 7.61 7.74 7.88 8.02 8.16
60 8.30 8.44 8.57 8.71 8.85 8.99 9.13 9.27 9.40 9.54
70 9.68 9.82 9.96 10.10 10.23 10.37 10.51 10.65 10.79 10.93
80 11.06 11.20 11.34 11.48 11.62 11.76 11.89 12.03 12.17 12.30
90 12.45 12.59 12.72 12.86 13.00 13.14 13.28 13.42 13.55 13.69
See NOTE on page 12-5 regarding table usage

TABLE X. PRESSURE CONVERSIONS

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

PSI 0 1 2 3 4 5 6 7 8 9
0 (kPa) 6.895 13.79 20.68 27.58 34.47 41.37 48.26 55.16 62.05
10 68.95 75.84 82.74 89.63 96.53 103.42 110.32 117.21 124.1 131.0
20 137.9 144.8 151.7 158.6 165.5 172.4 179.3 186.2 193.1 200.0
30 206.8 213.7 220.6 227.5 234.4 241.3 248.2 255.1 262.0 268.9
40 275.8 282.7 289.6 296.5 303.4 310.3 317.2 324.1 331.0 337.9
50 344.7 351.6 358.5 365.4 372.3 379.2 386.1 393.0 399.9 406.8
60 413.7 420.6 427.5 434.4 441.3 448.2 455.1 462.0 468.9 475.8
70 482.6 489.5 496.4 503.3 510.2 517.1 524.0 530.9 537.8 544.7
80 551.6 558.5 565.4 572.3 579.2 586.1 593.0 599.9 606.8 613.7
90 620.5 627.4 634.3 641.2 648.1 655.0 661.9 668.8 675.7 682.6
See NOTE on page 12-5 regarding table usage
OM1200 Standard Charts and Tables - Section 12
Page 12-5

TABLE XI. PRESSURE CONVERSIONS

Pounds/square inch (psi) To Megapascals (MPa)
Formula: psi x 0.0069 = MPa

PSI 0 10 20 30 40 50 60 70 80 90
0 (MPa) 0.069 0.14 0.21 0.28 0.34 0.41 0.48 0.55 0.62
100 0.69 0.76 0.83 0.90 0.97 1.03 1.10 1.17 1.24 1.31
200 1.38 1.45 1.52 1.59 1.65 1.72 1.79 1.86 1.93 2.00
300 2.07 2.14 2.21 2.28 2.34 2.41 2.48 2.55 2.62 2.69
400 2.76 2.83 2.90 2.96 3.03 3.10 3.17 3.24 3.31 3.38
500 3.45 3.52 3.59 3.65 3.72 3.79 3.86 3.93 4.00 4.07
600 4.14 4.21 4.27 4.34 4.41 4.48 4.55 4.62 4.69 4.76
700 4.83 4.90 4.96 5.03 5.10 5.17 5.24 5.31 5.38 5.45
800 5.52 5.58 5.65 5.72 5.79 5.86 5.93 6.00 6.07 6.14
900 6.21 6.27 6.34 6.41 6.48 6.55 6.62 6.69 6.76 6.83
See NOTE below regarding Table usage

NOTE: Tables such as Table VIII, IX, X, and XI may be used as in the following example:
Example: Convert 975 psi to kilopascals (kPa). 3. Multiply by 10:
970 psi = 6688 kPa.
1. Select Table X.
4. Go to PSI row 0, column 5; read 34.475
2. Go to PSI row 90, column 7; read 668.8
psi = 34.47 kPa. Add to step 3.
97 psi = 668.8 kPa.
5. 970 + 5 psi = 6688 + 34 = 6722 kPa.

TABLE XII. TEMPERATURE CONVERSIONS

Formula: F° - 32 ³ 1.8 = C° or C° x 1.8 + 32 = F°

CELSIUS FAHRENHEIT CELSIUS FAHRENHEIT CELSIUS FAHRENHEIT

C° F° C° F° C° F°
121 250 482 63 145 293 4 40 104
118 245 473 60 140 284 2 35 95
116 240 464 57 135 275 –1 30 86
113 235 455 54 130 266 –4 25 77
110 230 446 52 125 257 –7 20 68
107 225 437 49 120 248 –9 15 59
104 220 428 46 115 239 – 12 10 50
102 215 419 43 110 230 – 15 5 41
99 210 410 41 105 221 – 18 0 32
96 205 401 38 100 212 – 21 –5 23
93 200 392 35 95 293 – 23 – 10 14
91 195 383 32 90 194 – 26 – 15 5
88 190 374 29 85 185 – 29 – 20 –4
85 185 365 27 80 176 – 32 – 25 – 13
82 180 356 24 75 167 – 34 – 30 – 22
79 175 347 21 70 158 – 37 – 35 – 31
77 170 338 18 65 149 – 40 – 40 – 40
74 165 329 15 60 140 – 43 – 45 – 49
71 160 320 13 55 131 – 46 – 50 – 58
68 155 311 10 50 122 – 48 – 55 – 67
66 150 302 7 45 113 – 51 – 60 – 76
NOTE: The numbers in the unmarked columns refer to temperature in either degrees Celsius (C°) or Fahrenheit (F°). Select a number in
this unmarked column and read to the left to convert to degrees Celsius (C°) or read to the right to convert to degrees Fahrenheit (F°). If
starting with a known temperature (either C° or F°), find that temperature in the marked column and read the converted temperature in the
center, unmarked column.
Standard Charts and Tables - Section 12 OM1200
Page 12-6

TABLE XIII
COMMON CONVERSION MULTIPLIERS

COMMON CONVERSION MULTIPLIERS COMMON CONVERSION MULTIPLIERS

ENGLISH To METRIC METRIC To ENGLISH

To Convert Multiply Multiply

From TO By To Convert From TO By
inch – in. millimeter (mm) 25.40 millimeter (mm) inch – in. 0.0394
inch – in. centimeter (cm) 2.54 centimeter (cm) inch – in. 0.3937
foot – ft. meter (m) 0.3048 meter (m) foot – ft. 3.2808
yard – yd. meter (m) 0.914 meter (m) yard – yd. 1.0936
mile – mi. kilometer (km) 1.61 kilometer (km) mile – mi. 0.6210

sq. in. – in.2 sq. centimeters (cm2) 6.45 sq. centimeters (cm2) sq. in. – in.2 0.1550
2 2 929 2 2 0.001
sq. ft. – ft. sq. centimeters (cm ) sq. centimeters (cm ) sq. ft. – ft.
3 3 16.39 3 3 0.061
cu. in. – in. cu. centimeters (cm ) cu. centimeters (cm ) cu. in. – in.

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

cu. ft. – ft. 3 liters (l) 28.3 liters (l) cu. ft. – ft. 3
0.0353
ounce – oz. kilogram (kg) 0.028 grams (g) ounce – oz. 0.0353
fluid ounce – fl. oz. milliliter (ml) 29.573 milliliter (ml) fluid ounce – fl. oz. 0.0338
pound (mass) kilogram (kg) 0.454 kilogram (kg) pound (mass) 2.2046
pound (force) – lbs. Newton (N) 4.448 Newton (N) pound (force) – lbs. 0.2248
in. lbs. (force) Newton.meters (N.m) 0.113 Newton.meters (N.m) kilogram.meters (kg.m) 0.102
ft. lbs. (force) Newton.meters (N.m) 1.356 Newton.meters (N.m) ft. lbs. (force) 0.7376
ft. lbs. (force) kilogram.meters (kg.m) 0.138 kilogram.meters (kg.m) ft. lbs. (force) 7.2329
kilogram.meters kilogram.meters (kg.m) Newton.meters (N.m) 9.807
Newton.meters (N.m) 9.807
(kg.m)
Kilopascals (kPa) psi (pressure) 0.1450
psi (pressure) kilopascals (kPa) 6.895 megapascals (MPa) psi (pressure) 145.038
psi (pressure) megapascals (MPa) 0.007
kilograms/cm2 (kg/cm2) psi (pressure) 14.2231
psi (pressure) 2
kilograms/cm (kg/cm ) 2 0.0704
kilograms/cm2 (kg/cm2) kilopascals (kPa) 98.068
ton (short) kilogram (kg) 907.2
kilogram (kg) ton (short) 0.0011
ton (short) metric ton 0.0907
metric ton ton (short) 1.1023
quart – qt. liters (l) 0.946
liters (l) quart – qt. 1.0567
gallon – gal. liters (l) 3.785
liters (l) gallon – gal. 0.2642
HP (horsepower) Watts 745.7
Watts HP (horsepower) 0.00134
HP (horsepower) kilowatts (kw) 0.745
kilowatts (kw) HP (horsepower) 1.3410
OM2030 Safety - Section 20
Page 20-1

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

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

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

Safety Features
• Ensure all guards and covers are in their proper position. Have any damaged guards and covers repaired. (See
Operating Instructions - Walk-Around Inspection, Section 30)
• Learn the proper use of safety features such as safety locks, safety pins, and seat belts, and use these safety
features properly.
• Never remove any safety features. Always keep them in good operating condition.
• Improper use of safety features could result in serious bodily injury or death.

Clothing And Personal Items

• Avoid loose clothing, jewelry, and loose long hair. They can catch on
controls or in moving parts and cause serious injury or death. Additionally,
never wear oily clothes as they are flammable.
• Wear a hard hat, safety glasses, safety shoes, mask and gloves when
operating or maintaining a machine. Always wear safety goggles, hard
hat and heavy gloves if your job involves scattering metal chips or minute
materials--particularly when driving pins with a hammer or when cleaning
air cleaner elements with compressed air. Also, ensure that the work area
is free from other personnel during such tasks.

Unauthorized Modification
• Any modification made to this vehicle without authorization from Komatsu America Corp. can possibly create
hazards.
• Before making any modification, consult the authorized regional Komatsu America Corp. distributor. Komatsu
will not be responsible for any injury or damage caused by any unauthorized modification.
Safety - Section 20 OM2030
Page 20-2

Leaving The Operator’s Seat

• When preparing to leave the operator's seat, do not touch any control lever that is not locked. To prevent
accidental operations from occurring, always perform the following:
• Move the shift control lever to NEUTRAL and apply the parking brake.
• Lower the dump body, set the dump lever to the FLOAT position.
• Stop the engine. When exiting the machine, always lock compartments, and take the keys with you. If the
machine should suddenly move or move in an unexpected way, this may result in serious bodily injury or death.

Mounting And Dismounting

• Never jump on or off the machine. Never climb on or off a machine while it is moving.
• When climbing on or off a machine, face the machine and use the hand-hold and steps.
• Never hold any control levers when getting on or off a machine.
• Always maintain three-point contact with the hand-holds and steps to ensure that you support yourself.
• When bringing tools into the operator's compartment, always pass them by hand or pull them up by rope.
• If there is any oil, grease, or mud on the hand-holds or steps, wipe them clean immediately. Always keep these
components clean. Repair any damage and tighten any loose bolts.
• Use the handrails and steps marked by arrows in the diagram below when getting on or off the machine.

Fire Prevention For Fuel And Oil

• Fuel, oil, and antifreeze can be ignited by a flame. Fuel is extremely flammable and can be hazardous.
• Keep flames away from flammable fluids.
• Stop the engine and never smoke when refueling.
• Tighten all fuel and oil tank caps securely.
• Refueling and oiling should be done in well ventilated areas.
• Keep oil and fuel in a designated location and do not allow unauthorized persons to enter.
OM2030 Safety - Section 20
Page 20-3
Precautions With High Temperature Fluids
• Immediately after machine operation, engine coolant, engine oil, and hydraulic oil are at high temperatures and
are pressurized. If the cap is removed, the fluids drained, the filters are replaced, etc., there is danger of
serious burns. Allow heat and pressure to dissipate before performing such tasks and follow proper procedures
as outlined in the service manual.
• To prevent hot coolant from spraying:
1) Stop the engine.
2) Wait for the coolant temperature to decrease.
3) Depress the pressure release button on the cap to vent cooling system pressure.
4) Turn the radiator cap slowly to release the pressure before removing.
• 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 release the pressure before removing the cap.

Asbestos Dust Hazard Prevention

Asbestos dust is hazardous to your health when inhaled. If you handle materials containing
asbestos fibers, follow the guidelines below:
• Never use compressed air for cleaning.
• Use water for cleaning to control dust.
• Operate the machine or perform tasks with the wind to your back, whenever possible.
• Use an approved respirator when necessary.

Prevention Of Injury By Work Equipment

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

Fire Extinguisher And First Aid Kit

• Ensure fire extinguishers are accessible and proper usage techniques are known.
• Provide a first aid kit at the storage point.
• Know what to do in the event of a fire.
• Keep the phone numbers of persons you should contact in case of an emergency on
hand.
Safety - Section 20 OM2030
Page 20-4

Precautions When Using ROPS

• The Rollover Protection Structure (ROPS) must be properly installed for machine operation.
• The ROPS is intended to protect the operator if the machine should roll over. It is designed not only to support
the load of the machine, but also to absorb the energy of the impact.
• ROPS structures installed on equipment manufactured and designed by Komatsu America Corp. fulfills all of
the regulations and standards for all countries. If it is modified or repaired without authorization from Komatsu,
or is damaged when the machine rolls over, the strength of the structure will be compromised and will not be
able to fulfill its intended purpose. Optimum strength of the structure can only be achieved if it is repaired or
modified as specified by Komatsu.
• When modifying or repairing the ROPS, always consult your nearest Komatsu distributor.
• Even with the ROPS installed, the operator must always use the seat belt when operating the machine.

Precautions For Attachments

• When installing and using optional equipment, read the instruction manual for the attachment and the
information related to attachments in this manual.
• Do not use attachments that are not authorized by Komatsu America Corp., or the authorized regional Komatsu
distributor. Use of unauthorized attachments could create a safety problem and adversely affect the proper
operation and useful life of the machine.
• Any injuries, accidents, and product failures resulting from the use of unauthorized attachments will not be the
responsibility of Komatsu America Corp., or the authorized regional Komatsu distributor.
OM2030 Safety - Section 20
Page 20-5

PRECAUTIONS DURING OPERATION

Safety Is Thinking Ahead
Prevention is the best safety program. Prevent a potential accident by knowing the employer's safety require-
ments and all necessary job site regulations. In addition, know the proper use and care of all the safety equipment
on the truck. Only qualified operators or technicians should attempt to operate or maintain a Komatsu machine.
Safe practices start before the operator gets to the equipment!

Safety At The Worksite

• When walking to and from a truck, maintain a safe distance from all machines even when the operator is
visible.
• Before starting the engine, thoroughly check the area for any unusual conditions that could be dangerous.
• Examine the road surface at the job site and determine the best and safest method of operation.
• Choose an area where the ground is as horizontal and firm as possible before performing the operation.
• If you need to operate on or near a public road, protect pedestrians and cars by designating a person for work
site traffic duty or by installing fences around the work site.
• The operator must personally check the work area, the roads to be used, and existence of obstacles before
starting operations.
• Always determine the travel roads at the work site and maintain them so that it is always safe for the machines
to travel.
• If travel through wet areas is necessary, check the depth and flow of water before crossing the shallow parts.
Never drive through water which exceeds the permissible water depth.

Fire Prevention
• Thoroughly remove wood chips, leaves, paper and other flammable items
accumulated in the engine compartment. Failure to do so could result in a fire.
• Check fuel, lubrication, and hydraulic systems for leaks. Repair any leaks.
Clean any excess oil, fuel or other flammable fluids, and dispose of properly.
• Ensure a fire extinguisher is present and in proper working condition.
• Do not operate the machine near open flames.

Preparing For Operation

• Always mount and dismount while facing the truck. Never attempt to mount or dismount the truck while it is in
motion. Always use handrails and ladders when mounting or dismounting the truck.
• Check the deck areas for debris, loose hardware, and tools. Check for people and objects that might be in the
area.
• Become familiar with and use all protective equipment devices on the truck and ensure that these items (anti-
skid material, grab bars, seat belts, etc.) are securely in place.

Ventilation In Enclosed Areas

• If it is necessary to start the engine within an enclosed area, provide adequate
ventilation. Exhaust fumes from the engine can kill.
Safety - Section 20 OM2030
Page 20-6

In Operator’s Cab - Before Starting The Engine

• Do not leave tools or spare parts lying around or allow trash to accumulate in the cab of the truck. Keep all
unauthorized reading material out of the truck cab.
• Keep the cab floor, controls, steps, and handrails free of oil, grease, snow, and excess dirt.
• Check the seat belt, buckle and hardware for damage or wear. Replace any worn or damaged parts. Always
use the seat belts when operating a machine.
• Read and understand the contents of this manual. Read Sections 30 and 32 pertaining to safety and operating
instructions with special attention. Become thoroughly acquainted with all gauges, instruments and controls
before attempting operation of the truck.
• Read and understand the WARNING and CAUTION decals in the operator's cab.
• Ensure the steering wheel, horn, controls and pedals are free of any oil, grease or mud.
• Check operation of the windshield wiper, condition of wiper blades, and check the washer fluid reservoir level.
• Be familiar with all steering and brake system controls, warning devices, road speeds and loading capabilities,
before operating the truck.

Mirrors, Windows, And Lights

• Remove any dirt from the surface of the windshield, cab windows, mirrors and lights. Good visibility may
prevent an accident.
• Adjust the rear view mirror to a position where the operator can see best from the operator's seat. If any glass
or light should break, replace it with a new part.
• Ensure headlights, work lights and taillights are in proper working order. Ensure that the machine is equipped
with the proper work lamps needed for the operating conditions.

OPERATING THE MACHINE

When Starting The Engine
• Never start the engine if a warning tag has been attached to the controls.
• When starting the engine, sound the horn as an alert.
• Start and operate the machine only while seated in the operator’s seat.
• Do not allow any unauthorized persons in the operator's compartment or any other place on the machine.

Truck Operation - General

• Wear seat belt at all times.
• Only authorized persons are allowed to ride in the truck. Riders must be in the cab and belted in the passenger
seat.
• Do not allow anyone to ride on the decks or steps of the truck.
• Do not allow anyone to get on or off the truck while it is in motion.
• Do not move the truck in or out of a building without a signal person present.
• Know and obey the hand signal communications between operator and spotter. When other machines and
personnel are present, the operator should move in and out of buildings, loading areas and through traffic,
under the direction of a signal person. Courtesy at all times is a safety precaution!
• Immediately report any adverse conditions at the haul road, pit or dump area that may cause an operating
hazard.
OM2030 Safety - Section 20
Page 20-7
• Check for flat tires periodically during a shift. If the truck has been operating on a “flat”, do not park the
machine inside of a building until the tire cools. If the tire must be changed, do not stand in front of the rim
and locking ring when inflating a tire mounted on the machine. Observers should not be permitted in the area
and should be kept away from the side of such tires.

The tire and rim assembly may explode if subjected to excessive heat. Personnel should move to a remote
or protected location if sensing excessively hot brakes, smell of burning rubber or evidence of fire near
tire and wheel area.

If the truck must be approached to distinguish a fire, those personnel should do so only while facing the
tread area of the tire (front or back), unless protected by use of large heavy equipment as a shield. Stay at
least 50 ft. (15 m) from the tread of the tire.

In the event of fire in the tire and wheel area (including brake fires), stay away from the truck for at least 8
hours or until the tire and wheel are cool.
• Keep serviceable fire fighting equipment on hand. Report empty extinguishers for replacement or refilling.
• Always have the parking brake applied when the truck is parked and unattended. DO NOT leave the truck
unattended while the engine is running.
• Park the truck a safe distance away from other vehicles as determined by the supervisor.
• Stay alert at all times! In the event of an emergency, be prepared to react quickly and avoid accidents. If an
emergency arises, know where to get prompt assistance.

Check When Traveling In Reverse

Before operating the machine or work equipment, do as follows:
• Sound the horn to warn people in the area. For machines equipped with a
back-up alarm, ensure the alarm works properly.
• Check for personnel near the machine. Be particularly careful to check
behind the machine.
• When necessary, designate a person to watch the area near the truck and
signal the operator. This is particularly necessary when traveling in reverse.
• When operating in areas that may be hazardous or have poor visibility, designate a person to direct work site
traffic.
• Do not allow any one to enter the line of travel of the machine. This rule must be strictly observed even with
machines equipped with a back-up alarm or rear view mirror.

Traveling
• When traveling on rough ground, travel at low speeds. When changing direction, avoid turning suddenly.
• Lower the dump body and set the dump lever to the FLOAT position before traveling.
• If the engine should stop when the machine is in motion, the emergency steering system will be activated.
Apply the brakes immediately and stop the machine as quickly and safely as possible (off of the haul road, if
possible).
Safety - Section 20 OM2030
Page 20-8

Traveling On Slopes
• Traveling on slopes could result in the machine tipping over or slipping.
• Do not change direction on slopes. To ensure safety, drive to level ground before turning.
• Do not travel up and down on grass, fallen leaves, or wet steel plates. These materials may make the machine
slip on even the slightest slope. Avoid traveling sideways, and always keep travel speed low.
• When traveling downhill, use the retarder to reduce speed. Do not turn the steering wheel suddenly. Do not use
the foot brake except in an emergency.
• If the engine should stop on a slope, apply the service brakes fully and stop the machine. Apply the parking
brake after the machine has stopped.

Ensure Good Visibility

• When working in dark places, install work lamps and head lamps. Set up extra lighting in the work area if
necessary.
• Discontinue operations if visibility is poor, such as in mist, snow, or rain. Wait for the weather to
improve to allow the operation to be performed safely.

Operate Carefully On Snow

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

Avoid Damage To Dump Body

• When working in tunnels, on bridges, under electric cables, or when entering a parking place or any other place
where there are height limits; always use extreme caution. The dump body must be completely lowered before
driving the machine.

Driving Near High Voltage Cables

• Driving near high-voltage cables can cause electric shock. Always maintain safe distances between the
machine and the electric cable as listed below.

Voltage Minimum Safety Distance

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

The following actions are effective in preventing accidents while working near high voltages:
• Wear shoes with rubber or leather soles.
• Use a signalman to give warning if the machine approaches an electric cable.
• If the work equipment should touch an electric cable, the operator should not leave the cab.
• When performing operations near high voltage cables, do not allow anyone to approach the machine.
• Check with the electrical maintenance department about the voltage of the cables before starting operations.
OM2030 Safety - Section 20
Page 20-9
When Dumping
• Before starting the dumping operation, check that there is no person or objects behind the machine.
• Stop the machine in the desired location. Check again for persons or objects behind the machine. Give the
determined signal, then slowly operate the dump body. If necessary, use blocks for the wheels or position a
flagman.
• When dumping on slopes, machine stability is poor and there is danger of tip over. Always perform such
operations using extreme care.
• Never travel with the dump body raised.

Working On Loose Ground

• Avoid operating the machine near cliffs, overhangs, and deep ditches. If these areas collapse, the machine
could fall or tip over and result in serious injury or death. Remember that ground surfaces in these areas may
be weakened after heavy rain or blasting.
• Freshly laid soil and the soil near ditches is loose. It can collapse under the weight or vibration of the machine.
Avoid these areas whenever possible.

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

Parking The Machine

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

TOWING
When Towing, Fix Wire To Hook
• Improper towing methods may lead to serious personal injury and/or damage.
• Use a towing device with ample strength for the weight of this machine.
• Never tow a machine on a slope.
• Do not use tow rope that has kinks or is twisted.
• Do not stand astride the towing cable or wire rope.
• When connecting a machine that is to be towed, do not allow anyone to go between the tow machine and the
machine that is being towed.
• Set the coupling of the machine being towed in a straight line with the towing portion of the tow machine, and
secure it in position.
(For towing methods, refer to Section 30, Operating Instructions - Towing.)
Safety - Section 20 OM2030
Page 20-10

WORKING NEAR BATTERIES

Battery Hazard Prevention
• Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If you spill acid
on yourself, immediately flush the area with water.
• Battery acid can cause blindness if splashed into the eyes. If acid gets into the eyes, flush them immediately
with large quantities of water and see a doctor at once.
• If you accidentally drink acid, drink a large quantity of water, milk, beaten eggs or vegetable oil. Call a doctor or
poison prevention center immediately.
• When working with batteries always wear safety glasses or goggles.
• Batteries generate hydrogen gas. Hydrogen gas is very explosive, and is easily ignited with a small spark of
flame.
• Before working with batteries, stop the engine and turn the key switch to the OFF position.
• Avoid short-circuiting the battery terminals through accidental contact with metallic objects, such as tools,
across the terminals.
• When removing or installing, check which is the positive (+) terminal and negative (-) terminal.
• Tighten battery caps securely.
• Tighten the battery terminals securely. Loose terminals can generate sparks and lead to an explosion.

Starting With Booster Cables

• Always wear safety glasses or goggles when starting the machine with booster cables.
• When starting from another machine, do not allow the two machines to touch.
• Be sure to connect the positive (+) cable first when installing booster cables. Disconnect the ground or negative
(-) cable first during removal.
• If any tool touches between the positive (+) terminal and the chassis, it will cause sparks. Always use caution
when using tools near the battery.
• Connect the batteries in parallel: positive to positive and negative to negative.
• When connecting the ground cable to the frame of the machine to be started, connect it as far as possible from
the battery.
OM2030 Safety - Section 20
Page 20-11

PRECAUTIONS FOR MAINTENANCE

BEFORE PERFORMING MAINTENANCE

Warning Tag
• Starting the engine or operating the controls while others are performing
maintenance on the truck can lead to serious injurty and/or death.
• Always attach the warning tag to the control lever in the operator's cab to
alert others that you are working on the machine. Attach additional warning
tags around the machine, if necessary.
• These tags are available from your Komatsu distributor.
• Warning tag part number (09963-03000)

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

Stopping The Engine Before Service

• Before performing inspections or maintenance, stop the machine on firm flat ground, lower the dump body, stop
the engine and apply the parking brake.
• If the engine must be run during service, such as when cleaning the radiator, always move the shift control
lever to the NEUTRAL (N) position and apply the parking brake. Always perform this work with two people.
One person must sit in the operator's seat to stop the engine if necessary. Never move any controls not related
to the task at hand during these situations.
• When servicing the machine, use care not to touch any moving parts. Never wear loose clothing or jewelry.
• Put wheel blocks under the wheels to prevent machine movement.
• When performing service with the dump body raised, always place the dump lever in the HOLD position, and
apply the lock (if equipped). Install the body-up safety pins or cable securely.

Securing The Dump Body

Any time personnel are required to perform mainte-

nance on the vehicle with the dump body in the raised
position, the body-up retention cable MUST be
installed.
1. To hold the dump body in the up position, raise the
body to it's maximum height.
2. Remove cable (3) from its stored position on the
body, and install between rear body ear (1) and axle
housing ear (4).
3. Secure the cable clevis pins with cotter pins.
4. Return the cable to stored position (2) after mainte-
nance is complete.
Safety - Section 20 OM2030
Page 20-12

DURING MAINTENANCE
Personnel
• Only authorized personnel can service and repair the machine.

Attachments
• Place attachments that have been removed from the machine in a safe place and
manner to prevent them from falling.

Working Under The Machine

• Always lower all movable work equipment to the ground or to their lowest position
before performing service or repairs under the machine.
• Always block the tires of the machine securely.
• Never work under the machine if the machine is poorly supported.

Keep The Machine Clean

• Spilled oil or grease, scattered tools, etc. can cause you to slip or trip. Always
keep your machine clean and tidy.
• If water gets into the electrical system, there is danger that the machine may
may move unexpectedly and/or damage to components may occur. Do not
use water or steam to clean any sensors, connectors, or the inside of the
operator's compartment.
• Use extreme care when washing the electrical control cabinet. Do not allow
water to enter the control cabinet around the doors or vents. Do not allow
any water to enter the cooling air inlet duct above the electrical control cabinet. If water enters the control
cabinet (through any opening or crevice) major damage to the electrical components is possible.
• Never spray water into the rear wheel electric motor covers. Damage to the wheel motor armatures may occur.
• Do not spray water into the retard grids. Excess water in the retard grids can cause a ground fault, which will
prevent propulsion.

Rules To Follow When Adding Fuel Or Oil

• Spilled fuel and oil may cause slipping. Always clean up spills, immediately.
• Always tighten the cap of the fuel and oil fillers securely.
• Never use fuel to wash parts.
• Always add fuel and oil in a well-ventilated area.
OM2030 Safety - Section 20
Page 20-13
Radiator Water Level
• If it is necessary to add coolant to the radiator, stop the engine, and allow the
engine and radiator to cool down before adding the coolant.
• Depress the pressure release button on the cap to vent cooling system
pressure.
• Slowly loosen the cap to relieve any remaining pressure during removal.

Use Of Lighting
• When checking fuel, oil, coolant, or battery electrolyte, always use
lighting with anti-explosion specifications. If such lighting equipment is
not used, there is danger or explosion.

Precautions With The Battery

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

Handling High Pressure Hoses

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

Precautions With High Pressure Oil

• Do not forget that work equipment circuits are always under pressure.
• Do not add oil, drain oil, or perform maintenance or inspections before completely releasing the internal
pressure.
• Small, high pressure pin-hole leaks are extremely dangerous. The jet of high-pressure oil can pierce the skin
and eyes. Always wear safety glasses and thick gloves. Use a piece of cardboard or a sheet of wood to check
for oil leakage.
• If you are hit by a jet of high-pressure oil, consult a doctor immediately for medical attention.
Safety - Section 20 OM2030
Page 20-14

Precautions When Performing Maintenance Near High Temperature Or High Pressure

• Immediately after stopping operation, engine coolant and operating oils are
at high temperature and under high pressure. In these conditions, if the cap
is removed, the oil or water drained, or the filters are replaced, it may result
in burns or other injury. Wait for the temperature to cool and pressure to
subside, before performing the inspection and/or maintenance as outlined
in the service manual.

Rotating Fan And Belts

• Stay away from all rotating parts such as the radiator fan and fan belts.
• Serious bodily injury may result from direct or indirect contact with rotating
parts and flying objects.

Waste Materials
• Never dump waste oil into a sewer system, river, etc.
• Always put oil drained from your machine in appropriate containers. Never
drain oil directly onto the ground.
• Obey appropriate laws and regulations when disposing of harmful objects
such as oil, fuel, coolant, solvent, filters, batteries, and others.
OM2030 Safety - Section 20
Page 20-15

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

The tire inflation pressure and permissible speeds are general values. The actual values may differ depending on
the type of tire and the condition under which they are used. For details, please consult the tire manufacturer.
When tires become hot, a flammable gas is produced, and may ignite. It is particularly dangerous if the tires
become overheated while the tires are pressurized. If the gas generated inside the tire ignites, the internal pres-
sure will suddenly rise, and the tire will explode, resulting in danger to personnel in the area. Explosions differ from
punctures or tire bursts because the destructive force is extremely large. Therefore, the following operations are
strictly prohibited when the tire is pressurized:
• Welding the rim
• Welding near the wheel or tire.
• Smoking or creating open flames

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

Storing Tires After Removal

• As a basic rule, store the tires in a warehouse in which unauthorized persons cannot enter. If the tires are
stored outside, always erect a fence around the tires and put up “No Entry” and other warning signs that even
young children can understand.
• Stand the tire on level ground, and block it securely so that it cannot roll or fall over.
• If the tire should fall over, flee the area quickly. The tires for construction equipment are extremely heavy. Never
attempt to hold or support the tire. Attempting to hold or support a tire may lead to serious injury.
Safety - Section 20 OM2030
Page 20-16

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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OM2030 Safety - Section 20
Page 20-17

WHEN REPAIRS ARE NECESSARY

1. Only qualified maintenance personnel who understand the systems being repaired should attempt repairs.
2. Many components on the Komatsu truck are large and heavy. Insure that lifting equipment - hoists, slings,
chains, lifting eyes - are of adequate capacity to handle the lift.
3. Do not under a suspended load. Do not work under raised body unless body safety cables, props, or pins are
in place to hold the body in up position.
4. Do not repair or service the truck while the engine is running, except when adjustments can only be made
under such conditions. Keep a safe distance from moving parts.
5. When servicing any air conditioning system with refrigerant, wear a face shield and cold resistant gloves for
protection against freezing. Be certain to follow all current regulations for handling and recycling refrigerants.
6. Follow package directions carefully when using cleaning solvents.
7. If an auxiliary battery assist is needed, first use one cable to connect the 24V positive (+) post of the disabled
truck batteries to the 24V positive (+) post of the auxiliary assist. Use second cable to connect the 24V nega-
tive (-) post of the auxiliary assist battery to a frame ground (-) on the disabled truck away from the battery.
8. Always disconnect the positive and negative battery cables of the vehicle before doing any welding on the
unit. Failure to do so may seriously damage the battery and electrical equipment. Disconnect battery charging
alternator lead wire and isolate electronic control components before making welding repairs. (It is not neces-
sary to disconnect or remove any control circuit cards on electric drive dump trucks or any of the “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, suspensions, or hydraulic cylinders. Always avoid laying welding cables over or near the vehi-
cle electrical harnesses. Welding voltage could be induced into the electrical harness and possibly cause
damage to components.
9. If the truck is to be towed for any reason, use a rigid tow bar. Check truck cab for decal recommending special
towing precautions. (Also refer to the Operation and Maintenance Manual, Operating Instructions - Towing .)
10. Drain, clean and ventilate fuel tanks and/or hydraulic tanks before making any welding repairs.

Any operating fluid, such as hydraulic oil or brake fluid escaping under pressure, can have sufficient force
to enter a person's body by penetrating the skin. Serious injury and possibly death may result if proper
medical treatment by a physician familiar with this injury is not received immediately.

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

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

Do not stand in front of a rim and locking ring when inflating a tire mounted on the machine. Observers
should not be permitted in the area and should be kept away from the sides of such tires.

Do not weld or apply heat on the rim assembly with the tire mounted on the rim. Resulting gases inside the
tire may ignite, causing explosion of tire and rim.

14. Only a qualified operator or experienced maintenance personnel who are also qualified in operation should
move the truck under its own power in the repair facility or during road testing after repairs are complete.
Safety - Section 20 OM2030
Page 20-18

SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK

Preliminary Procedures Before Welding or Performing Maintenance
Prior to welding and/or repairing a 930E dump truck, maintenance personnel should attempt to notify a Komatsu
service representative. Only qualified personnel, specifically trained for servicing the AC Drive System, should per-
form this service.
If it is necessary to perform welding or repair to the truck without the field engineer present, the following proce-
dures should be followed to ensure that the truck is safe for maintenance personnel to work on and to reduce the
chance for damage to equipment.

ANYTIME THE ENGINE IS RUNNING:

• Do not open any of the cabinet doors or remove any covers.
• Do not use any of the power cables for hand holds or foot steps.
• Do not touch the retarder grid elements.

Before opening any cabinets or touching a grid element or a power cable, the engine must be shutdown
and the red drive system warning lights must not be illuminated.

Normal Engine Shutdown Procedure

1. Stop the truck out of the way of other traffic on a level surface (dry, if possible) and free of overhead power
lines or other obstructions (in case dump body should need to be raised).
a. Reduce engine speed to idle. Allow the engine to cool gradually by running at low idle for approx. 5 min-
utes.
b. Place the directional selector switch in NEUTRAL.
c. Apply the parking brake switch. Be sure the “parking brake applied” indicator light in the overhead display
panel is illuminated.
2. Place rest switch in ON position to put AC drive system in “rest” mode of operation. Be sure the “rest” indicator
light in the overhead panel is illuminated.
3. With engine cooled down, turn keyswitch counterclockwise to OFF position for normal shutdown of engine.
If the engine does not shutdown with keyswitch, use engine shutdown switch on operator cab center console,
and hold this switch down until engine stops.
4. With keyswitch OFF, and engine stopped, wait at least 90 seconds. Insure the steering circuit is completely
bled down by turning the steering wheel back and forth several times. No front wheel movement will occur
when hydraulic pressure is relieved. If the vehicle continues to steer after shutdown, notify maintenance per-
sonnel.
5. Verify that all the link voltage lights are off (one on back wall of operator cab, and two on deck control cabi-
nets). Notify maintenance personnel if any light remains illuminated longer than five minutes after engine
shutdown.
6. Close and lock all windows, remove key from keyswitch, and lock the cab to prevent possible unauthorized
truck operation. Dismount the truck properly. Put wheel chocks in place.
OM2030 Safety - Section 20
Page 20-19
Engine Shutdown Procedure Before Welding or Performing Maintenance
Normal operation of the drive system at shutdown should leave the system safe to maintain. However, in the event
of a system failure, performing the following procedure prior to any maintenance activities will ensure that no haz-
ardous voltages are present in the AC drive system.
1. Before shutting down the engine, verify the status of all the drive system warning lights on the overhead dis-
play panel. Use the lamp test switch to verify that all lamps are functioning properly.
If any of the red drive system warning lights remain on, do not attempt to open any cabinets, disconnect any
cables, or reach inside the retarder grid cabinet without a trained drive system technician present - even if
engine is off.
Only qualified personnel, specifically trained for servicing the AC drive system, should perform this
service.
2. If all red drive system warning lights are off, follow the “Normal Engine Shutdown Procedure”.
3. After the engine has been stopped for at least five minutes, inspect the link voltage lights on the exterior of the
main control cabinet and back wall of the operator's cab (DID panel). If all lights are off, the retard grids, wheel
motors, alternator, and related power cables are safe to work on.
4. Locate the GF cut-out switch in the access panel on the left side of the main control cabinet. Place the switch
in the “alternator cutout” position. This will prevent the alternator from re-energizing and creating system volt-
age until the switch is returned to its former position.
5. The blower motors, control cabinet and power cables connecting these devices are still unsafe. To establish
that these devices are safe, open the top control cabinet cover and inspect the red lights on the blower control
panel.
If these lights are off, the blower system, blower power cables and remainder of the control cabinet is safe to
work on.
If these lights are on, refer to steps 11 - 12.
6. Before welding on the truck, disconnect all electrical harnesses from the Engine Control System (ECS) inside
the electrical cabinet behind the operator's cab. Also, disconnect the ground strap from the ECS.
7. Do not weld on the rear of the control cabinet! The metal panels on the back of the cabinet are part of
capacitors and cannot be heated.
8. Do not weld on the retard grid exhaust louvers - they are made of stainless steel. Some power cable pan-
els throughout the truck are also made of aluminum or stainless steel. They must be repaired with the same
material or the power cables may be damaged.
9. Power cables must be cleated in wood or other non-ferrous materials. Do not repair cable cleats by encircling
the power cables with metal clamps or hardware. Always inspect power cable insulation prior to servicing the
cables and prior to returning the truck to service. Discard cables with broken insulation.
10. Power cables and wiring harnesses should be protected from weld spatter and heat.
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.
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.
Before doing any welding on the truck, always disconnect the battery charging alternator lead wire and isolate
electronic control components.
In addition, always disconnect the positive and negative battery cables of the vehicle. Failure to do so may
seriously damage the battery and electrical equipment.
Never allow welding current to pass through ball bearings, roller bearings, suspensions, or hydraulic cylin-
ders.
Safety - Section 20 OM2030
Page 20-20

11. If the red lights on the exterior of the control cabinet and/or the back wall of the operator's cab continue to be
illuminated after following the above procedure, a fault has occurred.
Leave all cabinet doors in place; do not touch the retard grid elements; do not disconnect any power cables,
or use them as hand or foot holds.
Notify your Komatsu service representative, immediately. Only qualified personnel, specifically trained for
servicing the AC drive system, should perform this service.
12. If the red lights on the blower control panel are illuminated after following the above procedure, a fault has
occurred. Reinstall the control cabinet panel. Do not perform maintenance on the blower control panel,
blower motor power cables.
Notify your Komatsu service representative, immediately. Only qualified personnel, specifically trained for
servicing the AC drive system, should perform this service.
13. Replace all covers and doors and place the GF cutout switch and battery disconnect switches in their original
positions. Reconnect all harnesses prior to starting the truck.

Leave the drive system in the “rest” mode until the truck is to be moved.
OM2200 Warnings And Cautions - Section 22
09/03 Page 22-1

WARNINGS AND CAUTIONS

The following pages give an explanation of the warning,
caution, and service instruction plates and decals
attached to the truck. The plates and decals listed here
are typical of this Komatsu model, but because of cus-
tomer options, individual trucks may have plates and
decals that are different from those shown here.
The plates and decals must be kept clean and legible. If
any decal or plate becomes unable to be read or dam-
aged, it should be replaced with a new one.
A warning decal surrounds the key switch located to the
right of the steering column on the instrument panel. The
warning stresses the importance of reading the operator's
manual before operation.

A grade/speed retard chart is located on the left front post

of the operator's cab and provides the recommended
maximum speeds to be used when descending various
grades with a loaded truck. Always refer to the decal in
operator's cab. This decal may change with optional truck
equipment such as: wheel motor drive train ratios,
retarder grids, tire sizes, etc.

A plate attached to the right rear corner of the cab

states the Rollover Protective Structure (ROPS)
and Falling Object Protective Structure (FOPS)
meets various SAE performance requirements.

! WARNING ! Do not make modifications to

this structure, or attempt to repair damage
without written approval from Komatsu. Unau-
thorized repairs will void certification.
Warnings And Cautions - Section 22 OM2200
Page 22-2 09/03

A warning instruction is applied below the parking brake and the rear wheel brake lock switches which are located
to the right of the steering column on the instrument panel. Pushing the top of the rocker-style switch turns the
function ON, pushing the bottom, turns it OFF.

The parking brake is spring applied and hydraulically released. It is designed to hold a stationary truck
when the engine is shutdown and keyswitch is turned OFF. The truck must be completely stopped
before applying the parking brake, or damage may occur to parking brake.To apply the parking brake,
press the rocker switch toward the ON symbol. To release the parking brake, press the rocker switch
toward the OFF symbol. When the keyswitch is ON and parking brake switch is applied, the parking
brake indicator light (A3, overhead panel) will be illuminated.
NOTE: Do not use the parking brake at shovel or dump. With keyswitch ON and engine running, sudden shock
caused by loading or dumping could cause the system’s motion sensor to release the park brake.
The wheel brake lock switch is for holding the truck while parked at the shovel during loading, or while
dumping. It applies the rear service brakes only. If the brake treadle valve does not operate, apply
this brake to stop the truck. Do Not use this brake as a parking brake when leaving the truck. With
engine shut down, the hydraulic system will eventually bleed down, releasing the service brakes.

Attached to the exterior of both battery compartments is a

danger plate. This plate stresses the need to keep from mak-
ing any sparks near the battery. When another battery or
24VDC power source is used for auxiliary power, all switches
must be OFF prior to making any connections. When con-
necting auxiliary power cables, positively maintain correct
polarity; connect the positive (+) posts together and then
connect the negative (-) lead of the auxiliary power cable to a
good frame ground. Do not connect to the negative posts
of the truck battery or near the battery box. This hookup
completes the circuit but minimizes danger of sparks near
the batteries.
Sulfuric acid is corrosive and toxic. Use proper safety gear,
goggles, rubber gloves and rubber apron when handling and
servicing batteries. Get proper medical help immediately, if required.

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

These decals are placed above the battery disconnect switches

on the right side of the front bumper to indicate OFF and ON posi-
tions of the switches.
OM2200 Warnings And Cautions - Section 22
09/03 Page 22-3
A warning plate is mounted on top of the radiator surge tank
cover near the radiator cap. The engine cooling system is pres-
surized. Always turn the key switch OFF and allow the
engine to cool before removing radiator cap. Unless the
pressure is first released, removing the radiator cap after the
engine has been running for a time will result in the hot coolant
being expelled from the radiator. Serious scalding and burn-
ing may result.

Warning plates are mounted on the frame in front of, and to the
rear, of both front tires. All personnel are warned that the clear-
ances change when the truck is steered and could cause serious
injury.

Warning plates are attached to both the hydraulic tank and fuel tank to
alert technicians not to work on the truck with the body in the raised posi-
tion unless body-up retention device (pins or cable) is in position.

These danger plates are mounted on the outside of each

frame rail to alert technicians to read the warning labels
attached to the side of each of the accumulators (see
below) prior to releasing internal nitrogen pressure or dis-
connecting any hydraulic lines or hardware. There are
similar decals mounted on top of each of the accumulators
(both steering and brake) with the same danger message.

These warning decals are mounted on the side of each of

the accumulators (both steering and brake) to alert techni-
cians to discharge all gas and hydraulic pressure, and to
read the maintenance/service manual prior to performing
any service.
Warnings And Cautions - Section 22 OM2200
Page 22-4 09/03

This danger plate is attached to all four suspensions.

The plate contains instructions for releasing internal pres-
sure before disconnecting any hardware.
Serious injury can occur if these directions are not fol-
lowed.

A plate on the side of the hydraulic tank furnishes instruc-

tions for filling the hydraulic tank.
Keep the system open to the atmosphere only as long as
absolutely necessary to lessen chances of system con-
tamination. Service the tank with clean Type C-4 hydraulic
oil. All oil being put into the hydraulic tank should be fil-
tered through 3 micron filters.

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

A warning plate is attached to the hydraulic tank to inform

technicians that high pressure hydraulic oil is present during
operation. When it is necessary to open the hydraulic sys-
tem, be sure engine is stopped and key switch is OFF to
bleed down hydraulic pressure. There is always a chance of
residual pressure being present. Open fittings slowly to allow
all pressure to bleed off before removing any connections.

Any operating fluid, such as hydraulic oil, escaping under pressure can
have sufficient force to enter a person's body by penetrating the skin. Seri-
ous injury and possibly death may result if proper medical treatment by a
physician familiar with this injury is not received immediately.
OM2200 Warnings And Cautions - Section 22
09/03 Page 22-5
A wheel motor oil level decal is attached to the gear cover
on both electric wheel motors. This decal stresses the
fact that the truck must be on a level surface and parked
for 20 minutes prior to checking the oil level. This is nec-
essary in order to get an accurate reading.

A decal plate is located on the frame near the left hoist cylin-
der which provides the operator or technician with the hook-
up procedure for dumping a loaded, disabled truck, by using
a functional truck for hydraulic power.
Refer to the Section L for additional instructions for using
this procedure.

Warning decals are applied to both brake accumulators located inside

the brake system cabinet behind the operator cab. These decals remind
servicing technicians to be sure to close the accumulator drain valves
after they have been opened to bleed brake pressure. It further warns
not to over-tighten the drain valves to prevent damage to the valve
seat(s).

This caution decal is placed near the battery disconnect

switches on the right side of the front bumper to alert servicing
technicians that before doing any welding on the truck, always
disconnect the battery charging alternator lead wire and iso-
late electronic control components before making welding
repairs.
In addition, always disconnect the positive and negative bat-
tery cables of the vehicle. Failure to do so may seriously dam-
age the battery and electrical equipment.
Always fasten the welding machine ground (-) lead to the piece being welded; grounding clamp must be
attached as near as possible to the weld area. Never allow welding current to pass through ball bearings, roller
bearings, suspensions, or hydraulic cylinders. Always avoid laying welding cables over or near the vehicle electri-
cal harnesses. Welding voltage could be induced into the electrical harness and possibly cause damage to compo-
nents.
Warnings And Cautions - Section 22 OM2200
Page 22-6 09/03

A high voltage danger plate is attached to the door of the rear

hatch cover. High voltage may be present!
Only authorized personnel should access this rear housing.

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

This caution decal is also placed around the retarding grid cabinet.

These warning plates are mounted on all of the AC drive

control housings and cabinets.
High voltage may be present, with or without, the
engine running!
Only authorized personnel should access these cabinets.
OM2200 Warnings And Cautions - Section 22
09/03 Page 22-7

This caution decal is placed on the back of the control cabinet to alert
service technicians that this area contains capacitors and must not be
disturbed in any manner.

This information decal is placed on the outside of the door

panel on the control cabinet wall that faces the right side of
the operator cab.

This decal is placed near three different indicator lights:

• In the operator cab, on the D.I.D. panel on the rear
wall.
• On the front of the control box which is mounted on the
right side of the main control cabinet.
• On the outside of the left control cabinet wall that faces
the right side of the operator cab. (See also
Information decal above.)

When any of these indicator lights are on, high voltage

is present throughout the propulsion and retarding
system. Extreme care should be exercised!
Warnings And Cautions - Section 22 OM2200
Page 22-8 09/03

This decal is placed on the ground level engine shutdown switch which
is mounted on the right side of the front bumper structure. It specifies
that this switch is for emergency shutdown only.

This page illustrates a variety of decals which are mounted on deck mounted cabinets, housings, and structures
which must be lifted in a specific manner, and from specific points, in order to safely move or lift any of these struc-
tures.
If any of these decals are damaged or defaced, so that it is no longer legible, it should be replaced immediately.
Maintenance personnel must follow these lifting instructions.
OM2200 Warnings And Cautions - Section 22
09/03 Page 22-9

A product identification plate is located

on the main frame in front of the right
side front wheel and shows the truck
model number, maximum G.V.W. and
product identification number (truck
serial number).
The product identification number (truck
serial number) contains information
which will identify the original manufac-
turing bill of material for this unit.
The complete truck serial number will be
required for the proper ordering of many
service parts and/or warranty consider-
ation.

The lubrication chart is mounted on the right hand side of the radiator grille structure. Refer to Section P, Lubrica-
tion and Service, in this manual for more complete lubrication instructions.
Warnings And Cautions - Section 22 OM2200
Page 22-10 09/03

NOTES
OM3038 8/03 Operating Instructions - Section 30
Page 30-1

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

Safety Is Thinking Ahead

Prevention is the best safety program. Prevent a potential accident by knowing the employer's safety requirements,
all necessary job site regulations, as well as, use and care of the safety equipment on the truck. Only qualified
operators or technicians should attempt to operate or maintain a Komatsu truck.
Safe practices start before the operator gets to the equipment!
• Wear the proper clothing. Loose fitting clothing, unbuttoned sleeves and jackets, jewelry, etc., can catch on a
protrusion and cause a potential hazard.
• Always use the personal safety equipment provided for the operator such as hard hats, safety shoes, safety
glasses or goggles. There are some conditions when protective hearing devices should also be worn for
operator safety.
• When walking to and from the truck, maintain a safe distance from all machines, even if the operator is visible.

At The Truck - Ground Level Walk Around Inspection

At the beginning of each shift, a careful walk around inspection of the truck should be performed before the opera-
tor attempts engine start-up. A walk around inspection is a systematic ground level inspection of the truck and its
components to insure that the truck is safe to operate before entering the operator's cab.
Start at the left front corner of the truck (see illustration, next page), and move in a counter-clockwise direction.
Move front-to-rear, across the rear, and continuing forward up the opposite side of the truck to the original starting
point.
If these steps are performed in sequence, and are repeated from the same point and in the same direction before
every shift, many potential problems may be avoided, or scheduled for maintenance. Unscheduled downtime and
loss of production can be reduced as a result.
Local work practices may prevent an operator from performing all tasks suggested here. To the extent permitted,
the operator should follow this or a similar routine.

! DANGER ! - HIGH VOLTAGE MAY BE PRESENT ON THIS TRUCK! DO NOT OPEN ANY ELECTRICAL CAB-
INET DOORS ON THIS TRUCK WHEN THE ENGINE IS RUNNING! NEVER CLIMB ON ANY POWER CABLES
OR USE POWER CABLES FOR HANDHOLDS OR FOOTHOLDS, UNLESS THE ENGINE HAS BEEN SHUT
DOWN AND SYSTEM HAS BEEN VERIFIED AT “REST”!

1. Start at left front of truck. While performing the walk around inspection, visually inspect all lights and safety
equipment for external damage from rocks or misuse. Make sure lenses are clean and unbroken.
Empty the dust pans on the left side air cleaner assemblies. Be sure battery box covers are in place and
secure.
2. Move in front of the left front tire, inspect the hub and brake assemblies for leaks and any abnormal condi-
tions. Check front wheel hub oil sight gauge for oil level.
Check that all suspension attaching hardware is secure and inspect mounting key area for evidence of wear.
Check that the suspension extension (exposed piston rod) is correct, and that there are no leaks.
3. With engine stopped, check engine oil level. Use the service light if necessary.
4. Inspect air conditioner belts for correct tension, obvious wear, and tracking. Inspect fan guard security and
condition. When leaving this point, be sure to turn off the service light, if used.
5. Inspect anchor end of steering cylinder for proper greasing and for security.
6. Move outboard of the front wheel, and inspect attaching nuts/studs to be sure all are tight and in tact. Check
tires for cuts, damage or bubbles Check for evidence of incorrect tire inflation.
Operating Instructions - Section 30 8/03 OM3038
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START HERE

Walk Around Inspection

OM3038 8/03 Operating Instructions - Section 30
Page 30-3
7. Move in behind the front wheel, and inspect the steering cylinder. Check the greasing and attaching hard-
ware. Check suspension attaching hardware and suspension extension. Be sure the suspension protective
boot is in good condition. Inspect the hub and brakes for any unusual conditions. Check entire area for leaks.
8. Inspect sight glass on hydraulic tank. With engine stopped and body down, hydraulic fluid must be visible in
upper sight glass.
9. Move around the hydraulic tank and in front of the rear dual tires; inspect the hoist cylinder for any damage
and leaks. Inspect both upper and lower hoist cylinder pins for security, and for proper greasing.
10. Before leaving this position, look under the lower edge of the chassis to be sure the flexible duct that carries
the air from the main blower to the final drive housing is in good condition with no holes or breakage. Also look
up at the main hydraulic pumps to see that there is no leakage or any other unusual condition with pumps or
pump drive shafts.
11. Move on around the dual tires, check to see that all wheel nuts/studs are in place and tight. Inspect wheel for
any oil that would indicate brake leakage or wheel motor leakage.
Check dual tires for cuts, damage or bubbles. Verify that inflation appears to be correct. If the truck has been
run on a "flat", the tire must be cooled before moving the truck inside. Check for any rocks that might be
lodged between dual tires. Check rock ejector condition and straightness (so that it can not damage a tire).
12. Inspect left rear suspension for damage and for correct rod exposure. Check for leaks. Ensure that the covers
over the chrome piston rod are in good condition and inspect for proper greasing.
13. Open rear hatch cover. Inspect for leaks around the parking brakes. Inspect condition of cooling air exhaust
ductwork to be certain that it is intact and that there are no obstructions.
14. While standing in front of the rear hatch, look up to see that rear lights are in good condition, along with the
back-up horns. Look up at panhard rod to see that it is getting proper greasing. Also look at both body hinge
pins for greasing and any abnormal condition. Check hoist limit switch and clear any mud/debris from con-
tacts.
15. Perform the same inspection on the right rear suspension as done on the left.
16. Move around the right dual tires; inspect between the tires for rocks, and check condition of the rock ejector.
Inspect the tires for cuts or damage, and for correct inflation.
17. Perform the same inspection for wheel nuts/studs and wheel leaks that was done on the left hand dual
wheels.
18. Move in front of right dual tires, and inspect the hoist cylinder in the same manner as the left side. Check
security and condition of body-up limit switch. Remove any mud/dirt accumulation from switch.
19. Move around the fuel tank. Inspect the fuel quantity gauge, (this should agree with what will show on the
gauge in the cab). Inspect the attaching hardware for the fuel tank at the upper saddles, and then at the lower
back of the tank for the security and condition of the mounts. Check hoist filters for leaks.
20. Move in behind the right front wheel, and inspect the steering cylinder. Check the greasing and attaching
hardware. Check suspension attaching hardware and suspension extension. Be sure the suspension protec-
tive boot is in good condition. Inspect the hub and brakes for any unusual conditions. Check entire area for
leaks.
21. Move out and around the right front wheel; inspect that all wheel nuts/studs are in place and tight.
22. Move in behind the front of the right front wheel, check hub and brakes for leaks and any unusual condition.
Inspect steering cylinder for security and for proper greasing. Inspect the engine compartment for any leaks
and unusual conditions. Inspect the fan guard and belts. Check for any rags or debris behind radiator.
23. Inspect auto lube system. See Automatic Lubrication System in Section 42, for specific details concerning the
auto lube system.
24. Move around to the right front of the truck, drop the air cleaner pans to remove dirt, latch up, and secure.
Inspect battery box cover for damage and be sure it is in place and secure.
25. As you move in front of the radiator, inspect for any debris that might be stuck in front of the radiator and
remove it. Check for any coolant leaks. Inspect headlights and fog lights.
Operating Instructions - Section 30 8/03 OM3038
Page 30-4

26. Before climbing ladder to first level, be sure ground level engine shutdown switch is ON. Inspect fire control
actuator to be sure safety pin is in place and plastic tie that prevents accidental actuation is in place and in
good condition. Be sure battery disconnect switches are ON. Always use grab rails and ladder when mount-
ing or dismounting the truck. Clean ladder and hand rails of any foreign material, such as ice, snow, oil or
mud.
27. Use stairs and handrails while climbing from first level to cab deck.

Always mount and dismount ladders facing the truck. Never attempt to mount or dismount while the truck
is in motion.
28. When checking coolant level in the radiator, use coolant level sight gauge. If it is necessary to remove the
radiator cap, shut down engine (if running), and relieve coolant pressure by slowly removing the radiator cap.

If the engine has been running, allow the coolant to cool before removing the fill cap or draining the radia-
tor. Serious burns may result if skin comes in contact with hot coolant.
29. Inspect covers over retarding grids to be sure latches are in place and secure. Inspect main air inlet to be sure
it is clear. Ensure all cabinet door latches are secure.
30. Move around the cab to the back. Open the doors to the brake cabinet; inspect for leaks.
31. Clean cab windows and mirrors; clean out cab floor as necessary. Ensure steering wheel, controls and pedals
are free of any grease or mud.
32. Stow personal gear in cab so that it does not interfere with any operation of the truck. Dirt or trash buildup,
specifically in the operator's cab, should be cleared. Do not carry tools or supplies in the cab of truck or on the
deck.
33. Adjust seat and steering wheel for use.
34. Read and understand the description of all operator controls listed in Operator Cab and Controls. Be familiar
with all control locations and functions before operating the truck.

ENGINE START-UP SAFETY PRACTICES

NEVER ATTEMPT TO START THE ENGINE BY SHORTING ACROSS THE STARTER TERMINALS. This may
cause fire, or serious injury or death to anyone in machine’s path.
START THE ENGINE FROM THE OPERATOR’S SEAT ONLY.
1. Ensure all personnel are clear of truck before starting engine. Always sound the horn as a warning before
actuating any operational controls. If the truck is in an enclosure, ensure adequate ventilation before start-up.
Exhaust fumes are dangerous!
2. Be sure the parking brake switch is in the ON position. Check and insure selector switch is in NEUTRAL
before starting.
Place rest switch in ON position (put drive system in "rest" mode of operation). Refer to discussion of the rest
switch in Operator Cab and Controls.
OM3038 8/03 Operating Instructions - Section 30
Page 30-5
3. If truck is equipped with auxiliary cold weather heater system(s), do not attempt to start engine while heat-
ers are in operation. Damage to coolant heaters will result!
4. The keyswitch is a three position (OFF, RUN, START)
switch. When the switch is rotated one position clock-
wise, it is in the RUN position and all electrical circuits
(except START) are activated.
a. Turn keyswitch to RUN (not START) position.
b. With selector switch in NEUTRAL, rotate key-
switch fully clockwise to START position, and hold
this position until engine starts (see NOTE below).
The START position is spring-loaded and will
return to RUN when the key is released.
c. After the engine has started, place rest switch in
the OFF position (de-activate the "rest" mode of
operation). Refer to Operator Cab and Controls for
more information on the rest switch.

NOTE: This truck is equipped with an engine prelube system. With this feature, a noticeable time delay may occur
(while engine lube oil passages are being filled and pressurized) before engine cranking will begin.

Cold Weather Starting

• Do not crank an electric starter for more than 30 seconds.
• Allow two minutes for cooling before attempting to start the engine again. Severe damage to the starter
motors can result from overheating.

AFTER ENGINE HAS STARTED

1. Become thoroughly familiar with steering and emergency controls. After engine has started and low pressure
and warning systems are normal, test the truck steering in extreme right and left directions. If the steering
system is not operating properly, shut the engine down, immediately. Determine the steering system problem
and have repaired before resuming operation.
2. Operate each of the truck's brake circuits at least twice prior to operating and moving the truck. These circuits
include individual activation from the operator's cab of the service brake, parking brake, and brake lock. With
the engine running and with the hydraulic circuit fully charged, activate each circuit, individually. If any applica-
tion or release of any brake circuit appears sluggish or improper, or if warning alarms are activated on appli-
cation or release, shut the engine down and notify maintenance personnel. Do not operate the truck until the
brake circuit in question is fully operational.
3. Check gauges, warning lights and instruments before moving the truck to ensure proper system operation
and proper instrument functioning. Give special attention to braking and steering circuit hydraulic warning
lights. If warning lights come on, shut down the engine immediately and determine the cause.
4. Insure headlights, worklights and taillights are in proper working order. Good visibility may prevent an acci-
dent. Check operation of windshield wiper.
5. When truck body is in dump position, do not allow anyone beneath it unless body-up retaining pin or cable is
in place.
6. Do not use the fire extinguisher for any purpose other than putting out a fire! If extinguisher is discharged,
report the occurrence so the used unit can be refilled or replaced.
7. Do not allow unauthorized personnel to ride in the truck. Do not allow anyone to ride on the ladder of the
truck.
8. Do not leave the truck unattended while the engine is running. Shut down the engine and apply the park
brake before getting out of the cab.
Operating Instructions - Section 30 8/03 OM3038
Page 30-6

MACHINE OPERATION SAFETY PRECAUTIONS

After the truck engine is started and all systems are functioning properly, the operator must follow all local safety
rules to insure safe machine operation.
If any of the red warning lights come on or if any gauge reads in the red area
during truck operation, a malfunction is indicated. Stop the truck as soon as
safety permits, and shut down the engine. Have the problem corrected
before resuming truck operation.

The truck is equipped with "slip/slide" control. If this function should

become inoperative, operating the truck with stalled or free spinning wheel
motors may cause serious damage to wheel motors! If the truck does not
begin to move within 10 seconds after depressing throttle pedal (selector
switch in a drive position), release throttle pedal and allow wheels to regain
traction before accelerating again.
1. Always look to the rear before backing the truck. Watch for and obey ground spotter's hand signals before
making any reverse movements. Sound the warning horn (3 blasts). Spotter should have a clear view of the
total area at the rear of the truck.
2. Operate the truck only while properly seated with seat belt fastened. Keep hands and feet inside the cab com-
partment while the truck is in operation.
3. Check gauges and instruments frequently during operation for proper readings.
4. Observe all regulations pertaining to the job site's traffic pattern. Be alert to any unusual traffic pattern. Obey
the spotter's signals.
5. Match the truck speed to haul road conditions and slow the truck in any congested area. Keep a firm grip on
the steering wheel at all times.
6. Do not allow the engine to run at idle for extended periods of time.
7. Check parking brake periodically during shift. Use parking brake only for parking. Do not use park brake for
loading / dumping. Do not attempt to apply parking brake while truck is moving!

Do not use "brake lock" or "emergency brake" (if equipped) for parking.
With engine stopped, hydraulic pressure will bleed down, allowing brakes
to release!

8. Check brake lock performance periodically for safe loading and dump operation.
9. Proceed slowly on rough terrain to avoid deep ruts or large obstacles. Avoid traveling close to soft edges and
the edge of fill area.
10. Truck operation requires concentrated effort by the driver. Avoid distractions of any kind while operating the
truck.

MACHINE OPERATION ON THE HAUL ROAD

1. Always stay alert! If unfamiliar with the road, drive with extreme caution. Cab doors should remain closed at
all times if truck is in motion or unattended.
2. Obey all road signs. Operate the truck so it is under control at all times. Govern truck speed by the road con-
ditions, weather and visibility. Report haul road conditions, immediately. Muddy or icy roads, pot holes or other
obstructions can present hazards.
3. Initial propulsion with a loaded truck should begin from a level surface whenever possible, but when there are
circumstances where starting on a hill or grade cannot be avoided. Refer to Starting On A Grade With A
Loaded Truck on the following page.
4. When backing the truck, give a back-up signal (three blasts on the horn); when starting forward, two blasts on
the horn. These signals must be given each time the truck is moved forward or backward.
5. Use extreme caution when approaching a haul road intersection. Maintain a safe distance from oncoming
vehicles.
OM3038 8/03 Operating Instructions - Section 30
Page 30-7
6. Maintain a safe distance when following another vehicle. Never approach another vehicle from the rear, in the
same lane, closer than 50 ft. (15 m). When driving on a down grade, this distance should not be less than 100
ft. (30 m).
7. Do not stop or park on a haul road unless unavoidable. If you must stop, move truck to a safe place, apply
parking brake, and shut down engine before leaving cab. Block wheels securely and notify maintenance per-
sonnel for assistance.
8. Before starting up or down a grade, maintain a speed that will insure safe driving and provide effective retard-
ing under all conditions (Refer to Operator Cab and Controls - Dynamic Retarding. The grade/speed retard
chart in the operator's cab should always be referenced to determine maximum safe truck speeds for
descending various grades with a loaded truck.
9. When operating truck in darkness, or when visibility is poor, do not move truck unless all headlights, clear-
ance lights, and tail lights are on. Do not back truck if back-up horn or lights are inoperative. Always dim head-
lights when meeting oncoming vehicles.
10. If the "emergency steering" light and/or "low brake pressure warning" light (if equipped) illuminate during oper-
ation, steer the truck immediately to a safe stopping area, away from other traffic if possible. Refer to item 7
above.
11. Check tires for proper inflation periodically during shift. If truck has been run on a "flat", or under-inflated tire, it
must not be parked in a building until the tire cools.

STARTING ON A GRADE WITH A LOADED TRUCK

Initial propulsion with a loaded truck should begin from a level surface whenever possible. There are circum-
stances when starting on a hill or grade cannot be avoided; use the following procedure:
1. Fully depress the foot-operated retarder/service brake pedal (Do Not use retarder lever) to hold the truck on
the grade. With service brakes fully applied, move the selector switch to a drive position (FORWARD/
REVERSE) and increase engine rpm with throttle pedal.
2. As engine rpm approaches maximum, and operator senses propulsion effort working against the brakes,
release the brakes and let truck movement start. Be sure to completely release the foot-operated retarder/ser-
vice brake pedal. As truck speed increases above 3-5 mph (5-8 kph) the Propulsion System Control (PSC)
will drop propulsion, if the retarder is still applied.
Releasing and reapplying dynamic retarding during a hill start operation will result in loss of propulsion.

PASSING
1. Do not pass another truck on a hill or blind curve!
2. Before passing, make sure the road ahead is clear. If a disabled truck is blocking your lane, slow down and
pass with extreme caution.
3. Use only the areas designated for passing.

LOADING
1. Pull into the loading area with caution. Remain at a safe distance while truck ahead is being loaded.
2. Do not drive over unprotected power cables.
3. When approaching or leaving a loading area, watch out for other vehicles and for personnel working in the
area.
4. When pulling in under a loader or shovel, follow "spotter" or "shovel operator" signals. The truck operator may
speed up loading operations by observing the location and loading cycle of the truck being loaded ahead,
then follow a similar pattern.
5. During loading, the operator must stay in the truck cab with engine running. Place the selector switch in NEU-
TRAL and apply the brake lock.
6. When loaded, pull away from shovel as quickly as possible but with extreme caution.
Operating Instructions - Section 30 8/03 OM3038
Page 30-8

DUMPING
Raising The Dump Body
1. Pull into dump area with extreme caution. Make sure area is clear of persons and obstructions, including
overhead utility lines. Obey signals directed by the spotter, if present.
Avoid unstable areas. Stay a safe distance from edge of dump area.
Position the truck on a solid, level surface before dumping.

As the body raises, the truck center of gravity will move. Truck must be on
level surface to prevent tipping / rolling!

2. Carefully maneuver truck into dump position. When backing truck into dump position, use only the foot-oper-
ated brake pedal to stop and hold truck; Do not rely on wheel brake lock to stop truck; this control is not mod-
ulated and applies rear service brakes only.
3. When truck is stopped and in dump position, apply wheel brake lock and move the selector switch to the
NEUTRAL position.
The dumping of very large rocks (10% of payload, or greater) or sticky
material (loads that do not flow freely from the body) may allow the mate-
rial to move too fast and cause the body to move rapidly and suddenly.
This sudden movement may jolt the truck violently and cause possible
injury to the operator, and/or damage to the hoist cylinders, frame, and/or body hinge pins. If it is neces-
sary to dump this kind of material, refer to the WARNING in the following procedure:

4. Pull the lever to the rear to actuate hoist circuit. (Releasing the lever anywhere
during "hoist up" will hold the body at that position.)
5. Raise engine rpm to accelerate hoist speed. Refer to the CAUTION below.

If dumping very large rocks or sticky material as described in WARNING

above, slowly accelerate engine rpm to raise body. When the material
starts to move, release hoist lever to HOLD position. If material does not
continue moving and clear body, repeat this procedure until material has
cleared body.
6. Reduce engine rpm as last stage of hoist cylinder begins to extend and let engine go to low idle as last stage
reaches half-extension.
7. Release hoist lever as last stage of hoist cylinder reaches full extension.
8. After material being dumped clears body, lower body to frame.

Lowering The Dump Body

(When dumping on flat ground):
It is very likely when dumping on flat ground that the dumped material will build up enough to prevent the body from
lowering. In this case, the truck will have to be driven forward a short distance (just enough to clear the material)
before the body can be lowered.
1. Shift selector switch to FORWARD, release brake lock, depress override button and drive just far enough for-
ward for body to clear material. Stop, shift selector switch to NEUTRAL, and apply brake lock.
2. Move hoist lever forward to DOWN position and release. Releasing the lever places hoist control valve in the
FLOAT position allowing the body to return to frame.
OM3038 8/03 Operating Instructions - Section 30
Page 30-9
NOTE: If dumped material builds up at the rear of the body and the body cannot be lowered, then perform Steps
"a" and "b" below:
a. Move hoist lever back to the RAISE position to fully raise the dump body. Then release the hoist lever so it
returns to the HOLD position.
b. Shift selector switch to FORWARD, release brake lock, depress override button and drive forward to clear
the material. Stop, shift selector switch to NEUTRAL, apply brake lock and lower body again.
NOTE: Failure to "hoist" the body after making an unsuccessful attempt at lowering the body may result in the
dump body suddenly lowering after the truck has pulled ahead of the material that was previously preventing the
body from lowering.

CAUTION! The truck is not to be moved with the dump body raised except for emergency
purposes only. Failure to lower body before moving truck may cause damage to hoist
cylinders, frame and/or body hinge pins.

3. With body returned to frame, move selector switch to FORWARD, release brake lock, and leave dump area
carefully.

Lowering The Dump Body

(When dumping over a berm or into a crusher):
1. Move hoist lever forward to DOWN position and release. Releasing the lever places hoist control valve in the
FLOAT position allowing the body to return to frame.
NOTE: If dumped material builds up at the rear of the body and the body cannot be lowered, perform steps "a" &
"b" below:
a. Move hoist lever back to the HOIST position to fully raise the dump body. Release the hoist lever so it
returns to the HOLD position.
NOTE: DO NOT drive forward if the tail of body will not clear the crusher wall in the fully raised position.
b. Shift selector switch to FORWARD, release brake lock, depress Override button and drive forward to clear
the material. Stop, shift selector switch to NEUTRAL, apply brake lock and lower body again.
NOTE: Failure to "hoist" the body after making an unsuccessful attempt at lowering the body may result in the
dump body suddenly lowering after the truck has pulled ahead of the material that was previously preventing the
body from lowering.

CAUTION! The truck is not to be moved with the dump body raised except for emergency
purposes only. Failure to lower body before moving truck may cause damage to hoist
cylinders, frame and/or body hinge pins.

2. With body returned to frame, move selector switch to FORWARD, release brake lock, and leave dump area
carefully.
Operating Instructions - Section 30 8/03 OM3038
Page 30-10

TOWING
Prior to towing a truck, many factors must be carefully considered. Serious personal injury and/or significant prop-
erty damage may result if important safety practices, procedures and preparation for moving heavy equipment are
not observed. Do not tow the truck any faster than 5 mph (8 kph).
Information on the towing attachments listed below is available from your area Komatsu service representative:
Front Bumper Modification Kit - MK3941: This kit contains the parts necessary to modify the front bumper for
installation of towing bosses. One MK3941 kit is required for each truck in the fleet.
Tow Adaptor Structure - MK3945: This structure must be ordered (or designed) to mate with the intended towing
vehicle and is intended for towing an unloaded vehicle only.
A disabled machine may be towed after the following minimum precautions have been taken.
1. Shut down engine.
2. If truck is equipped, install hydraulic connections for steering and dumping between towing and towed vehi-
cles. Check towed vehicle for braking system.
3. Inspect tow bar for adequacy (approximately 1.5 times the gross vehicle weight of truck being towed).
4. Determine that towing vehicle has adequate capacity to both move and stop the towed truck under all condi-
tions.
5. Block disabled truck to prevent movement while attaching tow bar.
6. Release disabled truck brakes and remove blocking.
7. Sudden movement may cause tow bar failure. Smooth, gradual truck movement is preferred.
8. Minimize tow angle at all times - never exceed 30°. The towed truck must be steered in the direction of the
tow bar.

SAFE PARKING PROCEDURES

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

NORMAL ENGINE SHUTDOWN PROCEDURE

The following procedure should be followed at each engine shutdown.
1. Stop the truck out of the way of other traffic on a level surface and free of overhead power lines or other
obstructions (in case dump body should need to be raised).
a. Reduce engine speed to idle.
b. Place the selector switch in NEUTRAL.
c. Apply the parking brake switch. Be sure the "parking brake applied" indicator light in the overhead display
panel is illuminated.
d. Allow engine to cool gradually by running at low idle for 3 to 5 minutes, or if preferred, activate the 5 minute
shutdown delay timer as described on the following page.
OM3038 8/03 Operating Instructions - Section 30
Page 30-11
2. Place rest switch in ON position to put AC Drive system in "rest" mode of operation. Be sure the "rest" indica-
tor light in the overhead panel is illuminated.
3. With engine cooled down, turn keyswitch counterclockwise to OFF position for normal shutdown of engine.
If engine does not shutdown with keyswitch, use engine shutdown switch on operator cab center console,
and hold this switch down until engine stops.
4. With keyswitch OFF, and engine stopped, wait at least 90 seconds. Insure steering circuit is completely bled
down by turning steering wheel back and forth several times. No front wheel movement will occur when
hydraulic pressure is relieved. If the vehicle continues to steer after shutdown, notify maintenance personnel.
5. Verify all link voltage lights are off (one on back interior wall of operator cab, two on electrical cabinet, on
deck), and notify maintenance personnel if remains illuminated longer than five minutes after the engine is
shut down.
6. Close and lock all windows, remove key from keyswitch and lock cab to prevent possible unauthorized truck
operation. Dismount truck properly. Put wheel chocks in place.

DELAYED ENGINE SHUTDOWN PROCEDURE

1. Stop the truck out of the way of other traffic on a level surface and free of overhead power lines or other
obstructions (in case dump body should need to be raised).
a. Reduce engine speed to low idle.
b. Place the selector switch in NEUTRAL.
c. Apply the parking brake switch. Be sure the parking brake applied indicator light in the overhead display
panel is illuminated.
2. Place rest switch in ON position to put AC Drive System in "rest" mode of operation. Be sure the "rest" indica-
tor light in the overhead panel is illuminated.
3. Refer to Instrument Panel and Indicator Lights in this section for location of the engine
shutdown switch with 5 minute idle timer delay. This is a 3-position rocker-type switch
(OFF-ON-MOMENTARY).
4. Press the top of the engine shutdown switch to select the ON (center) position. Press the
top of the switch again to activate the timer delay (MOMENTARY position). Release the
switch and allow it to return to the ON position.

When the engine shutdown timer has been activated, the timer delay indicator light in the
overhead status panel will illuminate to indicate that the shutdown timing sequence has
started. The engine will continue to idle for approximately 5 minutes to allow for proper
engine cool-down before stopping.

5. Turn the keyswitch counterclockwise to the OFF position to cause the engine to shutdown when the timing
sequence is complete. When the engine stops, this will activate the hydraulic bleeddown timer and turn off the
24 VDC electric circuits controlled by the keyswitch.
NOTE: To cancel the 5 minute idle timer sequence, press the timer delay shutdown switch to the OFF (lower)
position. If the keyswitch is in the OFF position, the engine will stop. If the keyswitch is in the ON position, the
engine will continue to run.
Operating Instructions - Section 30 8/03 OM3038
Page 30-12

SUDDEN LOSS OF ENGINE POWER

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

Dynamic retarding will not be available! Do not use the service brakes for continuous retarding purposes.
If possible, steer the truck to the side of the road while bringing it to a complete stop. Apply the parking brake as
soon as the truck has stopped moving. Turn key switch OFF and notify maintenance personnel immediately.
If the truck becomes disabled where traffic is heavy, mark the truck with warning flags in daylight or flares at night.
If the engine suddenly stops, there is enough hydraulic pressure stored in the brake and steering accumulators to
allow the operation of the steering and brake functions. However, this oil supply is limited so it is important to stop
the truck as quickly and safely as possible after the loss of engine power. If the brake supply pressure drops to a
pre-determined level, the "low brake pressure" warning light will illuminate and a buzzer will sound. If the brake
pressure continues to decrease, the "auto-apply" feature will activate and the service brakes will apply automati-
cally to stop the truck. Apply the parking brake as soon as the truck comes to a complete stop.
OM3038 8/03 Operating Instructions - Section 30
Page 30-13

RESERVE ENGINE OIL SYSTEM (Optional)

The reserve oil tank for the engine is designed to add more oil capacity to the engine and to make less frequent
servicing of the engine oil. The circulation of oil between the engine sump and reserve tank increases the total vol-
ume of working oil. This dilutes the effects of contamination and loss of additives and maintains the oil quality over
longer periods. A filter in the supply circuit protects the pumping unit and prevents transfer of contaminants to the
engine sump which might enter the tank during servicing. It also gives an added level of oil cleanup.

Operation
Engine oil is circulated between the engine sump and the
reserve tank by two electrically driven pumps within a sin-
gle pumping unit (11). The pump unit is mounted on the
side of the reserve tank. The pump unit is equipped with
an LED monitor light on one side.
Pump 1 (in the pump unit) draws oil from the engine
sump at a preset control point (determined by the height
of the suction tube). Oil above this point is withdrawn and
transferred to the reserve tank (9). This lowers the level
in the engine sump until air is drawn.
Air reaching the pumping unit activates Pump 2 (in the
pump unit) which returns oil from the reserve tank and
raises the engine sump level until air is no longer drawn
by Pump 1. Pump 2 then turns off. The running level is
continuously adjusted at the control point by alternation
between withdrawal and return of oil at the sump.

LED Monitor Light

• Steady - Pump 1 is withdrawing oil from the engine
sump and bringing down the oil level.
• Regular Pulsing - Pump 2 is returning oil to the
engine sump and raising the oil level.
• Irregular Pulsing - Oil is on the correct running level. RESERVE ENGINE OIL SYSTEM

Changing Oil 1. Oil Suction 8. Fill Cap

Drain both the engine sump and the reserve tank. Refill 2. Oil Tank Fill 9. Reserve Oil Tank
3. Fill Valve 10. Engine Fill Line
both engine and reserve tank with new oil to proper lev-
4. Engine Fill Line 11. Pump Unit
els. 5. Oil Level Sensor 12. Sight Gauge
Change engine and reserve tank filters as required. 6. Air Valve 13. Tank Return Line
7. Tank Fill Line 14. Oil Filter
Start engine and check for proper operation.
NOTE: Do not use the oil in the reserve tank to fill the engine sump. Both must be at proper level before starting
engine.
The engine oil level should be checked with the engine dipstick at every shift change. If the oil level in the engine is
incorrect, check for proper operation of the reserve engine oil system.
The oil level in the reserve tank must also be checked at every shift change. Oil must be visible in the middle sight
gauge (12). If not, add oil to the reserve tank by using the quick fill system utilizing the tank fill valve (3). For filling
instructions, refer to Section 40, Lubrication and Service.
Operating Instructions - Section 30 8/03 OM3038
Page 30-14

NOTES
OM3205 Operator Cab And Controls - Section 32
Page 32-1

OPERATOR CAB AND CONTROLS

FIGURE 32-1. CAB INTERIOR - OPERATOR VIEW

1. Steering Wheel 6. Heater/Air Conditioner Controls 11. Radio, AM/FM Stereo

2. Retarder Control Lever 7. Instrument Panel 12. Warning Lights Dimmer Control
3. Retarder/Service Brake Pedal 8. Grade/Speed Retard Chart 13. Warning/Status Indicator Lights
4. Throttle/Accelerator Pedal 9. Radio Speakers 14. Air Cleaner Vacuum Gauges
5. Heater/Air Conditioner Vents 10. Warning Alarm Buzzer 15. Windshield Wipers
Operator Cab And Controls - Section 32 OM3205
Page 32-2

STEERING WHEEL AND CONTROLS

The steering wheel (1, Figure 32-2) will telescope "in"
and "out" and adjust through a tilt angle to provide a
comfortable wheel position for most operators.

Horn Button
The horn (2, Figure 32-2) is actuated by pushing the
button in the center of the steering wheel. Operation
of the horn should be verified before moving the
truck. Observe all local safety rules regarding the use
of the horn as a warning signal device before starting
engine and moving the vehicle.

Telescope Lock Ring

The telescope lock ring (3, Figure 32-2) around the
horn button locks/unlocks the telescoping function of
the steering column. Rotating the ring 90° - 180°
counterclockwise (L.H. rotation), releases the column
to move "in" or "out". Rotating the ring clockwise FIGURE 32-2. STEERING WHEEL AND
(R.H. rotation), locks the column in the adjusted posi-
tion. DYNAMIC RETARDING
Tilt Wheel Lever Dynamic retarding is a braking torque (not a brake)
produced through electrical generation by the wheel-
Adjust the tilt of the steering wheel by pulling tilt
motors when the truck motion (momentum) is the
wheel lever (4, Figure 32-2) toward the steering
propelling force.
wheel and moving the wheel to the desired angle.
Releasing the lever will lock the wheel in the desired For normal truck operation, dynamic retarding
location. should be used to slow and control truck speed.

Turn Signal/Headlight Dimmer Dynamic retarding is available in FORWARD/

REVERSE at all truck speeds above 0 mph/kph;
Turn signal lever/headlight dimmer (5, Figure 32-2) is however, as the truck speed slows below 3 mph (4.8
used to activate turn signal lights and to select either kph), the available retarding force may not be effec-
high or low headlight beams. tive. Use the service brakes to bring the truck to a
complete stop.
Move the lever upward to signal a turn to
Dynamic retarding will not hold a stationary truck on
the right.
an incline; use the parking brake or wheel brake lock
for this purpose.
An indicator in the top, center of the instrument
panel will illuminate to indicate turn direction Dynamic retarding is available in NEUTRAL only
selected. Refer to Instrument Panel and Indicator when truck speed is above 3 mph (4.8 kph).
Lights in this section.
When dynamic retarding is in operation, engine rpm
will automatically go to an advance retard speed set-
Move the lever downward to signal a
ting. This rpm will vary depending on temperature of
turn to the left.
several electrical system components.
Moving the lever toward the steering Dynamic retarding will be applied automatically, if
wheel changes headlight beam. When the speed of the truck obtains the maximum speed
high beams are selected, the indicator setting programmed in the control system software.
in the top, center of the instrument panel will illu-
When dynamic retarding is activated, an indicator
minate.
light in the overhead display will illuminate. The
grade/speed retard chart should always be used to
determine safe downhill speeds. Refer to Grade/
Speed Retard Chart in this chapter.
OM3205 Operator Cab And Controls - Section 32
Page 32-3
Retarder Control Lever Service brakes should be applied only when
dynamic retarding requires additional braking force to
Retarder control lever (6, Figure 32-2) mounted on
slow the truck speed quickly, or when bringing the
the right side of the steering column can be used to
truck to a complete stop.
modulate retarding effort. The lever will command the
full range of retarding and will remain at a fixed posi-
tion when released.
Accelerator (Throttle) Pedal
a. When the lever is rotated to full “up” (coun-
terclockwise) position, it is in the OFF/no The accelerator (throttle) pedal (4, Figure 32-1) is a
retard position. An adjustable detent holds foot-operated pedal which allows the operator to con-
the lever in the OFF position. Refer to Sec- trol engine rpm, depending on pedal depression.
tion J in the service manual for adjustment
It is used by the operator to request torque from the
procedures.
motors when in forward or reverse. In this mode, the
b. When the lever is rotated to full "down" propulsion system controller commands the correct
(clockwise) position, it is in the full ON/retard engine speed for the power required. In NEUTRAL,
position. this pedal controls engine speed directly.
c. For long downhill hauls, the lever may be
positioned to provide desired retarding effort,
and it will remain where it is positioned.
NOTE: The retarder control lever must be rotated
back to the OFF position before the truck will resume
the propel mode of operation.
The lever and foot-operated retarder/service brake
pedal can be used simultaneously or independently.
The Propulsion System Controller (PSC) will deter-
mine which device is requesting the most retarding
effort and apply that amount.

Dynamic Retarder/Service Brake Pedal

Starting on a Grade With a Loaded Truck
Dynamic retarder/service brake pedal (3, Figure 32-
1) is a single, foot-operated pedal that controls both Initial propulsion with a loaded truck should begin
retarding and service brake functions. The first por- from a level surface whenever possible, but when
tion of pedal travel commands retarding effort there are circumstances where starting on a hill or
through a rotary potentiometer. The second portion grade cannot be avoided, use the following proce-
of pedal travel modulates service brake pressure dure:
directly through a hydraulic valve. Thus, the operator 1. Fully depress the foot-operated retarder/ser-
must first apply, and maintain, full dynamic retarding vice brake pedal (Do Not use retarder lever) to
in order to apply the service brakes. Releasing the hold the truck on the grade. With service brakes
pedal returns brake and retarder to the OFF position. fully applied, move the selector switch to a drive
When the pedal is partially depressed, the dynamic position (FORWARD/REVERSE) and increase
retarding is actuated. As the pedal is further engine rpm with throttle pedal.
depressed, to where dynamic retarding is fully 2. As engine rpm approaches maximum, and
applied; the service brakes (while maintaining full operator senses propulsion effort working
retarding) are actuated through a hydraulic valve against the brakes, release the brakes and let
which modulates pressure to the service brakes. truck movement start. Be sure to completely
Completely depressing the pedal causes full release the foot-operated retarder/service brake
application of both dynamic retarding and the pedal. As truck speed increases above 3-5 mph
service brakes. An indicator light in the overhead (5-8 kph) the Propulsion System Control (PSC)
panel (B3, Figure 32-8) will illuminate), and an will drop propulsion if the retarder is still applied.
increase in pedal resistance will be felt when the ser-
Releasing and reapplying dynamic retarding
vice brakes are applied.
during a hill start operation will result in loss of
For normal truck operation, dynamic retarding propulsion and, if truck speed is above 1-2
(lever or foot-operated pedal) should be used to mph, application of retarding effort.
slow and control the speed of the truck.
Operator Cab And Controls - Section 32 OM3205
Page 32-4

GRADE/SPEED RETARD CHART The "short term" numbers listed on the chart indicate
the combination of speeds and grades which the
Grade/speed retard chart (8, Figure 32-1 & shown vehicle can safely negotiate for a short duration
below) provides the recommended MAXIMUM before system components reach the maximum
retarding limits at various truck speeds and grades allowable temperature during retarding. These
with a fully loaded truck. speeds are faster than the "continuous" values,
This decal in the truck may differ from the decal reflecting the thermal capacity of various system
below due to optional truck equipment such as: components. System components can accept heat-
wheel motor drive train ratios, retarder grids, tire ing at a higher-than-continuous rate for a short period
sizes, etc. Always refer to this decal in the opera- of time. Beyond this short duration of time, the sys-
tor's cab, and follow these recommendations for tem would become overheated.
truck operation. If the vehicle is operated at "short term" grade and
The operator should reference this chart before speed limits for a period of time exceeding thermal
descending any grade with a loaded truck. Proper capacity, the Propulsion System Controller (PSC)
use of dynamic retarding will maintain a safe speed. gradually reduces retarding effort from "short term" to
"continuous". The "retard @ continuous" indicator
light will illuminate alerting the operator of the retard-
ing reduction and the need for a reduction in speed.
The operator must use the service brakes to quickly
slow the truck to maximum "continuous" retarding
limits or less.

Do Not LIGHTLY apply the service brakes when

attempting to slow the truck on a downhill grade.
Overheating of the brakes will result. Fully apply
the brakes (within safe limits for road conditions)
in order to quickly slow the truck to maximum
"continuous" retarding limits or less.
NOTE: The "three minute" curve is a minimum and
the actual time limit could be greater. Ambient
temperature, barometric pressure and recent motor
power levels can affect this number.
The "short term" rating will successfully accommo-
date most downhill loaded hauls. It is necessary to
divide haul road grade segment length by allowable
speed to determine actual time on grade. If actual
time on the grade exceeds the allowable limits, the
grade will need to be negotiated at the "continuous"
speed.
Two speed lists are provided, one for continuous The "continuous" numbers on the chart indicate the
retarding, and the second, for short term (approx. 3- combination of speeds and grades which the vehicle
minute) retarding. Both lists are matched to the truck can safely negotiate for unlimited time or distance
at maximum Gross Vehicle Weight (GVW). The two during retarding.
ratings are guidelines for proper usage of the retard
function on downhill grades. DO NOT exceed these recommended MAXIMUM
speeds when descending grades with a loaded truck.
OM3205 Operator Cab And Controls - Section 32
Page 32-5

INSTRUMENT PANEL
Instrument panel (7, Figure 32-1) includes a wide variety of switches, gauges, and indicators. Refer to Instrument
Panel and Indicator Lights, in this chapter for a detailed description of function and location of these components.

OVERHEAD PANEL AND DISPLAYS

The items listed below are located on the overhead panel. Refer to Figure 32-1 for the location of each item. A brief
description of each component is documented below.

Radio Speakers Status/Warning Indicator Light Panel

Radio speakers (9, Figure 32-1) for the AM/FM Ste- Panel (13, Figure 32-1) contains an array of indicator
reo radio are located at the far left and right of the lights to provide the operator with important status
overhead panel. messages concerning selected truck functions. Refer
to Instrument Panel and Indicator Lights, in this chap-
ter for a detailed description of these indicators.
Warning Alarm Buzzer
Warning alarm buzzer (10, Figure 32-1) will sound
Air Cleaner Vacuum Gauges
when activated by any one of several truck functions.
Refer to Instrument Panel and Indicator Lights, in this Air cleaner vacuum gauges
chapter for a detailed description of functions and (14, Figure 32-1) provide a
indicators that will activate this alarm. continuous reading of maxi-
mum air cleaner restriction
reached during operation. The
Cab Radio (Optional) air cleaner(s) should be ser-
viced when the gauge(s)
This panel will normally contain AM/FM Stereo radio shows the following maximum
(11, Figure 32-1). Refer to Section 70 for a more recommended restriction:
complete description of the radio and its functions.
Individual customers may use this area for other pur- Komatsu SSDA16V160 Engine: 25 inches of H2O
poses, such as a two-way communications radio. vacuum.
NOTE: After service, push the reset button on face of
gauge to allow the gauge to return to zero.
Warning Indicator Light Dimmer Control
Dimmer control (12, Figure 32-1) permits the opera-
tor to adjust the brightness of warning indicator lights
(13).

Windshield Wipers
Windshield wipers (15, Figure 32-1) are powered by
an electric motor. Refer to Instrument Panel and Indi-
cator Lights, in this chapter for a location and
description of the windshield wiper and washer con-
trols.
Operator Cab And Controls - Section 32 OM3205
Page 32-6

CENTER CONSOLE
The center console (1, Figure 32-3) contains:

(1) Center Console

(2) F-N-R Selector Switch
(3) Hoist Control Lever
(4) Ash Tray
(5) Cigar/Cigarette Lighter
(6) L.H. Window Control Switch
(7) R.H. Window Control Switch
(8) Engine Shutdown Switch
(9) Override/Fault Reset Switch
(10) Blank - Not Used on this truck
(11) RSC Switch
(12) Retarder Speed Control Dial
(13) Propulsion System Controller (PSC)
Diagnostic Port
(14) Engine Diagnostic Port (CENSE)
(15) Truck Control Interface (TCI)
(16) Passenger Seat
(mounted on top of the right hand
portion of the Console structure)
(17) Engine Diagnostic Port (QUANTAM)
(18) Modular Mining Port (Optional)
(19) Data Store Button

FIGURE 32-3. CENTER CONSOLE

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 three
position switch that controls the forward-neutral-
reverse motion of the truck. When the selector switch
handle is in the center "N" position, it is in NEUTRAL.
The handle must be in NEUTRAL to start the
engine.
The operator can select FORWARD drive
by moving the handle forward.

REVERSE drive can be selected by moving

the handle to the rear.

The truck must be stopped before the selec-

tor handle is moved to a drive position.
OM3205 Operator Cab And Controls - Section 32
Page 32-7
Hoist Control Lever Ash Tray
Hoist control (3, Figure 32-3) is a four position hand- Ash tray (4, Figure 32-3) is used for extinguishing
operated lever located between the operator seat and depositing smoking materials. Do Not use for
and the center console (see illustration below). flammable materials, such as paper wrappers, etc.
Be certain that all fire ash is extinguished!

Lighter
Lighter (5, Figure 32-3) may be used for lighting
cigars/cigarettes. Always use caution with smok-
ing materials!
This socket may also be used for a 12 VDC power
supply.

L.H. Window Control Switch

Control switch (6, Figure 32-3) is spring-loaded to the
OFF position.
Raising The Dump Body
• Pushing the front of the switch raises the left side
1. Pull the lever to the rear to actuate hoist circuit. cab window.
(Releasing the lever anywhere during "hoist up"
• Pushing the rear of the switch lowers the window.
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 R.H. Window Control Switch
hoist cylinders begin to extend and then let the
engine go to low idle as the last stage reaches Control switch (7, Figure 32-3) is spring-loaded to the
half-extension. OFF position.
4. Release hoist lever as the last stage reaches • Pushing the front of the switch raises the right
full extension. side cab window.
5. After material being dumped clears the body, • Pushing the rear of the switch lowers the window.
lower the body to frame.
Refer to Operating Instructions - Dumping, for more
complete details concerning this control
Engine Shutdown Switch
Engine shutdown switch (8, Figure 32-3)
is used for engine shutdown by depress-
Lowering The Dump Body: ing this button and holding it until engine
stops.
Move hoist lever forward to DOWN position and
release. Releasing the lever places hoist control
valve in the FLOAT position allowing the body to Use this switch to shutdown engine if engine does
return to frame. not shutdown by turning off keyswitch, or to shut-
down engine without turning off 24 VDC electric cir-
cuits.
There is also a ground level engine shutdown switch
at the left front corner of the truck.
Operator Cab And Controls - Section 32 OM3205
Page 32-8

Override/Fault Reset Switch Retard Speed Control (RSC) Adjust Dial

This push-button RSC adjust dial (12, Figure 32-3) allows the operator
switch (9, Figure to vary the downhill truck speed that the retard speed
32-3) is spring- control system will maintain when descending a
loaded to the OFF grade. This function can be overridden by either the
position. When accelerator, retard lever, or retard pedal.
pushed in and held,
When the dial is rotated counterclockwise
this switch may be used for several functions.
toward this symbol, the truck will descend
1. This switch permits the operator to override the a grade at lower speeds.
body-up limit switch and move the truck forward
When the dial is rotated clockwise toward
when the selector switch is in FORWARD, the
this symbol, the truck speed will increase.
dump body is raised, and the brakes are
released.
ALWAYS refer to the grade/speed retard chart in
Use of the override switch for this purpose is
intended for emergency situations only! the operator's cab, and follow the recommenda-
tions for truck operation. DO NOT exceed these rec-
2. The push button deactivates the retard pedal ommended MAXIMUM speeds when descending
function when speed of truck is below 3 mph grades with a loaded truck.
(4.8 kph).
3. The override switch is also used to reset an Throttle pedal position will override RSC setting. If
electric system fault when indicated by a red operator depresses throttle pedal to increase truck
warning light (Refer to Overhead Status/Warn- speed, dynamic retarding will not come on unless
ing Indicators in this section. truck overspeed setting is reached or foot operated
retard pedal is used. When throttle pedal is released
and RSC switch is on, dynamic retarding will come
on at, or above, the RSC dialed speed and will adjust
10, Figure 32-3 - Blank truck speed to, and maintain, the dialed speed.
This position is not used for the To adjust RSC control, pull switch (11) ON and start
930E. with dial (12) rotated toward fastest speed while driv-
ing truck at desired maximum speed. Relax throttle
pedal to let truck coast and turn RSC adjusting dial
In some other truck models, this posi- slowly counterclockwise until dynamic retarding is
tion is used for an engine idle switch. activated. Dynamic retarding will now be activated
automatically anytime the "set" speed is reached, the
RSC switch is on, and throttle pedal is released.
With RSC switch on and dial adjusted, the system
will function as follows: As truck speed increases to
the "set" speed and throttle pedal released, dynamic
Retard Speed Control (RSC) Switch
retarding will apply. As truck speed tries to increase,
Retard speed control switch (11, Figure 32-3) turns the amount of retarding effort will automatically adjust
the system on and off. Push the knob in for OFF and to keep the selected speed. When truck speed
pull the knob out to turn the system ON. decreases, the retarding effort is reduced to maintain
“IN” “OFF” the selected speed. If truck speed continues to
decrease to approximately 3 mph (4.8 kph) below
"set" speed, dynamic retarding will turn off automati-
cally. If truck speed must be reduced further, the
operator can turn the adjust dial to a new setting or
“OUT” “ON” depress the foot operated retard pedal.
If the operator depresses the foot operated retard
pedal and the retard effort called for is greater than
that from the automatic system, the foot pedal retard
will override RSC.
OM3205 Operator Cab And Controls - Section 32
Page 32-9
PSC Download Port Payload Meter And Download Connector
PSC download port (13, Figure 32-3) is for use by The payload meter (1, Figure 32-4) and download
qualified personnel to access diagnostic information connector (2) are used to provide management with
for the Propulsion System Controller (PSC). operational data such as tonnage hauled and cycle
times.
Refer to Section 6, Optional Equipment, for a more
complete description of the payload meter and its
Engine Diagnostics Download Port functions.

This 3-pin connector (14, Figure 32-3) is for use by Download connector (2, Figure 32-4) is used with a
qualified personnel to access the diagnostic informa- special cable to allow the payload meter (1) to com-
tion for the engine monitoring system. (CENSE). municate with a portable computer.
The payload meter is located on the back wall inside
of the operator’s cab.

TCI Download Port

This connector (15, Figure 32-3) is for use by quali-
fied personnel to access the Truck Control Interface
(TCI) diagnostic information and data.

Passenger Seat
The passenger seat (16, Figure 32-3) is mounted on
top of the right hand portion of the center console
structure.
The area beneath the passenger seat provides a
cabinet for various 24 VDC electrical components.
Consult the service manual for service involving any
of these components.

FIGURE 32-4. PAYLOAD METER III

1. Payload Meter III 2. Download Connector

Engine Control System
This 9-PIN connector (17, Figure 32-3) is for use by
qualified personnel to access the diagnostic informa-
tion for the engine control system. (QUANTUM)

Modular Mining System

This connector (18, Figure 32-3) is for use by quali-
fied personnel to access the Modular Mining System
for diagnostic information and data.
Operator Cab And Controls - Section 32 OM3205
Page 32-10

OPERATOR COMFORT
OPERATOR SEAT
The operator's seat provides a fully adjustable cush-
ioned ride for driver comfort and easy operation.

Adjustment
The following adjustments are available to the opera-
tor while sitting in the seat.
• Headrest (1, Figure 32-5): Adjust up, down, fore,
or aft by moving headrest to desired position.
• Armrests (3): Rotate adjusting knob until armrest
is at desired angle.
• Backrest: Rotate knob (9) to adjust the backrest
angle.
• Seat Belt Harness: Operator must always have
four-point seat belt harness (2) buckled in place
and properly adjusted during machine operation.
• Air Lumbar Support: Use lumbar hand pump (8)
to adjust the air support. A release button on the
back of the hand pump releases the air from the
lumbar support.
• Weight Adjustment: Adjust the weight
adjustment dial to match the approximate weight
of the operator. The dial ranges from 110 - 265
lbs. (50 - 120 kg).
• Fore/Aft Adjustment: Lift lever (8) and hold.
Slide the seat to a comfortable position and
release the lever to lock the adjustment.
• Seat Height: Lift lever (7) and then push the FIGURE 32-5. OPERATOR’S SEAT
lever down to raise the seat one level. Remove
body weight from the seat to allow it to adjust. To
lower the seat one level, push lever (7) down, 1. Headrest 6. Fore/Aft Lever
and then pull the lever up. Release lever to lock 2. Seat Belt 7. Seat Height/Tilt
the adjustment. 3. Armrest Adjustment Lever
4. Seat Belt Anchor 8. Lumbar Pump
• Seat Tilt: Pull lever (7) up to tilt the seat 5. Weight Adjustment 9. Backrest Angle
rearward. Push the lever down to tilt the seat
Dial Adjustment Knob
forward. Release the lever to lock the
adjustment.
OM3205 Operator Cab And Controls - Section 32
Page 32-11

HEATER / AIR CONDITIONER

COMPARTMENT AND CONTROLS
Heater/Air Conditioner Selector Switch
The heater/air conditioner compartment contains the
heater/air conditioner controls (6, Figure 32-1) and Selector switch (5, Figure 32-6) allows the operator
some of the heater/air conditioner components, such to select heat, A/C, or neither. The left position of the
as the blower motor assembly and heater coils. Opti- switch activates the air conditioning and the right side
mum cab air climate can be selected by using the fol- of the switch activates the heater. The middle posi-
lowing controls in various combinations. tion is OFF. Neither the heat nor the air conditioning
can be activated in this position.
Heater/Air Conditioner Vents NOTE: The air conditioner will not operate unless the
Each heater/air conditioner vent (6, Figure 32-6) is a fan control knob is turned ON.
flapper type which may be opened or closed or
rotated 360° for optimum air flow. There are four
(three not shown) across the top of the panel, one
each in the right and left panel modules, and four
below the panel.

Defroster Control Switch

Defroster control switch (1, Figure 32-6) directs
heated air for windshield defrosting. "Down" position
of the toggle switch is OFF. "Up" position of the tog-
gle switch is ON.

Heat Control Switch

Heater control 2, Figure 32-6) directs heated air to
the cab floor for heating of the cab. "Down" position
of the toggle switch is OFF. "Up" position of the tog-
gle switch is ON.

Temperature Control Knob

Temperature control knob (3, Figure 32-6) allows the
operator to select a comfortable temperature.
Rotating the knob counter-clockwise (blue arrow) will
select cooler temperatures. Full counter-clockwise
position is the coldest air setting. Rotating the knob
clockwise (red arrow) will select warmer tempera-
tures. Full clockwise position is the warmest heater
setting.

Fan Control Knob

Fan control knob (4, Figure 32-6) controls the cab air
fan motor. The fan motor is a 3-speed motor: low
(setting 1), medium (setting 2), and high (setting 3).
Speeds are selected by rotating the control knob
clockwise to the desired position. OFF is full counter-
clockwise position (setting 0).

FIGURE 32-6. A/C & HEATER CONTROLS

Operator Cab And Controls - Section 32 OM3205
Page 32-12

NOTES
OM3205 Operator Cab And Controls - Section 32
Page 32-13

INSTRUMENT PANEL AND INDICATOR LIGHTS

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

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

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

This symbol may be used alone This symbol identifies a rotary

or with another symbol. This control or switch. Rotate the knob
symbol identifies the ON position clockwise or counterclockwise for
of a switch or control. functions.

This symbol identifies the This symbol identifies a switch

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

This symbol identifies the

"Pulled-Out" position of a push-
pull switch or control.

INSTRUMENT PANEL
(Figure 32-7)
The operator must understand the function and oper-
ation of each instrument and control. Control func-
tions are identified with "international" symbols that
the operator should learn to recognize immediately.
This knowledge is essential for proper and safe oper-
ation.
Items that are marked “optional” do not apply to
every truck.
Operator Cab And Controls - Section 32 OM3205
Page 32-14

FIGURE 32-7. PANEL GAUGES, INDICATORS, AND CONTROLS

1. Keyswitch 15. Right Turn Signal Indicator Light
2. Engine Shutdown Switch with Timer Delay 16. High Beam Headlight Indicator Light
3. Backup Light Switch (N./O.) 17. Left Turn Signal Indicator Light
4. Ladder Light Switch (3 - Way) 18. Digital Speedometer
5. Fog Light Switch (N./O.) 19. Voltmeter Gauge
6. Panel Illumination Light(s) 20. Engine Oil Pressure Gauge
7. Vent(s) - Cab Air Conditioner/Heater 21. Engine Water Temperature Gauge
8. Not used on 930E 22. Fuel Gauge
9. Rotating Beacon Light Switch (N./O.) (Optional) 23. AC Drive System Temperature
10. Heated Mirror Switch (N./O.) (Optional) 24. Engine Hourmeter
11. Not used on 930E 25. Hydraulic/Brake Oil Temperature
12. Wheel Brake Lock Switch (N./O.) 26. AC Rest Switch
13. Parking Brake Switch (N./O.) 27. Headlights Switch (N./O.)
14. Digital Tachometer 28. Wiper / Washer Switch
29. Panel Illumination Lights Dimmer Rheostat

WIRE NUMBERS
1. 712/21PB/11S 11. 71/79M/SPR55/79H/72F/ 21. 712D/31TS/710/49
2. 11S/11TD/11R SPR54 22. 712D/38G/710/49
3. 712/47S/47L/710 12. 712BL/52B/39H/710/SPR59 23. 15V/72MT/49/710
4. 11L/48A/48B 13. 71/52C/21PB/21 24. 11L/36
5. 11L/48F 14. 41TS/74X/74Z/710 25. 15V/34BT/710/49
6. 49/710 15. 45R/710 26. 710/72RQ
7. N/A 16. 41H/710 27. 11D/41L/41TS
8. 712/28E 17. 45L/710 28. High 66S/Low 66L/710/66P
9. 11L/11RB 18. 41TS/77/77A/710 Park/712W / Washer 66
10. 712/69M/SPR56/SPR57/ 19. 712D/710/49 29. 49/41TS
SPR58 20. 712D/31PS/710/49
OM3205 Operator Cab And Controls - Section 32
Page 32-15

PANEL GAUGES, INDICATORS, AND CONTROLS

(Figure 32-7)
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, it is in the RUN
position and all electrical circuits (except START are activated.
1. With selector switch in NEUTRAL, rotate keyswitch fully
clockwise to START position, and hold this position until
engine starts. START position is spring-loaded to return to
RUN when key is released.
2. After engine has started, place rest switch in OFF position
(de-activate the "rest" mode of operation). Refer to discus-
sion of rest switch (26, Figure 32-7).

Engine Shutdown Switch with 5 Minute Idle Timer Delay

The timer delayed, engine shutdown switch (2, Figure 32-7) is a 3-position, rocker type switch
with OFF, ON and MOMENTARY positions. When used, the engine is allowed to idle for
approximately 5 minutes before actual shutdown occurs. The delayed shutdown feature allows
the engine to cool down slowly, reducing internal temperatures as coolant is circulated through
the engine.

Operation
1. Stop the truck, and reduce engine rpm to low idle. Place the selector switch in NEUTRAL and apply the park-
ing brake switch. Place the rest switch in ON position (put drive system in "rest" mode of operation). Refer to
the discussion of the rest switch later in this chapter.
2. Press the top of the engine shutdown switch to select the ON (center) position. Press the top of the switch
again to activate the timer delay (MOMENTARY position). Release the switch and allow it to return to the ON
position.
When the engine shutdown timer has been activated, the timer delay indicator light (C4, Figure 32-8) in the
overhead status panel will illuminate to indicate that the shutdown timing sequence has started. The engine
will continue to idle for approximately 5 minutes to allow for proper engine cool-down before stopping.
3. Turn the keyswitch counterclockwise to the OFF position to cause the engine to shutdown when the timing
sequence is complete. When the engine stops, this will activate the hydraulic bleeddown timer and turn off the
24 VDC electric circuits controlled by the keyswitch.
NOTE: To cancel the 5 minute idle timer sequence, press the timer delay shutdown switch to the OFF (lower)
position. If the keyswitch is in the OFF position, the engine will stop. If the keyswitch is in the ON position, the
engine will continue to run.

4. With keyswitch OFF, and engine stopped, wait at least 90 seconds. Ensure the steering circuit is completely
bled down by turning the steering wheel back and forth several times. No front wheel movement will occur
when hydraulic pressure is relieved.
5. Verify all the link voltage lights turn off within 5 minutes after the engine is shut down. (One is located in the
cab behind the operator seat, two others are located in the access panel at the left front corner of the electri-
cal cabinet. If the lights remain on, refer to Section E in the service manual for additional instructions and
information.
6. Close and lock all windows, remove key from keyswitch and lock cab to prevent possible unauthorized truck
operation. Dismount the truck properly.
Operator Cab And Controls - Section 32 OM3205
Page 32-16

Fog Lights (Optional)

Fog lights (5, Figure 32-7) are optional equipment that are useful in foggy conditions and heavy
rain. Pressing the top of the rocker switch turns the lights on. Pressing the bottom of the switch
turns the lights off.

Ladder Light Switch

Ladder light switch (4, Figure 32-7) turns the ladder lights on or off after or before using ladder.
Pressing the top of the rocker switch turns the lights on. Pressing the bottom of the switch
turns the lights off. Another switch is mounted at the front left of truck near the base of ladder.

Manual Backup Switch

Manual backup switch (3, Figure 32-7) allows backup lights to be turned on for added visibility
and safety when the selector switch (see Operator Controls) is not in REVERSE position.
When the switch is in the ON position, the manual back up light indicator (B4, overhead panel,
Figure 32-8) will be illuminated.

Panel Illumination Lights

Panel illumination lights (6, Figure 32-7) provide illumination for the instrument panel. Brightness is controlled by
the panel light dimmer switch (28).

Cab/Air Conditioner Vents

Cab/air conditioner vents (7, Figure 32-7) are spherically mounted and may be directed by the operator to provide
the most comfortable cabin air flow.

(8, Figure 32-7) Not Used

Rotating Beacon Light Switch (Optional)

The optional rotating beacon light is activated by rocker-type switch (9, Figure 32-7) when it is
switched to the ON position.

Heated Mirror Switch (Optional)

The optional heated mirror is activated by this rocker-type switch (10, Figure 32-7) when it is
switched to the ON position.

(11, Figure 32-7) Not Used

OM3205 Operator Cab And Controls - Section 32
Page 32-17
Wheel Brake Lock Control
Wheel brake lock control (12, Figure 32-7) should be used with engine running for dumping and loading
operations only. The brake lock switch actuates the hydraulic brake system which locks the rear wheel
service brakes only. When pulling into shovel or dump area, stop the truck using the foot-operated ser-
vice brake pedal. When truck is completely stopped and in loading position, apply the brake lock by
pressing the rocker switch toward the ON symbol. To release, press the rocker switch toward the OFF symbol.

Use at shovel and dump only to hold truck in position.

Do not use this switch to stop truck, unless foot-oper-
ated treadle valve is inoperative. Use of this switch
applies rear service brakes at full, unmodulated pres-
sure!
Do not use brake lock for parking. With engine
stopped, hydraulic pressure will bleed down, allowing
brakes to release!

Parking Brake Control

The parking brake is spring applied and hydraulically released. It is designed to hold a stationary truck
when the engine is shutdown and keyswitch is turned OFF. The truck must be completely stopped
before applying the parking brake, or damage may occur to parking brake. To apply the parking brake,
press parking brake control switch (13, Figure 32-7) toward the ON symbol. To release the parking
brake, press the switch toward the OFF symbol. When the keyswitch is ON and parking brake switch is applied, the
parking brake indicator light (A3, overhead panel, Figure 5-8) will be illuminated.
NOTE: Do not use the parking brake at shovel or dump. With keyswitch ON and engine running, sudden shock
caused by loading or dumping could cause the system's motion sensor to release the park brake.

Tachometer
Tachometer (14, Figure 32-7) registers engine crankshaft speed in hundreds of revolutions per minute (rpm).
Governed rpm
Low Idle - 600 rpm
High Idle - 1900 rpm
Full Load - 1910 rpm
Operator Cab And Controls - Section 32 OM3205
Page 32-18

Right Turn Signal Indicator

Indicator (15, Figure 32-7) illuminates to indicate the right turn signals are operating when the
turn signal lever on the steering column is moved upward. Moving the lever to its center posi-
tion will turn indicator off.

High Beam Indicator

High beam indicator (16, Figure 32-7) when lit, indicates that the truck headlights are on high
beam. To switch headlights to high beam, push the turn indicator lever away from steering
wheel. For low beam, pull lever toward the steering wheel.

Left Turn Signal Indicator

Indicator (17, Figure 32-7) illuminates to indicate the left turn signals are operating when the
turn signal lever on the steering column is moved downward. Moving the lever to its center
position will turn indicator off.

Speedometer/Payload Meter Display

Speedometer/payload meter display (18, Figure 32-7) indicates the truck speed in miles per hour (mph), or in kilo-
meters per hour (kph). The display also shows payload meter information. For more information, see Section 6 -
Optional Equipment, in the service manual.

Voltmeter
Voltmeter (19, Figure 32-7) indicates the voltage of the 24V battery system. Normal indicated
voltage at high rpm is 27 to 28 volts with batteries in fully charged condition. When keyswitch
(10) is ON and engine is not running, voltmeter indicates battery charge condition.

Engine Oil Pressure Gauge

Engine oil pressure gauge (20, Figure 32-7) indicates pressure in the engine lubrication sys-
tem in pounds per square inch (psi).
Normal operating pressure after engine warm up should be:
Idle - 20 psi (138 kPa) Minimum
Rated Speed - 45 to 70 psi (310 - 483 kPa)

Water Temperature Gauge

Water temperature gauge (21, Figure 32-7) indicates the temperature of the coolant in the
engine cooling system. The temperature range after engine warm-up and truck operating
under normal conditions should be:
185°-207°F (85°-97°C)

Fuel Gauge
Fuel gauge (22, Figure 32-7) indicates how much diesel fuel is in the fuel tank.
The fuel tank capacity is 1200 gallons (4542 liters).
OM3205 Operator Cab And Controls - Section 32
Page 32-19
AC Drive System Temperature Gauge
AC drive system temperature gauge (23, Figure 32-7) indicates the drive system temperature.
There are three colored bands: green; yellow; and red. Green indicates normal operation.
Yellow indicates the system temperature is rising. There is also an amber (yellow) temperature
warning light in the overhead panel (C5, Figure 32-8) that will illuminate when the temperature
exceeds a certain level. When this condition occurs, the operator should consider changing
truck operation in order to reduce system temperature.
If the AC drive system temperature should reach the red band, continued operation could damage components in
the system.
Safely stop truck, shutdown engine, and notify maintenance personnel, immediately.

Hourmeter
Hourmeter (24, Figure 32-7) registers the total number of hours the engine has been in opera-
tion.

Hydraulic Oil Temperature Gauge

Hydraulic oil temperature gauge (25, Figure 32-7) indicates oil temperature in the hydraulic
tank. There are two colored bands: green, and red. Green indicates normal operation.
As the needle approaches the red zone, minimum engine idle speed will increase to help cool
the oil.
Red indicates high oil temperature in the hydraulic tank. Continued operation could damage
components in the hydraulic system. There is also a red temperature warning light in the overhead panel (D5, Fig-
ure 32-8) that will illuminate when the temperature exceeds a certain level (when the needle enters the red zone).
If this condition occurs, the operator should safely stop the truck, move selector switch to NEUTRAL, apply the
park brake, and operate engine at 1200 - 1500 rpm to reduce system temperature.
If temperature gauge does not move into the green range after a few minutes, and the red overhead indica-
tor light does not go out, shutdown truck and notify maintenance personnel, immediately.

Rest Switch
Rest switch (26, Figure 32-7) is a "rocker" type switch with a locking device for the OFF
(left side) position. When in this position, a small black tab must be pushed to the left to
unlock the switch before it can be depressed to switch to the ON (right side) position.
When in the ON position, an internal amber lamp will illuminate. The switch should be
activated to de-energize the AC drive system whenever the engine is to be shut-
down, or the truck parked for a length of time with the engine running.
The selector switch must be in NEUTRAL and the vehicle not moving to enable this function. This will allow the
engine to continue running while the AC drive system is de-energized.
Activation of the rest switch alone does NOT completely ensure that the drive
system is safe to work on. Refer to Section 2, Safety, for more information on
servicing a 930E truck. Check all "link-on", or "link energized", indicator
lights to verify the AC drive system is de-engergized before performing any
maintenance on the drive system.
DO NOT activate the rest switch while the truck is moving! The truck may
unintentionally enter the “rest” mode after stopping.

An amber (yellow) indicator light in the overhead panel (B6, Figure 32-8) will illuminate when
the "rest" state has been requested and entered.
Operator Cab And Controls - Section 32 OM3205
Page 32-20

Light Switch
The instrument panel lights, clearance lights, and the headlights are controlled by this three
position rocker type switch (27, Figure 32-7). OFF is selected by pressing the bottom of the
switch. Press the top of the switch until it reaches the first detent to select the panel, clearance,
and tail lights only. Press the top of the switch again, until it reaches the second detent to
select headlights, as well as panel, clearance, and tail lights.

Windshield Wiper and Washer

Windshield wiper control switch (28, Figure 32-7) is a four position rotary switch with intermit-
tent wiper delay and wash feature.
OFF position is the detented position when the knob is rotated fully counterclockwise against
the stop. The intermittent wiper position is located between OFF and the first detent position,
when rotating the knob clockwise.
• Rotating the knob closer to the first detent position decreases the time interval between
wiper strokes.
• Rotate the knob clockwise to the first detent position for slow speed.
• Rotate the knob to the second detent position for fast speed.

Press and hold the knob "in" to activate the windshield washer system.

Panel Light Dimmer

Panel light dimmer control (29, Figure 32-7) is a rheostat which allows the operator to vary the
brightness of the instruments and panel lights.

• Rotating knob to the full counterclockwise position turns panel lights on to brightest
condition.
• Rotating knob clockwise continually dims lights until OFF position is reached at full
clockwise rotation.

Payload Meter Switch

Payload meter switch (30, Figure 32-7) is a two-way, momentary rocker switch. The top position is the
SELECT position. The SELECT position is used to step through the different displays. The lower posi-
tion is the SET position. The SET position is used to set the operator ID, or clear the load and total ton
counters. Refer to Section 6, Optional Equipment, for a more complete description of the payload
meter system and its functions.
OM3205 Operator Cab And Controls - Section 32
Page 32-21

OVERHEAD STATUS / WARNING INDICATORS

FIGURE 32-8. OVERHEAD STATUS / WARNING INDICATOR

Row / Indicator Indicator Color Row / Indicator Indicator Color

Column Description Wire Index Column Description Wire Index
A1* Not Used 12FD/34TL A5 No Power Red-12M/73-7PI
B1* Low Steering Pressure Red-12FD/33A B5 Propulsion System Amber-12F/79WI
C1 Low Accumulator Pr. Red-12F/33K Warning

D1 Not Used Red-12F/79V C5 Propulsion System Amber -12F/34TW

Temperature
E1 Low Brake Pressure Red-12F/33L
D5 Hydraulic Oil Temperature Red-12F/34TGI
A2* Hydraulic Tank Level Red-12FD4/34LL High
B2* Low Automatic Amber-12FD8/ E5 Stop Engine Red-12M/528A
Lubrication Pressure 68LLP
A6 NO PROPEL Red-12M/75NPI
C2* Circuit Breaker Tripped Amber-12FD/31CB
B6 Propulsion System @ Rest Amber-12M/72PR
D2* Hydraulic Oil Filter Amber-12MD/39
C6* Propulsion System Not Amber-12MD/72NR
E2* Low Fuel Amber-12MD/38 Ready
A3* Park Brake Applied Amber-12MD/52A D6* Reduced Propulsion Amber-12MD/72LP
B3* Service Brake Applied Amber-12MD/44L System
C3* Body Up Amber-12MD6/63L E6* Retard @ Continuous Amber-12MD/76LR
Level
D3* Dynamic Retarding Amber-12MD/44DL
-Switches-
E3 Stop Engine Red-12M/509MA
7 Hazard Lights Switch N/O 11L/45L/45R
A4* Not Used Amber-12MD/SPR2
8 Lamp Check Switch N/O 33H/528/710/712
B4* Manual Back-Up Lights Amber-12MD/47L
(Mom.)
C4* 5 Min. Shutdown Timer Amber-12MD/23L1
D4* Retard Speed Control Amber-12MD/31R * NOTE: Brightness for these Indicator Lamps can be
adjusted by using dimmer control (12, Figure 32-1).
E4* Check Engine Amber-12MD7/419
Operator Cab And Controls - Section 32 OM3205
Page 32-22

STATUS / WARNING INDICATOR LIGHT SYMBOLS

Indicator lights which are amber (yellow) in color alert the operator that the indicated truck function requires some
precaution when lighted.
Indicator lights which are red in color alert the operator that the indicated truck function requires immediate action
by the operator. Safely stop the truck and shut down the engine.
DO NOT OPERATE THE TRUCK WITH A RED WARNING LIGHT ILLUMINATED.
Refer to Figure 32-8 and the descriptions below for explanations of the symbols. Location of
the symbols is described by rows (A-E) and columns (1 - 6).

A1. Not Used

Not currently used. Reserved for future use or options.

B1. Low Steering Pressure

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

C1. Low Accumulator Precharge Pressure

The low accumulator precharge warning light, if illuminated, indicates low nitrogen precharge
for the steering accumulator(s). To check for proper accumulator nitrogen precharge, engine
must be stopped and hydraulic system completely bled down; turn keyswitch to RUN position.
The warning light will not illuminate if system is properly charged. The warning light will flash if
the nitrogen precharge within the accumulator(s) is below 1100 ± 45 psi (7585 ± 310 kPa).
If low accumulator precharge warning light flashes, notify maintenance per-
sonnel. Do not attempt further operation until the accumulators have been
recharged with nitrogen to 1400 psi (9653 kPa). Sufficient energy for emer-
gency steering may not be available, if system is not properly charged.

D1. Not Used

Not currently used. Reserved for future use or options.

E1. Low Brake Pressure

This red indicator light indicates a malfunction within the hydraulic brake circuit. If this light
comes on and buzzer sounds, shut down truck operation and notify maintenance personnel.
NOTE: Adequate hydraulic fluid is stored to allow the operator to safely stop the truck.
OM3205 Operator Cab And Controls - Section 32
Page 32-23
A2. Low Hydraulic Tank Level
This warning light indicates the oil level in the hydraulic tank is below recommended level.
Damage to hydraulic pumps may occur if operation continues. Shut truck down and notify
maintenance personnel immediately.

B2. Low Automatic Lubrication System Pressure

This amber light will illuminate if the automatic lubrication system fails to reach 2,200 PSI (at
the junction block located on the rear axle housing) within one minute after the lube timer ini-
tiates a cycle of grease. To turn the light off, turn key switch OFF, then back to ON again. Notify
maintenance personnel at earliest opportunity after light comes on.

C2. Circuit Breaker Tripped

This light will illuminate if any of the circuit breakers in the relay circuit control boards are
tripped. The relay circuit boards are located in the electrical control cabinet.
NOTE: Additional circuit breakers are in the operator cab behind the center console, however
tripping of these circuit breakers should not activate this light.

D2. Hydraulic Oil Filter Monitor

This light indicates a restriction in the high pressure filter assembly for either the steering or
hoist circuit. This light will come on before filters start to bypass. Notify maintenance personnel
at earliest opportunity after light comes on.
NOTE: The filter monitor warning light may also illuminate after the engine is initially started if
the oil is cold. If the light turns off after the oil is warmed, filter maintenance is not required.

E2. Low Fuel

This amber low fuel indicator will illuminate when the usable fuel remaining in the tank is
approximately 25 gallons (95 liters). A warning buzzer will also sound.
Operator Cab And Controls - Section 32 OM3205
Page 32-24

A3. Parking Brake

This amber parking brake indicator will illuminate when the parking brake is applied. Do not
attempt to drive truck with parking brake applied.

B3. Service Brake

This amber service brake indicator light will illuminate when the service brake pedal is applied
or when wheel brake lock or emergency brake is applied. Do not attempt to drive the truck
from stopped position with service brakes applied, except as noted in Section 30, Operating
Instructions - Starting On A Grade With A Loaded Truck.

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

D3. Dynamic Retarding

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

E3. Stop Engine

This red engine monitor warning light will illuminate if a serious engine malfunction is detected
in the electronic engine control system.
• Electric propulsion to the wheelmotors will be discontinued.
• Dynamic retarding will still be available if needed to slow or stop the truck.

Stop the truck as quickly as possible in a safe area and apply

parking brake.
SHUT DOWN THE ENGINE IMMEDIATELY. Additional engine
damage is likely to occur if operation is continued.
Listed below are a few conditions that could cause the stop engine light to illuminate:
• Low Oil Pressure - red warning light will illuminate, but engine does not shutdown.
• Low Coolant Level - red warning light will illuminate, but engine does not shutdown.
• Low Coolant Pressure - red warning light will illuminate, but engine does not shutdown.
• High Coolant Temperature - red warning light will illuminate, but engine does not shutdown.
OM3205 Operator Cab And Controls - Section 32
Page 32-25
A4. Not Used
Reserved for future use or options.

B4. Manual Backup Lights

This amber indicator will illuminate when the manually operated manual backup switch (3, Fig-
ure 32-7, Instrument Panel) is turned ON.

C4. Engine Shutdown Timer - 5 Minute Idle

When the engine shutdown timer switch has been activated (2, Figure 32-7, Instrument Panel),
this indicator light will illuminate to indicate that the shutdown timing sequence has started.
Information detailing the operation of this switch is outlined earlier in this section.

D4. Retard Speed Control Indicator

This amber light is illuminated when the RSC switch mounted on the console is pulled out to
the ON position. The light indicates the retarder is active. It is for feedback only and does not
signal a problem.

E4. Check Engine

This amber check engine indicator will illuminate if a malfunction is detected by the engine
electronic control system.
If this indicator illuminates, truck operation may continue, but maintenance personnel
should be alerted as soon as possible.
Operator Cab And Controls - Section 32 OM3205
Page 32-26

A5. No Power
This red “no retard/no propel” indicator light indicates a fault has occurred which has eliminated
the retarding and propulsion capability. A warning buzzer will also sound.
If this condition occurs, the operator should safely stop the truck, move selector switch
to NEUTRAL, apply the parking brake, shutdown the engine, and notify maintenance
personnel immediately.

B5. Propulsion System Warning

When this amber indicator is illuminated, the light indicates a “no propel” or “no retard” event
may be about to occur. It is intended to provide advance notice of these events when possible.
It does not require the operator to stop the truck, but may suggest that truck operation be
appropriately modified, in case a red alarm does occur.

C5. Propulsion System Temperature

This amber AC drive system temperature warning light indicates the drive system temperature
is above a certain level. When this condition occurs, the operator should consider modifying
truck operation in order to reduce system temperature. The operator is not required to stop the
truck at this time.

D5. High Hydraulic Oil Temperature

This red warning light indicates high oil temperature in the hydraulic tank. Several things occur
before the red light illuminates:
• If the truck is moving, and the oil temperature exceeds 221° F (105° C), the minimum idle
speed will be 1200 rpm (normally 1050).
• If the truck is moving, and the oil temperature goes above 230° F (110° C), the minimum
idle speed will be 1700 rpm (normally 1050).
• If the truck is stopped, and the oil temperature goes above 212° F (100° C) the minimum idle speed will be
1000 rpm (normally 750).
NOTE: Once the oil cools down to the normal operating range, the engine rpm will return to normal speed.
• The red warning light will illuminate if the oil temperature rises above 248° F (120° C). Continued operation
could damage components in the hydraulic system.
If this condition occurs, the operator should safely stop the truck, move selector switch to NEUTRAL, apply the
parking brake, and operate engine at 1200 - 1500 rpm to reduce system temperature.
If temperature gauge (25, Figure 32-7) does not move into the green range after a few minutes, and the red over-
head indictor light does not go out, notify maintenance personnel immediately.

E5. Stop Engine

This red engine monitor warning light will illuminate if a serious engine malfunction is detected
in the electronic engine control system.
• Electric propulsion to the wheel motors will still be available.
• Dynamic retarding will still be available if needed to slow or stop the truck.
Stop the truck as quickly as possible in a safe area and
apply parking brake. SHUT DOWN THE ENGINE IMMEDIATELY. Additional
engine damage is likely to occur if operation is continued.
An example of a condition that could cause the stop engine light to illuminate:
If engine governor senses an overspeed condition, the ECM will close the fuel solenoid and stop the flow of fuel to
the engine until engine speed is back within normal operating range.
OM3205 Operator Cab And Controls - Section 32
Page 32-27
A6. No Propel
The red “no propel” light indicates a fault has occurred which has eliminated the propulsion capability.
If this condition occurs, the operator should safely stop the truck, move selector switch to NEUTRAL,
apply the parking brake, shutdown the engine, and notify maintenance personnel, immediately.

B6. Proper System @ Rest

The amber “propel system @ rest” light is used to indicate that the AC drive system is de-energized and propulsion
is not available. This light is activated when the instrument panel rest switch is turned ON and the AC drive system
is de-energized. The three link energized lights (one on rear wall of operator cab, and two on the deck-mounted
control cabinets) should NOT be illuminated at this time.

C6. Propel System Not Ready

The amber indicator light functions during start-up much like the hourglass icon on a computer
screen. This light indicates the computer is in the process of performing the self-diagnostics
and set-up functions at start-up. Propulsion will not be available at this time.

D6. Reduced Propulsion

The amber “reduced propulsion” light is used to indicate that the full AC drive system perfor-
mance in propulsion is not available. At this time, the only event that should activate this light is
the use of “limp home mode”. This mode of operation requires a technician to enable.

E6. Retard At Continuous Level

The amber “retard continuous” light indicates the retarding effort is at the continuous level.
The operator should control the speed of the truck in accordance to the "continuous" speeds
on the grade / speed retard chart on page 32-4.
Operator Cab And Controls - Section 32 OM3205
Page 32-28

Hazard Warning Lights

Hazard warning light switch (7, Figure 32-8) flashes all the turn signal lights. Pressing the
bottom side of the rocker switch (toward the triangle) activates these lights. Pressing the
top side of the rocker switch (toward the OFF symbol) turns these lights off.

Lamp Test Switch

Lamp test switch (8, Figure 32-8) is provided to allow the operator to test the indicator
lamps prior to starting the engine. To test the lamps, and the warning horn, turn key
switch (1, Figure 32-6) to the RUN position and press the bottom side of the rocker
switch for the CHECK position. All lamps should illuminate, except those which are for
“optional” equipment that may not be installed. The warning horn should also sound. Any
lamp bulbs which do not illuminate should be replaced before operating the truck.
Releasing the spring-loaded switch will allow the switch to return to the OFF position.

Link-On Warning Light

The link on (or link energized) indicator light is located next to the D.I.D. display panel behind
the passenger seat and indicates the AC drive system is energized.
The D.I.D. display panel is for use by maintenance personnel only, and is located out of the
operator's field of vision for that reason.
OM4036 Lubrication & Service - Section 40
Page 40-1

LUBRICATION AND SERVICE

Recommended preventive maintenance will contrib- HYDRAULIC TANK SERVICE
ute to the long life and dependability of the truck and
its components. The use of proper lubricants and the There are two sight gauges on the side of the
performance of checks and adjustments at the rec- hydraulic tank. With engine stopped, keyswitch OFF,
ommended intervals is most important. hydraulic system bled down and body down, oil
should be visible in the top sight gauge. If hydraulic
Lubrication requirements are referenced to the lube oil is not visible in the top sight gauge, follow Adding
key found in the Lubrication Chart (page 40-3). For Oil instructions below.
detailed service requirements for specific compo-
nents, refer to the service manual section for that Adding Oil
component (i.e. Section H for suspensions, Section L
for hydraulic system, etc.). Keep the system open to the atmosphere only as
long as absolutely necessary to lessen chances of
Refer to manufacturer's service manual when servic- system contamination.
ing any components of the General Electric system.
Service the tank with clean Type C-4 hydraulic oil
Refer to engine manufacturer's service manual when only. All oil being put into the hydraulic tank should
servicing the engine or any of its components. be filtered through 3 micron filters.
1. With engine stopped, keyswitch OFF, hydraulic
The service intervals presented here are in hours of
system bled down and body down, check to
operation. These intervals are recommended in
see that hydraulic oil is visible in the top sight
lieu of an oil analysis program which may deter-
gauge.
mine different intervals. However, if the truck is
being operated under extreme conditions, some or 2. If hydraulic oil is not visible in the top sight
all, of the intervals may need to be shortened and the gauge, remove the tank fill cap and add clean,
service performed more frequently. filtered C-4 hydraulic oil (Lubrication Chart,
Lube Key “B”) until oil is visible in the top sight
The 930E truck is equipped with a Lincoln Automatic gauge.
Lubrication System. The initial setup for this system
3. Replace fill cap.
provides for nominal amounts of lubricant to be deliv-
ered to each serviced point. The lubrication injectors 4. Start engine. Raise and lower the dump body
can be adjusted to vary the amount of lubricant deliv- three times.
ered. In addition, the timer for lubrication intervals is 5. Repeat Steps 1 through 4 until oil is maintained
normally adjustable. For adjustments to these in the top sight gauge with engine stopped,
devices, refer to Automatic Lubrication System later body down, and hydraulic system bled down.
in this manual.

930E SERVICE CAPACITIES

WHEEL MOTOR SERVICE
Crankcase: Liters U.S.
Due to differences in gear ratio and component evo-
(including 4 oil filters) Gallons
lution/design, wheel motor service intervals may be
Komatsu SSDA16V160 Engine 280 74 unit number and/or mine specific. Because of the
Cooling System: 594 157 wide variety of factors involved, it is necessary to
Komatsu SSDA16V160 Engine consult your area Komatsu representative for all
wheel motor service intervals and instructions. Gen-
Hydraulic System: 1325 350
eral intervals for oil service and sampling are listed in
Refer to “Hydraulic Tank Service”
the interval charts.
Wheel Motor Gear Box 76 20
(each side)
Fuel Tank (Diesel Fuel Only) 4542 1200
Lubrication & Service - Section 40 OM4036
Page 40-2

COOLANT LEVEL CHECK RESERVE ENGINE OIL SYSTEM

(Optional)
Inspect the coolant sight gauge. If coolant cannot be
seen in the sight gauge, it is necessary to add cool- The reserve oil tank for the engine is designed to add
ant to the system before truck operation. Refer to the more oil capacity to the engine to reduce the frequent
procedure below for the proper filling procedure. servicing of the engine oil. The engine oil level must
still be checked every shift using the dipstick. If
RADIATOR FILLING PROCEDURE engine oil level is not correct, check for proper opera-
tion of reserve oil system. Never add oil to engine
unless it has been drained.
If the engine oil has been drained from the oil pan,
the new oil must be added to the engine oil pan
Cooling system is pressurized due to thermal before starting. Do Not use the oil in the reserve tank
expansion of coolant. Do Not remove radiator to fill an empty engine with oil. After an oil change,
cap while engine and coolant are hot. Severe both engine and reserve tank must be full of oil
burns may result. before starting the engine.
1. With engine and coolant at ambient tempera-
ture, remove radiator cap. Reserve Oil Tank Filling Procedure (Remote fill)

Note: If coolant is added using the Wiggins quick fill 1. Connect the pressure supply hose from the new
system, the radiator cap MUST be removed prior to oil supply to the quick coupler on the truck.
adding coolant. Open valve on supply hose to apply pressure.
2. Fill radiator with proper coolant mixture (as 2. Pull out on switch (2, Figure 40-1) to turn the
specified by the engine manufacturer) until system on.
coolant is visible in the sight gauge. 3. Push start switch (3). The "VALVE OPEN" light
3. Install radiator cap. (5) should illuminate and the filling process will
begin.
4. Run engine for 5 minutes, check coolant level.
4. When tank is full, the "VALVE OPEN" light will
5. If coolant is not visible in the sight gauge, repeat
turn off and the “FULL” light (4) will illuminate.
steps 1 through 4. Any excess coolant will be
discharged through the vent hose after the 5. Close the oil supply valve in the fill hose.
engine reaches normal operating temperature. 6. Press and hold start switch (3) for a couple of
7. Disconnect the new oil supply hose.
Engine coolant must always be visible in the sight
gauge before truck operation. 8. Push switch (2) in to turn system power OFF.

COOLING SYSTEM
ANTI-FREEZE RECOMMENDATIONS
(Ethylene Glycol Permanent Type Anti-Freeze)
Percentage of Protection
Anti-Freeze To:
10 + 23° F - 5° C
20 + 16° F - 9° C
25 + 11° F - 11° C
30 + 4° F - 16° C
35 - 3° F - 19° C
40 - 12° F - 24° C
45 - 23° F - 30° C
50 - 34° F - 36° C
55 - 48° F - 44° C
60 - 62° F - 52° C FIGURE 40-1.
Use only anti-freeze that is compatible with engine as
specified by engine manufacturer. 1. Remote Control Box 4. “FULL” Light
2. System Switch 5. “VALVE OPEN”
3. Start Switch Light
OM4036 Lubrication & Service - Section 40
Page 40-3

LUBRICATION CHART
 Lubrication & Service - Section 40 OM4036
Page 40-4

10 HOUR (DAILY) INSPECTION

Truck Serial Number______________________ Site Unit Number_______________ Date_______________

Hourmeter_____________ Name of Service Technician___________________________________

TASK COMMENTS CHECKED INITIALS

1. MACHINE - Inspect the entire machine for leaks,
worn parts, and damage. Repair as necessary.
2. FAN DRIVE AND TURBOCHARGERS - Check for
leaks, vibration or unusual noise. Check alternator
and fan belt condition and alignment.
3. RADIATOR - Check the coolant level and fill with the
proper mixture as shown in the Cooling System Rec-
ommendation Chart in this chapter. Refer to the
engine manual for proper coolant additives.
4. ENGINE -
a. Check the oil level on the dipstick. Refer to
the engine manual for oil recommendations.
(Lube Key “A”).
NOTE: If the truck is equipped with a reserve engine
oil tank, the oil should be visible in the center (middle)
sight gauge. If not, add oil to the reserve tank until oil
is visible in the top sight gauge. Also, with the engine
running, check operation of the LED indicator light.
See below for description of LED light signals. Refer
to Figure 40-1.
LED Light Signals:
• Steady - Pump 1 is withdrawing oil from the
engine sump and bringing down the oil level.
• Regular pulsing - Pump 2 is returning oil to the
engine sump and raising the oil level.
• Irregular pulsing - Oil is at the correct running
level.

b. Inspect exhaust piping for security.

c. Check for abnormal noises and fluid leaks.
5. HYDRAULIC TANK - Check the oil level in the tank;
add oil if necessary. Refer to Section L, Hydraulic
Tank - Filling Instructions. Oil should be visible in the
sight glass. - Do Not overfill. Lube Key “B”.
6. BATTERIES - Check the electrolyte level and add
water if necessary.
7. 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.
8. COOLING AIR DUCTWORK - Inspect ductwork from
the blower to the rear drive case. Ensure that duct-
work is secure, free of damage, and unrestricted.
 OM4036 Lubrication & Service - Section 40
Page 40-5

10 HOUR (DAILY) INSPECTION (Continued)

Truck Serial Number______________________ Site Unit Number_______________ Date_______________

Hourmeter_____________ Name of Service Technician___________________________________

TASK COMMENTS CHECKED INITIALS

9. AIR INTAKE PIPING - Check all mounting hardware,
joints, and connections. Ensure no air leaks exist and
all hardware is properly tightened. Figure 40-2.
10. AIR CLEANERS - Check the air cleaner vacuum
gauges in the operator cab, Figure 40-3. The air
cleaner(s) should be serviced if the gauge(s) shows
the following maximum restriction:
Komatsu SSDA16V160 Engine:
. . . . . . . . . . . . . . . . . . . . . . . . 25 in. of H2O vacuum.
Refer to Section C in the service manual for servicing
instructions for the air cleaner elements. Empty the air
cleaner dust caps.
NOTE: After service, push the reset button on face of
gauge to allow the gauge to return to zero.
11. BODY-UP & HOIST LIMIT SWITCHES - Clean the
sensing areas of any dirt accumulation and inspect
the wiring for any signs of damage.
12. 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 40 psi
(275 kPa). Reinstall the filter. Refer to Figure 40-4.

FIGURE 40-2. FIGURE 40-3. FIGURE 40-4.

1. Filter Cover 2. Cab Filter
 Lubrication & Service - Section 40 OM4036
Page 40-6

10 HOUR (DAILY) INSPECTION (Continued)

Truck Serial Number______________________ Site Unit Number_______________ Date_______________

Hourmeter_____________ Name of Service Technician___________________________________

TASK COMMENTS CHECKED INITIALS

13. FUEL FILTERS (Fuel Separators) - Drain water from
the bottom drain valve on each fuel separator.
14. AUTOMATIC LUBE SYSTEM -
• Check the grease reservoir; fill as required. Lube
Key “D”.
• When filling the reservoir, check the grease filter
indicator. Clean or replace the grease filter if the
indicator detects a problem.
• Inspect the system and check for proper
operation. Be certain the following important
areas are receiving adequate amounts of grease.
Lube Key “D”.
Steering Linkage
Final Drive Pivot Pin -
Rear Suspension Pin Joints - Upper & Lower
Body Hinge Pins -
Hoist Cylinders Pins - Upper & Lower
Anti-sway Bar - Both Ends
 OM4036 Lubrication & Service - Section 40
Page 40-7

50 HOUR LUBRICATION AND MAINTENANCE CHECKS

Truck Serial Number______________________ Site Unit Number_______________ Date_______________

Hourmeter_____________ Name of Service Technician___________________________________

TASK COMMENTS CHECKED INITIALS

*1. FUEL FILTERS - Change the fuel filters, (fuel
separators).
Refer to engine manufacturer's maintenance manual
for fuel filter replacement instructions.
*2. HYDRAULIC SYSTEM FILTERS - Replace filter ele-
ments only, after the initial 50, 100, and 250 hours of
operation; then at each 500 hours of operation there-
after.

*These checks are required only after the initial hours of operation (such as: the commissioning of a new truck,
or after a new or rebuilt component installation).
 Lubrication & Service - Section 40 OM4036
Page 40-8

100 HOUR LUBRICATION AND MAINTENANCE CHECKS

Truck Serial Number______________________ Site Unit Number_______________ Date_______________

Hourmeter_____________ Name of Service Technician___________________________________

TASK COMMENTS CHECKED INITIALS

*1. HYDRAULIC SYSTEM FILTERS - Replace filter ele-
ments only, after the initial 100 and 250 hours of
operation; then at each 500 hours of operation there-
after.

*These checks are required only after the initial hours of operation (such as: the commissioning of a new truck,
or after a new or rebuilt component installation), check:
 OM4036 Lubrication & Service - Section 40
Page 40-9

250 HOUR LUBRICATION AND MAINTENANCE CHECKS

The 10 hour lubrication and maintenance checks should also be performed at this time.
NOTE: “Lube Key” references are to the Lubrication Chart.

Truck Serial Number______________________ Site Unit Number_______________ Date_______________

Hourmeter_____________ Name of Service Technician___________________________________

TASK COMMENTS CHECKED INITIALS

1. ENGINE - Refer to Cummins Operation & Mainte-
nance manual for complete specifications regarding
engine lube oil specifications.
NOTE: If the engine is equipped with the *Centinel™
oil system and/or the Eliminator™ filter system,
engine oil and filter change intervals are extended
beyond 250 hours. Refer to Cummins Operation &
Maintenance manual for specific oil and filter change
intervals.
* The Centinel™ system is a duty-cycle-dependent
lubrication management system whereby oil is
blended with the fuel and burned and an extension of
oil change intervals can occur.
a. Change engine oil. Lube Key “A”.
b. Replace lube oil filters.
NOTE: When installing spin-on filter elements, follow
the instructions as specified by the filter manufacturer.
The tightening instructions are normally printed on the
outside of the filter. Do not use a wrench or strap to
tighten filter elements.
c. If the truck is equipped with a reserve engine
oil tank, change the reserve tank oil filter.
d. Check belt tension and condition of each
accessory belt. Refer to Cummins Operation
& Maintenance manual for specific adjust-
ment instructions.
e. Check the torque on the mounting capscrews
on cooling fan (1, Figure 40-5). Tighten eight
capscrews (2) to 175 ft.lbs. (237 Nm).
2. COOLING SYSTEM -
a. COOLANT MIXTURE - Check for proper
coolant mixture. Add coolant as required.
b. COOLANT FILTERS - Change coolant filters.
c. COOLING SYSTEM HOSES - Check cooling
system hoses for damage and signs of deteri-
oration.
Refer to the Cummins maintenance manual for cool-
ant filter replacement instructions and proper coolant
mixture instructions.

(CONTINUED NEXT PAGE)

 Lubrication & Service - Section 40 OM4036
Page 40-10

250 HOUR LUBRICATION AND MAINTENANCE (Continued)

TASK COMMENTS CHECKED INITIALS

3. FUEL FILTERS - Change the fuel filters (fuel separa-
tors). Refer to Cummins Operation & Maintenance
manual for specific filter replacement instructions.
4. FUEL TANK - Drain water and sediment from the fuel
tank. Refer to Section B, Fuel Tank - Cleaning.
5. STEERING LINKAGE - Check the torque on pin
retaining nuts (1, Figure 40-6) on the steering linkage.
(525 ft.lbs. (712 N.m) Check the torque on tie rod
retaining nuts (2). (310 ft.lbs. (420 N.m)
6. HYDRAULIC PUMP DRIVESHAFT & U-JOINTS -
Add one or two applications of grease to each grease
fitting. Check that each bearing of the cross & bearing
assembly is receiving grease. Lube Key “D”.
7. REAR WHEEL MOUNTING - Using a mirror on a long
rod and a flashlight, inspect all inner and outer wheel
mounting nuts/studs for any evidence of looseness,
damage, or missing hardware.
If wheel mounting nuts/studs must be secured or
replaced, the outer wheel must be removed for
access. Refer to the Shop manual, Section G, for
these procedures.

FIGURE 40-5. FIGURE 40-6.

 OM4036 Lubrication & Service - Section 40
Page 40-11

250 HOUR LUBRICATION AND MAINTENANCE (Continued)

TASK COMMENTS CHECKED INITIALS

8. REAR AXLE HOUSING - Check the rear axle housing
for fluid leaks by removing the two drain plugs on the
bottom of the axle housing. If fluid is present, the
cause must be found and corrected before releasing
the truck to operation.
9. MAGNETIC PLUG - Remove the magnetic plugs from
the front wheel hub covers and inspect for debris.
Clean the plugs and perform any necessary repairs.
Refer to Figure 40-7.
10. MOTORIZED WHEELS - Check for the correct oil
level. Rotate a magnetic plug to the 6 o’clock position
and remove the plug. The oil level should be even
with the bottom of the plug opening. Inspect the mag-
netic plugs for ferrous materials. Service the wheel
motor as necessary. Refer to Figure 40-8.
11. WHEEL MOTOR OIL SAMPLING - Refer to Section
G5, Wheel Motor, for oil sampling information.
*12. HYDRAULIC SYSTEM FILTERS - Replace filter ele-
ments only after the initial 250 hours of operation;
then at each 500 hours of operation thereafter. Check
oil level. Add oil as necessary. Lube Key “B”.

*This check is required only after the first 250 hours of operation (such as: the commissioning of a new truck,
or after a new or rebuilt component installation), check:

FIGURE 40-7.
 Lubrication & Service - Section 40 OM4036
Page 40-12

500 HOUR LUBRICATION AND MAINTENANCE CHECKS

Maintenance requirements for every 10, 50, & 250 hour Lubrication and Maintenance Checks should also be car-
ried out at this time.
NOTE: “Lube Key” references are to the Lubrication Chart.

Truck Serial Number______________________ Site Unit Number_______________ Date_______________

Hourmeter_____________ Name of Service Technician___________________________________

TASK COMMENTS CHECKED INITIALS

1. FINAL DRIVE CASE BREATHERS - Remove the
breather elements for the motorized wheels. Clean or
replace the elements.
2. HYDRAULIC SYSTEM FILTERS - Replace the tank
breathers and high pressure filter elements. Check
the oil level. Add oil as necessary. Lube Key “B”.
3. 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. BODY-UP & HOIST LIMIT SWITCHES - Check oper-
ation of the switches. Clean and adjust as necessary.
6. HOIST ACTUATOR LINKAGE - Check operation.
Clean, lubricate, and adjust as necessary.
7. PARKING BRAKE - Refer to Section J, Parking Brake
Maintenance. Perform the recommended inspections.
8. RESERVE ENGINE OIL SYSTEM (OPTIONAL)
a. Check electrical system connections for tight-
ness, corrosion and physical damage. Check
the battery, oil pressure switch, junction
boxes, remote control fill box and the circuit
breakers.
b. Examine all electrical cables over their entire
length for possible damage.
c. Examine all hoses, including those on the
reserve tank and the ones leading to and
from the engine. Check for leaks, cracks or
other damage. Check all fittings for tightness,
leakage or damage.
9. WHEEL MOTOR OIL (Initial 500 hours only) -
Change or filter wheel motor gear oil only after initial
500 hours or operation. Wheel motor gear oil must be
filtered or changed every 2500 hours of operation
thereafter.
 OM4036 Lubrication & Service - Section 40
Page 40-13

1000 HOURS LUBRICATION AND MAINTENANCE CHECKS

Maintenance for every 10, 250, & 500 hour Lubrication and Maintenance Checks should be performed at this time.
NOTE: “Lube Key” references are to the Lubrication Chart.

Truck Serial Number______________________ Site Unit Number_______________ Date_______________

Hourmeter_____________ Name of Service Technician___________________________________

TASK COMMENTS CHECKED INITIALS

1. HYDRAULIC TANK - Drain the hydraulic tank and
clean the inlet strainer. Refill the tank with oil; approx-
imate capacity 250 gal. (947 l). Use Lube Key “B”.
2. RADIATOR - Clean the cooling system with a quality
cleaning compound. Flush with water. Refill the sys-
tem with anti-freeze and water solution. Check the
Cooling System Recommendation Chart in this sec-
tion for the correct mixture. Refer to the Cummin’s
Operation and Maintenance Manual for the correct
additive mixture.
3. FUEL TANK - Remove the breather and clean in sol-
vent. Dry with pressurized air and reinstall.
4. OPERATOR'S SEAT - Apply grease to the slide rails.
Lube Key “D”.
5. AUTOMATIC BRAKE APPLICATION - Ensure the
brakes are automatically applied when brake pres-
sure decreases below the specified limit. Refer to
Section J, Brake Check-out Procedure.
6. AUXILIARY BLOWER - Apply a few applications of
grease to the auxiliary blower bearings. Two grease
zerks (1, Figure 40-9) are located on blower (2).

FIGURE 40-8. AUXILIARY BLOWER

1. Grease Zerk 2. Auxiliary Blower
Lubrication & Service - Section 40 OM4036
Page 40-14

2500 HOUR MAINTENANCE CHECKS

Truck Serial Number______________________ Site Unit Number_______________ Date_______________

Hourmeter_____________ Name of Service Technician___________________________________

TASK COMMENTS CHECKED INITIALS

WHEEL MOTOR GEAR OIL - Wheel motor gear oil
must be filtered or changed every 2500 hours of oper-
ation.

5000 HOUR MAINTENANCE CHECKS

Truck Serial Number______________________ Site Unit Number_______________ Date_______________

Hourmeter_____________ Name of Service Technician___________________________________

TASK COMMENTS CHECKED INITIALS

AIR CLEANERS - Clean the Donaclone tubes in the
pre-cleaner section of the air filter. Use low pressure
cold water or low pressure air to clean the tubes.
Refer to Section C, Air Cleaners.
NOTE: Do not use a hot pressure washer or high
pressure air to clean the tubes. Hot water/high pres-
sure causes the pre-cleaner tubes to distort.
OM4200 Automatic Lubrication System - Section 42
Page 42-1

AUTOMATIC LUBRICATION SYSTEM

GENERAL DESCRIPTION During the down stroke, the pump cylinder is
extended into the grease. Through the combination
The Lincoln Automatic Lubrication System is a pres- of shovel action and vacuum generated in the pump
surized lubricant delivery system which delivers a cylinder chamber, the grease is forced into the pump
controlled amount of lubricant to designated lube cylinder. Simultaneously, grease is discharged
points. The system is controlled by an electric timer through the outlet of the pump. The volume of grease
which signals a solenoid valve to operate a hydraulic during intake is twice the amount of grease output
motor powered grease pump. Hydraulic oil for pump during one cycle. During the upstroke, the inlet check
operation is supplied by the truck steering circuit. valve closes, and one half the grease taken in during
Grease output is proportional to the hydraulic motor the previous stroke is transferred through the outlet
input flow. A pump control manifold, mounted on top check and discharged to the outlet port.
of the hydraulic motor, controls input flow and pres-
sure. A 24VDC Solenoid mounted on the manifold
turns the pump on and off.
The pump is driven by the rotary motion of the
hydraulic motor, which is then converted to recipro-
cating motion through an eccentric crank mecha- Over-pressurizing of the system, modifying
nism. The reciprocating action causes the pump parts, using incompatible chemicals and fluids,
cylinder to move up and down. The pump is a posi- or using worn or damaged parts, may result in
tive displacement, double-acting type as grease out- equipment damage and/or serious personal
put occurs on both the up and the down stroke. injury.
• DO NOT exceed the stated maximum working
pressure of the pump, or of the lowest rated
component in the system.
• Do not alter or modify any part of this system
unless approved by factory authorization.
• Do not attempt to repair or disassemble the
equipment while the system is pressurized.
• Make sure all fluid connections are securely
tightened before using this equipment.
• Always read and follow the fluid
manufacturer's recommendations regarding
fluid compatibility, and the use of protective
clothing and equipment.
• Check all equipment regularly and repair, or
replace, worn or damaged parts immediately.

This equipment generates very high grease pres-

sure. Extreme caution should be used when
operating this equipment as material leaks from
loose or ruptured components can inject fluid
through the skin and into the body causing seri-
ous bodily injury including possible need for
FIGURE 42-1. PUMP AND RESERVOIR
amputation. Adequate protection is recom-
COMPONENTS
mended to prevent splashing of material onto the
1. Hose from Filter 7. Pressure Gauge skin or into the eyes.
2. Outlet to Injectors 8. Pump Assembly
3. Hydraulic Motor 9. Flow Control Valve If any fluid appears to penetrate the skin, get
4. Pressure 10. Pressure Switch emergency medical care immediately! Do not
Reducing Valve 11. Relay Box treat as a simple cut. Tell attending physician
5. Solenoid Valve 12. Grease Reservoir exactly what fluid was injected.
6. Vent Valve 13. Vent Hose
Automatic Lubrication System - Section 42 OM4200
Page 42-2

FIGURE 42-2. AUTO LUBE SYSTEM INSTALLATION

NOTE: The above illustration shows the standard location for the lube pump & reservoir (right platform). This
assembly may be located on left platform on some models.

1. L.H. Suspension, Top Bearing 13. R.H. Hoist Cylinder, Top Bearing
2. L.H. Suspension, Bottom Bearing 14. R.H. Hoist Cylinder, Bottom Bearing
3. L.H. Body Pivot Pin 15. R.H. Anti-Sway Bar Bearing
4. L.H. Hoist Cylinder, Top Bearing 16. Vent Hose
5. L.H. Hoist Cylinder, Bottom Bearing 17. Junction Box
6. L.H. Anti-Sway Bar Bearing 18. Pressure Switch, N.O., 2500 psi (17 237 kPa)
7. Rear Axle Pivot Pin 19. Grease Pump
8. Grease Supply From Pump 20. Vent Valve
9. Pressure Switch, N.O., 2000 psi (13 789 kPa) 21. Filter
10. R.H. Suspension, Top Bearing 22. Grease Supply to Injectors
11. R.H. Suspension, Bottom Bearing 23. Truck Frame
12. R.H. Body Pivot Pin 24. Injector
OM4200 Automatic Lubrication System - Section 42
Page 42-3

SYSTEM COMPONENTS Vent Valve (6, Figure 42-1)

With the vent valve closed, the pump continues to
Filter (21, Figure 42-2)
operate until maximum grease pressure is achieved.
A filter assembly mounted on the grease reservoir fil- As this occurs, the vent valve opens and allows the
ters the grease prior to refilling the reservoir from the grease pressure to drop to 0, so the injectors can
shop supply. A bypass indicator alerts service per- recharge for their next output cycle.
sonnel when the filter requires replacement.
Lubrication Cycle Timer (1, Figure 42-4)
Hydraulic Motor and Pump (3 & 8, Figure 42-1)
The solid state lubrication cycle timer provides a 24
The rotary hydraulic pump is a fully hydraulically VDC timed-interval signal to energize the solenoid
operated grease pump. An integrated pump control valve (5, Figure 42-1), providing oil flow to operate
manifold is incorporated with the motor to control the grease pump motor. This timer is mounted in the
input flow and pressure. Electrical Interface Cabinet.
Note: The pump crankcase oil level must be Delay Timer (11, Figure 42-4)
maintained to the level of the pipe plug port. If
necessary, refill with 10W-30 motor oil. The delay timer, located in the Electrical Interface
Cabinet, provides a one minute delay in the low pres-
sure warning lamp circuit to allow a normally operat-
ing system to attain full grease system pressure
without activating the warning lamp. If the system
fails to reach 2000 psi (13 789 kPa) within this time
period, the timer will apply 24VDC to several relays
Hydraulic oil supply inlet pressure must not
which will illuminate the low pressure warning lamp in
exceed 3000 psi (20 685 kPa). Exceeding the
the overhead display. An external 604K ohm resistor
rated pressure may result in damage to the sys-
determines the delay period.
tem components and personal injury.
Pump Cutoff Pressure Switch (N.O. 2500 psi [17
237 kPa]) (10, Figure 42-1)
Grease Reservoir (12, Figure 42-1)
This pressure switch de-energizes the pump sole-
The reservoir has an approximate capacity of 60 lbs. noid relay when the grease line pressure reaches the
(27 kg) of grease. When the grease supply is replen- switch pressure setting, turning off the motor and
ished by filling the system at the service center, the pump.
grease is passed through the filter to remove con-
taminants before it flows into the reservoir. Grease Pressure Failure Switch (N.O. 2000 psi
[13 789 kPa]) (9, Figure 42-2)
Pressure Reducing Valve (4, Figure 42-1)
This pressure switch monitors grease pressure in the
The pressure reducing valve, located on the manifold injector bank on the rear axle housing. If the proper
reduces the hydraulic supply pressure (from the truck pressure is not sensed within 60 seconds (switch
steering circuit) to a suitable operating pressure, contacts do not close), several relays energize, actu-
[325-350 psi (2 240-2 415 kPa)] for the hydraulic ating a warning lamp circuit to notify the operator a
motor used to drive the lubricant pump. problem exists in the lube system.

Flow Control Valve (9, Figure 42-1) Pressure Gauge (7, Figure 42-1)
The flow control valve mounted on the manifold, con- The pressure gauge monitors hydraulic oil pressure
trols the amount of oil flow to the hydraulic motor. to the inlet of the hydraulic motor.
The flow control valve has been factory adjusted
and the setting should not be disturbed. Injectors (24, Figure 42-2)
Each injector delivers a controlled amount of pres-
Solenoid Valve (5, Figure 42-1)
surized lubricant to a designated lube point. Refer to
The solenoid valve, when energized, allows oil to Figure 42-2 for locations.
flow to the hydraulic motor.
Automatic Lubrication System - Section 42 OM4200
Page 42-4

SYSTEM OPERATION
Normal Operation
1. During truck operation, the lubrication cycle timer
(1, Figure 42-4) will energize the system at a 5. During this period, the injectors will meter the
preset time interval. appropriate amount of grease to each lubrication
2. The timer provides 24 VDC through the normally point.
closed relay, RB7K5 (4) used to energize the 6. When grease pressure reaches the pressure
pump solenoid valve (5), allowing hydraulic oil switch (3, Figure 42-4) setting, the switch con-
provided by the truck steering pump circuit to tacts will close and energize the relay RB7K5,
flow to the pump motor and initiate a pumping removing power from the hydraulic motor/pump
cycle. solenoid and the pump will stop. The relay will
3. The hydraulic oil pressure from the steering cir- remain energized until grease pressure drops
cuit is reduced to 325 to 350 psi (2 240 to 2 413 and the pressure switch opens again or until the
kPa) by the pressure reducing valve (4, Figure timer turns off.
42-3) before entering the motor. In addition, the 7. After the pump solenoid valve is de-energized,
amount of oil supplied to the pump is limited by hydraulic pressure in the manifold drops and the
the flow control valve (6). Pump pressure can be vent valve will open, releasing grease pressure
read using the gauge (5) mounted on the mani- in the lines to the injector banks. When this
fold. occurs, the injectors are then able to recharge for
4. With oil flowing into the hydraulic motor, the the next lubrication cycle.
grease pump will operate, pumping grease from 8. The system will remain at rest until the lubrication
the reservoir to the injectors (13), through a cycle timer turns on and initiates a new grease
check valve (10) and to the vent valve (11). cycle.

FIGURE 42-3. HYDRAULIC SCHEMATIC

1. Hydraulic Oil Return 6. Flow Control Valve 11. Vent Valve
2. Hydraulic Oil Supply 7. Hydraulic Motor 12. Orifice
3. Pump Solenoid Valve 8. Grease Pump 13. Injector Bank
4. Pressure Reducing Valve 9. Pressure Switch (N.O.)
5. Motor Pressure Gauge 10. Check Valve
OM4200 Automatic Lubrication System - Section 42
Page 42-5

Pressure Failure Detection Circuits will energize relay RB7K4 (12) after 60 seconds,
turning on the “low lube system pressure” warn-
1. When the lubrication cycle is initiated, 24VDC
ing lamp on the overhead display. After RB7K4
flows through relay RB7K1 (7, Figure 42-4) N.C.
relay energizes, it will energize relay RB7K3
contacts to a 1 minute delay timer (11).
(10).
2. If the system is operating normally, grease pres-
4. Once RB7K3 is energized, it will latch and
sure at the rear axle injector bank will rise to
remain energized as long as the keyswitch is on.
pressure switch (6) setting of 2000 psi (13.8
In addition, RB7K4 will also remain energized
MPa) and energize relay RB7K1 (7), removing
and the “low lube pressure” warning lamp will
24VDC from the delay timer.
remain on to notify the operator a problem exists
3. If a problem occurs and the system is not able to and the system requires service.
attain 2000 psi (13.8 MPa), the delay timer (11)

FIGURE 42-4. ELECTRICAL SCHEMATIC

1. Lubrication Cycle Timer 9. Circuit Breaker CB9 (In Electrical Interface
2. Circuit Breaker CB7 (In Electrical Interface Cabinet)
Cabinet) 10. Relay K3 (On Relay Board RB7)
3. Pressure Switch; N.O., 2500 psi (17 237) 11. Circuit Time Delay Module
4. Relay K5 (On Relay Board RB7) 12. Relay K4 (On Relay Board RB7)
5. Grease Pump Motor Solenoid Valve 13. Low Grease Pressure Warning Lamp (On
6. Pressure Switch; N.O. 2000 psi (13 790) Overhead Display Panel)
7. Relay K1 (On Relay Board RB7) 14. Warning & Caution Lamp Test Switch (On
8. Lube System Manual Test Switch Overhead Display Panel)
Automatic Lubrication System - Section 42 OM4200
Page 42-6

GENERAL INSTRUCTIONS
Required Lubricant For System
Grease requirements will depend on ambient tem-
peratures encountered during truck operation:
• Above 90°F (32°C) - Use NLGI No.2
multipurpose grease (MPG).
• -25° to 90°F (-32° to 32°C) - Use NLGI No. 1
multipurpose grease (MPG).
• Below -25°F (-32°C) - Refer to local supplier for
extreme cold weather lubricant requirements.

System Priming
The system must be full of grease and free of air
pockets to function properly. After maintenance, if the
primary or secondary lubrication lines were replaced,
it will be necessary to re-prime the system to eject all
entrapped air.
1. Fill lube reservoir with lubricant, if necessary.
2. To purge air from the main supply line, remove
the main supply line at the Lincoln Lube canis-
ter and connect an external grease supply to
the line.
3. Remove plugs from each injector group in
sequence (right front, left front, and rear axle).
4. Using the external grease source, pump grease
until grease appears at the group of injectors
and re-install the pipe plug. Repeat for remain-
ing injector groups.
5. Remove the caps from each injector and con-
nect an external grease supply to the zerk on FIGURE 42-5. FILTER ASSEMBLY
the injector and pump until grease appears at
the far end of the individual grease hose or the 1. Housing 6. Spring
joint being greased. 2. Bypass Indicator 7. Bowl
3. O-Ring 8. O-Ring
4. Backup Ring 9. Plug
5. Element
Filter Assembly
The filter assembly element (5, Figure 42-5) should
be replaced if the bypass indicator (2) shows exces-
sive element restriction.
OM4200 Automatic Lubrication System - Section 42
Page 42-7

LUBRICANT PUMP
Pump Housing Oil Level
The pump housing must be filled to the proper level
with SAE 10W-30 motor oil. Oil level should be
checked at 1000 hour intervals. To add oil, remove
pipe plug (3, Figure 42-6) and fill housing to bottom
of plug hole.

Pump Pressure Control

High pressure hydraulic fluid from the truck steering
system is reduced to 325 to 350 psi (2 240 to 2 413
kPa) by the pressure reducing valve located on the
manifold on top of the pump motor. This pressure
can be read on the gauge installed on the manifold
and should be checked occasionally to verify pres-
sure is within the above limits.

Pressure Control Valve Adjustment FIGURE 42-6. PUMP CONTROLS

1. With the truck engine running, activate the lube
system manual test switch to start the hydraulic 1. Pump Pressure 3. Oil Level Plug
motor and pump. Control 4. Flow Control Valve
2. Loosen the locknut on the pressure control (1, 2. Pressure Gauge
Figure 42-6) by turning the nut counterclock-
wise.
3. Turn the valve stem counterclockwise until it no
longer turns. (The valve stem will unscrew until
it reaches the stop - it will not come off.)
Note: This is the minimum pressure setting, which is
about 170 psi (1 172 kPa).
4. With the pump stalled against pressure, turn the
pressure control valve stem clockwise until 325
to 350 psi (2 240 to 2 413 kPa) is attained on
the manifold pressure gauge (2).
5. Tighten the locknut to lock the stem in position.
Note: The flow control valve (4) is factory adjusted to
2.5 GPM (9.5 L/min.). Do not change this setting.
Automatic Lubrication System - Section 42 OM4200
Page 42-8

INJECTOR OPERATION

STAGE 1.
The injector piston (2) is in its normal or
“rest” position. The discharge chamber (3) is
filled with lubricant from the previous cycle.
Under the pressure of incoming lubricant (6),
the slide valve (5) is about to open the pas-
sage (4) leading to the measuring chamber
(1) above the injector piston (2).

STAGE 2.
When the slide valve (5) uncovers the pas-
sage (4), lubricant (6) is admitted to the mea-
suring chamber (1) above the injector piston
(2) which forces lubricant from the discharge
chamber (3) through the outlet port (7) to the
bearing.

STAGE 3.
As the injector piston (2) completes its
stroke, it pushes the slide valve (5) past the
passage (4), cutting off further admission of
lubricant (6) to the passage (4) and measur-
ing chamber (1). The injector piston (2) and
slide valve (5) remain in this position until
lubricant pressure in the supply line (6) is
vented.

STAGE 4.
After venting, the injector spring expands,
causing the slide valve (5) to move, so that
the passage (4) and discharge chamber (3)
are connected by a valve port (8). Further
expansion of the spring causes the piston to
move upward, forcing the lubricant in the
measuring chamber (1) through the passage
(4) and valve port (8) to refill the discharge
chamber (3).

Injector is now ready for the next cycle.

OM4200 Automatic Lubrication System - Section 42
Page 42-9

INJECTORS (SL-1 Series “H”))

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

Injector Adjustment
FIGURE 42-7. TYPE SL-1 INJECTOR
The injectors may be adjusted to supply from 0.008
in3 to 0.08 in3 (0.13 cc to 1.31 cc) of lubricant per 1. Adjusting Screw 11. Spring Seat
injection cycle. The injector piston travel distance 2. Locknut 12. Plunger
determines the amount of lubricant supplied. This 3. Piston Stop Plug 13. Viton Packing
travel is in turn controlled by an adjusting screw in 4. Gasket 14. Inlet Disc
the top of the injector housing. 5. Washer 15. Viton Packing
6. Vito O-Ring 16. Washer
Turn the adjusting screw (1, Figure 42-7) counter- 7. Injector Body Assy. 17. Gasket
clockwise to increase lubricant amount delivered and 8. Piston Assembly 18. Adapter Bolt
clockwise to decrease the lubricant amount. 9. Fitting Assembly 19. Adapter
When the injector is not pressurized, maximum injec- 10. Plunger Spring 20. Viton Packing
tor delivery volume is attained by turning the adjust-
ing screw (1) fully counterclockwise until the
indicating pin (8) just touches the adjusting screw. At
the maximum delivery point, about 0.38 inch (9.7
NOTE: Piston assembly (8) has a visible indicator pin
mm) adjusting screw threads should be showing.
at the top of the assembly to verify the injector
Decrease the delivered lubricant amount by turning
operation.
the adjusting screw clockwise to limit injector piston
travel. If only half the lubricant is needed, turn the
adjusting screw to the point where about 0.19 inch
(4.8 mm) threads are showing. The injector will be
set at minimum delivery point with about 0.009 inch
(0.22 mm) thread showing.
NOTE: The above information concerns adjustment
of injector delivery volume. The timer adjustment
should also be changed, if overall lubricant delivery is
too little or too much. Injector output should NOT be
adjusted to less than one-fourth capacity.
Automatic Lubrication System - Section 42 OM4200
Page 42-10

SYSTEM CHECKOUT
To check system operation (not including timer), pro-
ceed as follows:
1. Turn keyswitch ON and start the engine.
2. Actuate the lube system test switch at the reser-
voir/pump assembly on the front bumper.
3. The motor and pump should operate until the
system attains 2500 psi (17 237 kPa).
4. Once the required pressure is achieved, the
pump motor should turn off and the system
should vent.
5. Check for pump, hose or injector damage or
leakage with the system under pressure.
6. After checking system, shutdown engine,
observing normal precautions regarding high
voltage present in the propulsion system before
attempting to repair lube system.
FIGURE 42-8. TIMER (TOP COVER REMOVED)

1. Timer Enclosure
Lubrication Cycle Timer Check
2. Red LED (Light Emitting Diode)
To check the solid state timer operation without wait- 3. Timer Selector
ing for the normal timer setting, proceed as follows:
1. Remove timer dust cover. Lubrication Cycle Timer Adjustment
NOTE: The timer incorporates a liquid and dust tight The timer is factory set for a nominal 2.5 minute (off
cover which must be in place and secured at all times time) interval. Dwell time is approximately 1 minute,
during truck operation. 15 seconds. A longer interval (off time) is obtained by
2. Adjust timer selector (3, Figure 42-8) to 5 minute turning the selector knob (3, Figure 42-8) to the
interval setting. desired position.
3. The timer should cycle in five minutes if the truck NOTE: Set timer by turning the selector knob (3) to
is operating. the 2.5 minute setting point. Then, turn the Selector
NOTE: If the timer check is being made on a cold clockwise, one detent at a time, to the desired
start, the first cycle will be approximately double the setting, or until the maximum limit of eighty minutes
nominal setting. All subsequent cycles should be is reached.
within the selected time tolerance. The timer is a sealed unit, do not attempt disas-
4. Voltage checks at the timer should be accom- sembly.
plished if the above checks do not identify the
problem.
a. Insure timer ground connection is clean
and tight.
b. Using a volt-ohm meter, read the voltage
between positive and negative posts on the
solid state timer with the truck keyswitch
ON. Normal reading should be 18-26 VDC,
depending upon whether or not the engine
is running.
OM4200 Automatic Lubrication System - Section 42
Page 42-11

SYSTEM TROUBLESHOOTING CHART

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

POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION

TROUBLE: Pump Does Not Operate

Lube system not grounded. Correct grounding connections to pump assembly

and truck chassis.
Electrical power loss. Locate cause of power loss and repair. Check circuit
breaker CB7. Be sure keyswitch is "ON".
Timer malfunction. Replace timer assembly.
Solenoid valve malfunctioning. Replace the solenoid valve assembly.
RB7K5 Relay malfunctioning Replace relay.
Motor or pump malfunction. Replace motor and/or pump assembly.
Pressure switch defective Replace pressure switch.

NOTE: On initial startup of the lube system, the timing capacitor will not contain a charge, therefore the first timing
cycle will be about double in length compared to the normal interval. Subsequent timer cycles should be as
specified.

TROUBLE: Pump Will Not Prime

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

TROUBLE: Pump Will Not Build Pressure

Air trapped in lubricant supply line. Prime system to remove trapped air.
Lubricant supply line leaking. Check lines and connections to repair leakage.
Vent valve leaking. Clean or replace vent valve.
Pump worn or scored. Repair or replace pump assembly.

TROUBLE: Injector Indicator Stem Does Not Operate

NOTE: Normally, during operation, the injector indicator stem will move into the body of the injector when pressure
builds properly. When the system vents (pressure release) the indicator stem will again move out into the adjusting
yoke.

Malfunctioning injector - usually indicated by Replace individual injector assembly.

the pump building pressure and then venting.
All injectors inoperative - pump build up not Service and/or replace pump assembly.
sufficient to cycle injectors.
Automatic Lubrication System - Section 42 OM4200
Page 42-12

POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION

TROUBLE: Pressure Gauge Does Not Register Pressure

No system pressure to the pump motor. Check hydraulic hose from steering system.
No 24 VDC signal at pump solenoid. Determine problem in 24 VDC electric system.
Pressure reducing valve set too low. Refer to Pressure Control Valve Adjustment.
Relay (RB7K5) may be defective. Replace relay.

TROUBLE: Pump Pressure Builds Very Slowly Or Not At All

No signal at RB7K5 relay. Check Timer and CB7.

Pressure switch may be defective. Replace pressure switch.
Pressure reducing valve may be set too low. Refer to Pressure Control Valve Adjustment.
Grease viscosity may be too high for temperature Replace grease with a lower viscosity lubricant.
at which pump is operating.
Pump inlet check or outlet check may have foreign Remove, inspect and clean, if necessary.Inspect
matter trapped causing leakage. sealing surfaces between checks. Replace if rough
or pitted.
Lubricant supply line leaks or is broken. Repair lubricant supply line .
Insufficient hydraulic oil supply. Check oil pressure and flow to motor.

TROUBLE: Lube Cycle Timer Not Operating

Timer BAT (-) connection is not on grounded mem- Connect to good ground.
ber.
Timer BAT (+) connection not on circuit continu- Establish direct connection between Timer BAT (+)
ously connected to BAT (+) terminal during opera- connection and 24 V BAT (+) terminal.
tion of vehicle.
Loose wire connections at any of the timer termi- Secure wire connections.
nals.

TROUBLE: Timer Stays Timed Out

Commutation failure in timer caused by damaged Replace Timer.

component.
Output relay contacts welded shut caused by Replace Timer.
extended short to ground.
Solenoid valve connected to "IGN" terminal of Correct wiring hook-up.
timer instead of terminal marked "SOL".
OM4200 Automatic Lubrication System - Section 42
Page 42-13

POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION

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

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

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

Timer out of adjustment or damaged component. Refer to Timer Adjustment and re-adjust timer or
replace timer.
Automatic Lubrication System - Section 42 OM4200
Page 42-14

PREVENTATIVE MAINTENANCE PROCEDURES

The following maintenance procedures should be 4. Inspect all bearing points for a bead of lubricant
used to insure proper system operation. around the bearing seal.

Daily Lubrication System Inspection It is good practice to manually lube each bearing
point at the grease fitting provided on each Injector.
1. Check grease reservoir level. This will indicate if there are any frozen or plugged
• Inspect grease level height after each shift of bearings, and will help flush the bearings of contami-
operation. Grease usage should be consistent nants.
from day-to-day operations. 5. System Checkout
• Lack of lubricant usage would indicate an a. Remove all SL-1 injector cover caps to
inoperative system. Excessive usage would allow visual inspection of the injector cycle
indicate a broken supply line. indicator pins during system operation.
2. Check filter bypass indicator when filling reser-
b. Start truck engine.
voir. Replace element if bypassing.
3. Check all grease feed line hoses from the SL-1 c. Actuate the lube system test switch. The
Injectors to the lubrication points. hydraulic motor and grease pump should
operate.
a. Repair or replace all damaged feed line
hoses. d. With the grease under pressure, check
each SL-1 injector assembly. The cycle
b. Make sure that all air is purged and all new indicator pin should be retracted inside the
feed line hoses are filled with grease injector body.
before sending the truck back into service.
e. When the system attains 2500 psi (17 237
4. Inspect key lubrication points for a bead of lubri-
kPa), the pump should shut off and the
cant around seal. If a lubrication point appears
pressure in the system should drop to zero,
dry, troubleshoot and repair problem.
venting back to the grease reservoir.
250 Hour Inspection f. With the system vented, check all of the
1. Check all grease feed line hoses from the SL-1 SL-1 injector indicator pins; all of the pins
Injectors to the lubrication points (see, Figure should be visible. Replace or repair injec-
42-1). tors, if defective.

a. Repair or replace all worn / broken feed g. Reinstall all injector cover caps.
line hoses. h. Check timer operation.
b. Make sure that all air is purged and all new
feed line hoses are filled with grease
before sending the truck back into service. Note: With engine running, lube system should
activate within 5 minutes. The system should build
2. Check all grease supply line hoses from the 2000 to 2500 psi within 25-40 seconds.
pump to the SL-1 injectors.
a. Repair or replace all worn / broken supply
lines. i. If the system is working properly, the truck
is ready for operation.
b. Make sure that all air is purged and all new
supply line hoses are filled with grease j. If the system is malfunctioning, refer to the
before sending the truck back into service. troubleshooting chart.
3. Check grease reservoir level.
a. Fill reservoir if low.
1000 Hour Inspection
b. Check reservoir for contaminants. Clean, if
required. Check pump housing oil level and correct if neces-
sary.
c. Check that all filler plugs, covers and
breather vents on the reservoir are intact
and free of contaminants.
OM5031 Specifications - Section 5
Component Description Page 5-1

MAJOR COMPONENT DESCRIPTION

Truck And Engine Operator's Cab
The 930E Dump Truck is an off-highway, rear dump The operator cab has been engineered for operator
truck with AC Electric Drive. The gross vehicle weight comfort and to allow for efficient and safe operation of
is 1,100,000 lbs. (498 960 kg). The engine is a the truck. The cab provides wide visibility, with an inte-
Komatsu SSDA16V160 rated @ 2700 HP (2014 kW). gral 4-post ROPS/FOPS stucture, and an advanced
analog operator environment. It includes a tinted
Alternator (GE-GTA42) safety-glass windshield and power-operated side win-
dows, a deluxe interior with a fully adjustable seat with
The diesel engine drives an in-line alternator at engine lumbar support, a fully adjustable/tilt steering wheel,
speed. The alternator produces AC current which is controls mounted within easy reach of the operator,
rectified to DC within the main control cabinet. The rec- and an analog instrument panel which provides the
tified DC power is converted back to AC by groups of operator with all instruments and gauges which are
devices called "inverters", also within the main control necessary to control and/or monitor the truck's operat-
cabinet. Each inverter consists of six "phase modules" ing systems.
under the control of a "gate drive unit" (GDU). The
GDU controls the operation of each phase module.
Power Steering
Each phase module contains an air-cooled solid-state
The truck is equipped with a full time power steering
switch referred to as a "gate turn-off thyristor" (GTO).
system which provides positive steering control with
The GTO cycles on and off at varying frequencies to
minimum operator effort. The system includes nitro-
create an AC power signal from the DC supply.
gen-charged accumulators which automatically provide
The AC power signal produced by each inverter is a emergency power if the steering hydraulic pressure is
variable-voltage, variable-frequency signal (VVVF). reduced below an established minimum.
Frequency and voltage are changed to suit the operat-
ing conditions. Dynamic Retarding
The dynamic retarding is used to slow the truck during
AC Induction Traction Motorized Wheels normal operation or control speed coming down a
The alternator output supplies electrical energy to the grade. The dynamic retarding ability of the electric sys-
two wheel motors attached to the rear axle housing. tem is controlled by the operator through the activation
The motorized wheels use three-phase AC induction of the retarder pedal (or by operating a lever on the
motors with full-wave AC power. steering wheel) in the operators cab and by setting the
RSC (Retarder Speed Control). Dynamic Retarding is
The two wheel motors convert electrical energy back to
automatically activated, if the truck speed goes to a
mechanical energy through built-in gear trains within
preset overspeed setting.
the wheel motor assembly. The direction of the wheel
motors is controlled by a forward or reverse hand
selector switch located on the center console. Brake System
Service brakes at each wheel are oil-cooled multiple
Blower disc brakes applied by an all-hydraulic actuation sys-
tem. Depressing the brake pedal actuates both front
Both the inverters and the wheel motors produce heat
and rear brakes, after first applying the retarder. All
while in operation and must be cooled. Cooling air is
wheel brakes will be applied automatically, if system
provided by a dual impeller in-line blower mounted on
pressure decreases below a preset minimum.
the alternator.
The parking brake is a dry disc type, mounted inboard
Suspension on each rear wheel motor, and is spring-applied and
hydraulically-released with wheel speed application
HYDRAIR®II suspension cylinders located at each protection (will not apply with truck moving).
wheel provide a smooth and comfortable ride for the
operator and dampens shock loads to the chassis dur-
ing loading and operation.
Specification - Section 5 OM5031
Page 5-2 Componenet Descriptions

930E
930E MAJOR COMPONENTS
MAJOR COMPONENTS
OM5031 Specifications - Section 5
Component Description Page 5-3

SPECIFICATIONS
These specifications are for the standard Komatsu
930E Truck. Customer Options may change this listing.

ENGINE SERVICE CAPACITIES

Komatsu SSDA16V160 . . . . . . . . . . . . . . . . . . . . . . U.S. Gallons. . . . (Liters)
No. of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Crankcase * . . . . . . . . . . . . . . . . 74. . . . . . . . . . . .280
Operating Cycle. . . . . . . . . . . . . . . . . . . . . . . 4-Stroke * Includes Lube Oil Filters
Rated Brake HP. . . 2700 HP (2014 kW) @ 1900 RPM Cooling System . . . . . . . . . . . . . 157 . . . . . . . . . . .594
Flywheel HP . . . . . 2550 HP (1902 kW) @ 1900 RPM Fuel . . . . . . . . . . . . . . . . . . . . . .1200 . . . . . . . . . .4542
Weight* (Dry) . . . . . . . . . . . . 21,182 pounds (9608 kg) Hydraulic System. . . . . . . . . . . . 350 . . . . . . . . . 1325
* Weight does not include Radiator, Sub-frame, or Alternator Wheel Motor Gear Box . . . . . 25/Wheel . . . . 95/Wheel

AC ELECTRIC DRIVE SYSTEM HYDRAULIC SYSTEMS

(AC/DC Current) Hoist & Brake Cooling Pump: . . . . . . . . Tandem Gear
Alternator . . . . . . . . . . . . . . General Electric GTA - 42 Rated @ . . . . . . . 246 GPM (931 l/min.) @ 1900 RPM
Dual Impeller, In-Line Blower 12,000 cfm (340 m³/ min) . . . . . . . . . . . . . . . . . . . . . . .and 2500 psi (17 237 kPa)
Motorized Wheels . . . . GDY106 AC Induction Traction Steering/Brake Pump: . Pressure Compensated Piston
Motors Rated @ . . . . . . . . 65 GPM (246 l/min.) @ 1900 RPM
. . . . . . . . . . . . . . . . . . . . . . . . Wheel Slip/Slide Control . . . . . . . . . . . . . . . . . . . . . . .and 2750 psi (18 961 kPa)
Standard Gear Ratio* . . . . . . . . . . . . . . . . . . . 32.62:1 Relief Pressure-Hoist. . . . . . . . . . 2500 psi (17.2 MPa)
Maximum Speed . . . . . . . . . . . . . .40 MPH (64.5 km/h) Relief Pressure-Steering/Brake . . 4000 psi (27.6 MPa)
*NOTE: Wheel motor application depends upon GVW, haul road grade and Hoist Cylinders (2) . . . . . . . . . . . . . . 3-Stage Hydraulic
length, rolling resistance, and other parameters. Komatsu & G.E. must analyze
each job condition to assure proper application. Tank (Vertical/Cylindrical) . . . . . . . . . Non-Pressurized
Tank Capacity . . . . . . . . . . 250 US Gal. (947 Liters)
DYNAMIC RETARDING Filtration . . . . . . . . . . . . . . In-line replaceable elements
Suction. . . . . . . . . . . . . . . .Single, Full Flow, 100 Mesh
Electric Dynamic Retarding . . . . . . . . . . . . . . Standard
Hoist & Steering Filters . . . . . . . . .Beta 12 Rating =200
Maximum Rating . . . . . . . . . . . . . . 5400 HP (4026 kW)
Continuous . . . . . . . . . . . . . . . . . . 3300 HP (2460 kW) . . . . . . . . . . . . . . . . . . . . . Dual In-Line, High Pressure
Continuously rated high-density blown grids with retard at engine idle and
retard in reverse propulsion. SERVICE BRAKES
BATTERY ELECTRIC SYSTEM All Hydraulic Actuation. . . . . . . . . with Traction System
. . . . . . . . . . . . . . . . . . . . . . . Wheel Slip / Slide Control
Batteries . . . . . . . . . . . . . . . . . . . . . . bumper mounted Front and Rear Oil-Cooled Multiple Discs- each wheel
. . .4 x 8D & 2 x 30H 12 Volt Batteries in Series/Parallel Total Friction Area / Brake . . . . 15,038 in² (97 019 cm²)
. . . . . . . . . . . . . . . . . . . . . . 220 Ampere-Hour Capacity Maximum Apply Pressure . . . . . 2500 psi (17 238 kPa)
. . . . . . . . . . . . . . . . . . . . . . . . . With Disconnect Switch
Alternator . . . . . . . . . . . . 24 Volt, 240 Ampere Output
STEERING
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volt
Starters (2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volt Turning Circle (SAE) . . . . . . . . . . . .97 ft. 7 in. (30.4 m)
Twin hydraulic cylinders with accumulator assist to pro-
vide constant rate steering.
Emergency power steering automatically provided by
accumulators.
Specification - Section 5 OM5031
Page 5-4 Componenet Descriptions

STANDARD DUMP BODY CAPACITIES WEIGHT DISTRIBUTION

AND DIMENSIONS
Capacity, Empty Vehicle . . . . . . . . . Pounds . . . . . (Kilograms)
Heaped @ 2:1 (SAE) . . . . . . . . . . .276 yd3 (211 m3) Front Axle (49.3%) . . . . . . 226,699 . . . . . . . (102 830)
Rear Axle (50.7 %) . . . . . . 233,137 . . . . . . . (105 750)
Struck . . . . . . . . . . . . . . . . . . . . . . .224 yd3 (171 m3) Total (50% Fuel) . . . . . . . . 459,836. . . . . . . (208 580)
Width (Inside) . . . . . . . . . . . . . . . . . 26 ft. 9 in. (8.15 m)
Depth . . . . . . . . . . . . . . . . . . . . . . . . 10 ft. 7 in. (3.2 m) Loaded Vehicle . . . . . . . . Pounds . . . . . (Kilograms)
Loading Height . . . . . . . . . . . . . . . . . . . . 23 ft. (7.01 m) Front Axle (33.9%) . . . . . . 363,000 . . . . . . . (164 656)
Dumping Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Rear Axle (66.1%) . . . . . . 737,000 . . . . . . . (334 301)
Total * . . . . . . . . . . . . . . . 1,100,000 . . . . . . (498 957)

TIRES *Not to exceed 1,100,000 lbs. (498 957 kg) including

options, fuel, and payload. Weights in excess of this
Radial Tires (standard) . . . . . . . . . . . . . . . . . 53/80 R63 amount require factory approval.
. . . . . . . . . . . . . . . . . . . . . . . . Rock Service, Tubeless
Rims . . . . . . . . . . . . . . . . . . . . .(patented Phase I rims)
OM6009 Payload Meter III - Section 60
Page 60-1

PAYLOAD METER III ™

INDEX
OPERATION SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Data Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Data Gathering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Suspension Pressure Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inclinometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operator Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operator Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Speed Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Body-Up Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Brake Lock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Payload Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Communications Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Keyswitch Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Payload Meter Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Load Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Wiring and Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TCI Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATOR’S DISPLAY AND SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Reading the Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Reading the Load Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Using the Operator ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Using the Load and Ton Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Total Ton Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Total Load Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Clearing the Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Viewing Live Sensor Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Other Display Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PAYLOAD OPERATION & CALCULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Description of Haul Cycle States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Haul Cycle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Load Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Carry Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Measurement Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SOURCES FOR PAYLOAD ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Payload Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Loading Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pressure Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Swingloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Speed and Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
HAUL CYCLE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Haul Cycle Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Haul Cycle Warning Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
A: Continuous Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
B: Loading to Dumping Transition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
C: No Final Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
D: Maneuvering to Dumping Transition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
E: Average Load or Tare Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Payload Meter III - Section 60 OM6009
Page 60-2

F: Final Zone to Dumping Transition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

H: False Body Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
I: Body Up Signal Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
J: Speed Sensor Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
K: New Tare Not Calculated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
L: Incomplete Haul Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
M: Haul Cycle Too Long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
N: Sensor Input Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Alarm Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Frame Torque Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Sprung Weight Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Maximum Speed Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
PC SOFTWARE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
PC Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installing the PLMIII Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DOWNLOADING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
PLMIII SYSTEM CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Starting Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Displayed Payload Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Time Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Connection Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Connecting to the Payload Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Configure the Payload Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Setting the Date and Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Setting the Truck Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Setting the Gauge Display Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Setting the Frame Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Setting the Truck Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Setting the Komatsu Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Setting the Komatsu Customer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Clean Truck Tare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Inclinometer Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DATA ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Sorting on Truck Unit Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Creating a Query . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Sorting on Truck Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Sorting on Date Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Sorting on Time Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Payload Detail Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Creating Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Summary - one page report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Detailed - multi-page report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Creating Graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Exporting Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
CSV Export . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Compressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
To export data in ZIP format: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Importing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Deleting Haul Cycle Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Viewing Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Deleting Alarm Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
OM6009 Payload Meter III - Section 60
Page 60-3

OPERATION SECTION Data Gathering

Windows 95/98/NT software is available to down-
Introduction
load, store and view payload and fault information.
Payload Meter III (PLMIII) measures, displays and The PC software will download an entire truck fleet
records the weight of material being carried by an off- into one Paradox database file. Users can query the
highway truck. The system generally consists of a database by date, time, truck type and truck number
payload meter, a gauge display, deck-mounted lights, to produce reports, graphs and export the data. The
and sensors. The primary sensors are four suspen- software can export the data in '.CSV' format that can
sion pressures and an inclinometer. Other inputs be easily imported into most spreadsheet applica-
include a body up signal, brake lock signal, and tions. The Windows software is not compatible with
speed. the Payload Meter 2 system.
It is important that each payload meter be configured
for each truck using the PC software. The informa-
Data Summary tion for frame serial number and truck number is
5208 haul cycles can be stored in memory. The fol- used by the database program to organize the pay-
lowing information is recorded for each haul cycle: load data. In addition, the payload meter must be
configured to make calculations for the proper truck
• Payload model. Improper configuration can lead to data loss
• Operator ID number (0000-9999) and inaccurate payload calculations.
• 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 of
day
• Average speed loaded and empty
• Empty carry-back load
• Haul-cycle, loading, dumping start time of day.
• Peak positive and peak negative frame torque
with time of day
• Peak sprung load with time of day
• Tire ton-mph for each front and average per rear
tires

The payload meter stores lifetime data that cannot be

erased. This data includes:
• Top 5 maximum payloads and time stamps.
• Top 5 positive and negative frame torque and
time stamps
• Top 5 maximum speeds and time stamps
Payload Meter III - Section 60 OM6009
Page 60-4

COMPONENT DESCRIPTION
System Diagram

Suspension Pressure Sensors Operator Display

PLMIII uses a two-wire pressure sensor. The range The speedometer/display gauge is used as a
for the pressure sensor is 4000 psi (281 kg/cm2) speedometer and payload display. The top display
is used for speed and can display metric (km/h) or
and the overload limit is 10,000 psi (700 kg/cm2).
English (mph) units. Grounding terminal #4 on the
One wire to the sensor is the supply voltage and the
back of the speedometer will switch the meter to
other is the signal. The 0-4000 psi range is con-
display metric units. Leaving terminal #4 uncon-
verted into an electrical current between 4-20 ma.
nected will cause the gauge to display English units.
The supply voltage for the sensor is nominally
The speedometer can be adjusted using a calibra-
+18vdc. Each pressure sensor has an 90" length of
tion potentiometer in the back just like existing
cable that is terminated with #10 ring terminals. The
speedometers.
cable is specially shielded and reinforced to provide
mechanical strength and electronic noise immunity.
A typical part number for the pressure sensor is
The payload meter uses the lower display for pay-
PC0328.
load information. The normal display mode shows
Inclinometer the current payload. The display can be changed to
show the load and total tons counter or the Operator
The inclinometer is used to increase the accuracy of ID. Using the operator switch on the dash panel,
load calculations on an incline. The inclinometer the current suspension pressures and incline can be
uses three wires. For the sensor, red is the +18vdc displayed. The units for display are set using the
supply voltage, black is ground and the white is the PC software. Payloads can be displayed in Short
signal. The incline signal is a voltage between 1 Tons, Long Tons or Metric Tons. A typical part num-
and 4 volts. Zero degrees of incline is represented ber for this gauge is the PC0550.
by 2.6vdc on the signal line. The voltage signal will
be decreased by 0.103vdc for every degree of nose
up incline. A typical part number for the inclinome-
ter assembly is 7861-92-5330.
OM6009 Payload Meter III - Section 60
Page 60-5
Operator Switch Payload Meter
The payload operator switch is used to set, view and The payload meter is housed in a black aluminum
clear the Total Load Counter and Total Ton Counter. housing. There is a small window on the face of the
It is also used to enter the Operator ID number (0- unit. Status and active alarm codes can be viewed
9999). This switch can also be used to view the sus- through the window. During normal operation, a two-
pension pressures and inclinometer. The payload digit display flashes 0 back and forth. Active fault
meter operator switch is located on the dashboard. It codes will be displayed for two seconds. These
is a two-way momentary switch. The top position is codes are typically viewed using the laptop computer
the SELECT position. The SELECT position is used connected to the serial communications port.
step through the different displays. The lower posi-
There is one 40-pin connector on the payload meter.
tion is the SET position. The SET position is used to
A jack-screw is used to hold the payload meter and
set the Operator ID or clear the load and total ton
wire harness connector housings together. This
counters. Normally the inputs from the switch to the
screw requires a 4mm or 5/32 hex wrench. The cor-
payload meter are open circuit. The switch momen-
rect tightening torque for this screw is 25 lb-in. Four
tarily connects the circuit to ground.
bolts hold the payload meter housing to its mounting
bracket in the cab.

Speed Input The circuit board inside the payload meter housing is
made from multi-layer, dual-sided surface-mount
PLMIII uses a speed signal to calculate speed, dis- electronics. There are no field serviceable compo-
tance, and other performance data. This input is crit- nents inside. The electronics are designed to with-
ical to the proper operation of the system. PLMIII stand the harsh operating environment of the mining
receives this signal from the speedometer/operator industry. Opening the payload meter housing will
display on the dashboard. The same signal dis- result in voiding the warranty.
played to the operator is used by the system. Dis-
tance calculations are made based on the rolling
radius of the tires for a particular truck.
Communications Ports
The payload meter has two RS232 serial communi-
Body-Up Switch cations ports and two CAN ports. Connections for
the two serial ports are available inside the payload
The Body-Up input signal is received from a mag- meter junction box. The two CAN ports are available
netic switch located on the inside of the truck frame, for future electronics systems.
forward the pivot pin of the truck body. This is the
same switch typically used for input to the drive sys- Serial port #1 is used to communicate with the dash-
tem. When the body is down, the switch closes and board display. It is also used to connect to the laptop
completes the circuit to 71-Control Power. 24vdc computer. The display gauge will remain blank when
indicates the body is down. Open circuit indicates the PC is using the serial port. This port initially oper-
that the body is up. ates with serial settings at 9600,8,N,1. These set-
tings change automatically to increase the
communications rate when the PC is using the port.
This serial port uses a 3-wire hardware connection.
Brake Lock Switch
Serial port #2 is used to communicate to other on-
The brake lock is used to lock the rear brakes on the board electronics like Modular Mining's Dispatch®
truck. It is necessary for the accurate calculation of system or the Scoreboard from Komatsu. This port
swingloads during the loading process. Without the uses a 3-wire hardware connection. Connections to
brake lock applied, the payload meter will not calcu- this serial port need to be approved by Komatsu.
late swingloads during the loading process. Without Several protocol options are available and detailed
the brake lock, the payload meter will assume that technical information is available depending on
the truck was loaded using a continuous loader and licensing.
flag the haul cycle record. All other functions will be
normal regardless of brake lock usage. The brake
lock input comes from the switch located on the dash
panel. The brake lock switch connects the circuit to
ground. Open circuit indicates brake lock off.
Ground indicates brake lock on.
Payload Meter III - Section 60 OM6009
Page 60-6

Keyswitch Input Load Lights

PLMIII monitors the status of the keyswitch. 24vdc PLMIII uses load lights to indicate to the shovel oper-
indicates that the keyswitch is on, open indicates the ator the approximate weight of the material in the
keyswitch is off. The payload meter does not receive truck. The load lights are illuminated only when the
its electrical power from the keyswitch circuit. The brake lock is applied. The lights are controlled by the
payload meter will remain on for several seconds payload meter through a series of relays in the junc-
after keyswitch is removed. When the keyswitch tion box. The payload meter controls the relays with
power is removed, payload meter performs a series 24vdc outputs. A 24vdc signal from the payload
of internal memory operations before turning itself meter powers the relay coil and connects battery
off. To allow for these operations, the keyswitch power to the load light. When the relay is not pow-
should be turned off for at least 15 seconds before ered by the payload meter, a pre-warm resistor con-
turning the keyswitch back on. The payload meter nects the load light to a reduced voltage. This circuit
will automatically reset itself without error if not pre-warms the load light filaments and reduces the
enough time is given for these operations. The dis- inrush current when the light is fully illuminated. This
play may blink briefly. lengthens the operating life of the load lights.
The load lights progressively indicate to the shovel
operator the approximate weight of the material in
Payload Meter Power the truck.
The payload meter receives its power from the bat- A flashing green light indicates the next swingload
tery circuit on the truck. Removing battery power will make the measured load greater than 50% of
from the payload meter before removing keyswitch rated load. A solid green light indicates that the cur-
and waiting 15 seconds may result in lost haul cycle rent load is greater than 50% of rated capacity.
data. The payload meter turns itself off approximately
15 seconds after the keyswitch power is removed. A flashing amber light indicates the next swingload
Some haul cycle data will be lost if battery power is will make the measured load greater than 90% of
removed before waiting 15 seconds. The payload rated load. A solid amber light indicates that the cur-
meter system operates at a nominal voltage of 24vdc rent load is greater than 90% of rated capacity.
at 1 to 2 amps depending on options. The payload A flashing red light indicates the next swingload will
meter is designed to turn itself off if the supply volt- make the measured load greater than 105% of rated
age rises above 36vdc. The payload meter is also load. A solid red light indicates that the current load
protected by a 5 amp circuit breaker located in the is greater than 105% of rated capacity.
junction box.
The optimal loading target is a solid green and amber
Power to the load lights comes from the same battery lights with a flashing red light. This indicates that the
circuit. The load lights are powered through a relay. load is between 90% and 105% of rated load for the
The keyswitch circuit controls the relay. The load truck and the next swingload will load the truck over
lights are also protected by a 15 amp circuit breaker 105%.
in the junction box.
OM6009 Payload Meter III - Section 60
Page 60-7
Wiring and Termination
Most of the PLMIII truck connections use a heavy-
duty cable. This yellow multi-conductor cable uses a
16awg, finely stranded wire designed for continuous
motion operations. The conductors are protected by
a foil and braided shield for electronic noise immunity
and physical strength. A typical part number for this
wire is LW086-63. This wire is typically terminated
with a #10 ring terminal, part number VH2584. Most
connections for the PLMIII system are made in the
payload meter junction box.

TCI Outputs
The GE drive system on the 930E requires informa-
tion from the payload meter regarding the loaded
condition of the truck. There are three outputs from
the payload meter to GE to indicate the relative load
in the truck. 24 vdc on the 73MSL circuit indicates
that the load is 70% of rated load. 24 vdc on the
73FSL circuit indicates the truck is 100% loaded.
The 73OSL circuit is not currently used.
Payload Meter III - Section 60 OM6009
Page 60-8

OPERATOR’S DISPLAY AND SWITCH Using the Operator ID

The current Operator ID number is recorded with
each haul cycle. The number can be between 0 and
Reading the Speedometer 9999.
The top window of the speedometer/display gauge is
the speedometer section. The display shows the
To set the Operator ID:
speed indicated by the frequency being received by
the gauge. This can be adjusted using the potenti- 1. Press the “SELECT” switch until id= is dis-
ometer on the back of the gauge. In addition, the played.
units for the display can be changed. Terminal #4 2. Hold the “SET” button until 0000 is displayed.
controls the displayed units. If #4 is grounded, the The first digit should be flashing.
display will be metric. If terminal #4 is left open, the
3. Press the “SET” button again to change the
display will be in English units.
digit.
4. Press the “SELECT” button once to adjust the
second digit.
Reading the Load Display
5. Use the “SET” button again to change the digit.
The lower display on the speedometer/display gauge 6. Press the “SELECT” button once to adjust the
is used for payload information. The SELECT posi- third digit.
tion on the operator switch allows the user to scroll
through a number of useful displays. The order for 7. Use the “SET” button again to change the digit.
the displays is as follows: 8. Press the “SELECT” button once to adjust the
fourth digit.
9. Use the “SET” button again to change the digit
• PL= Payload 10. Press the “SELECT” button one more time to
• Id= Operator ID enter the ID.
• tl= Total Shift Tons If no buttons are pressed for 30 seconds, the display
will return to normal operation. The number being
• l(= Shift Load Counter entered will be lost and the ID number returns to the
• lF= Left Front Suspension Pressure previous ID number.

• rF= Right Front Suspension Pressure

• lr= Left Rear Suspension Pressure Using the Load and Ton Counter
• rr= Right Rear Suspension Pressure PLMIII allows the truck operator to monitor and track
the total tons hauled and the number of haul cycles
• in= Inclinometer during the shift. This display can be cleared at the
beginning of each shift to allow the operator to record
how many loads and tons have been hauled during
The display holds the displayed information until the the shift.
SELECT switch is pressed again. The suspension
pressures, inclinometer, and payload displays are Total Ton Counter
based on current sensor inputs.
The Total Ton Counter records the number of tons
Communications to the display use the same serial hauled since the last time it was cleared. This dis-
link as the download connection. Whenever another play is in 100’s of tons. For example, if the display
computer is connected to serial port #1 to download
or configure the system, the lower display will blank.
shows 432 the total tons is 43,200. This display
This is not the same connection used by mine dis- can be cleared at the beginning of each shift to allow
patch systems. the operator to record how many tons have been
hauled during the shift. The units are selected using
the PC software.
• To view the Total Ton Counter press and release
the “SELECT” switch until tl= is displayed on
the gauge.
OM6009 Payload Meter III - Section 60
Page 60-9
Total Load Counter The inclinometer displays whole degrees of incline.
Positive incline is truck nose up. The gauge will
The Total Load Counter records the number of loads
quickly display the type of information shown every
hauled since the last time it was cleared. This dis-
10 seconds. For example, if the left-front pressure is
play can be cleared at the beginning of each shift to
allow the operator to record how many loads have being displayed, Lf= will flash on the display
been hauled during the shift.
every minute. Only the payload display, pl=
does not display this information.
• To view the Total Load Counter press and release
the “SELECT” switch until l(= is displayed on
the gauge. • Left Front Pressure - To display the pressure in
the left-front suspension, press and release the
“SELECT” switch until Lf= is displayed.
Clearing the Counters
• Right Front Pressure - To display the pressure in
Clearing the Total Ton Counter or Total Load Counter the right-front suspension, press and release the
clears both records. “SELECT” switch until rf= is displayed.
• Left Rear Pressure - To display the pressure in
To clear the total ton and total load counter: the left-rear suspension, press and release the

1. Press the “SELECT” switch until tl= or

“SELECT” switch until lr= is displayed.
• Right Rear Pressure - To display the pressure in
l(= is displayed. the right-rear suspension, press and release the
2. Hold the “SET” button until the display clears. “SELECT” switch until rr= is displayed.
• Inclinometer - To display the truck incline, press
Viewing Live Sensor Data and release the “SELECT” switch until in= is
displayed.
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 during
regularly scheduled service periods to check the
state of the suspensions. These displays are live Other Display Messages
and will update as the values change.
On startup of the payload meter system, the gauge
The live displays cannot be cleared and the SET but- display will scroll the truck type that the PLMIII is con-
ton will have no effect. figured for. For example, on a 930E, the gauge will
The units for the display are controlled by the config- scroll, ----930E---.
uration of the payload meter. If the payload meter is
set to display metric units, the pressures will be dis-
played in tenths of kg/cm2. For example, if the dis- If the PLMIII encounters memory problems, it will dis-

play shows 202 the actual value is 20.2 kg/cm2. If play ER88 where 88 is the specific memory error.
the payload meter is set to display short tons, the In this very rare circumstance, the system should be
pressures will be displayed in psi (lbs/in2). To convert turned off for 30 seconds and restarted.
from kg/cm2 to psi, multiply by 14.2. 1 1kg/cm2 =
14.2 psi. There is no way to detect the units setting
for the gauge without the PC software.
Payload Meter III - Section 60 OM6009
Page 60-10

PAYLOAD OPERATION & CALCULATION lock applied, the meter will switch to loading and
record the continuous_loading flag in the haul cycle.
Description of Haul Cycle States
The payload meter switches from loading to maneu-
The typical haul cycle can be broken down into eight vering as soon as the truck begins moving. The
distinct stages or states. Each state requires the pay- maneuvering zone is 160m and is designed to allow
load meter to make different calculations and store the operator to reposition the truck under the shovel.
different data. More payload can be added anytime within the
maneuvering zone. Once the truck travels 160m (0.1
"States" or stages of a typical haul cycle miles) the payload meter switches to the final_zone
1. Tare Zone and begins calculating payload. If the body is raised
while the payload meter is in the maneuvering state,
2. Empty the no_final_load flag will be recorded in the haul
3. Loading cycle record, no payload will be calculated, and the
4. Maneuvering meter will switch to the dumping state.
5. Final Zone While in the final_zone moving faster than 5 km/h (3
6. Hauling mph), the payload meter calculates the loaded
7. Dumping sprung weight of the truck. The same advanced
algorithm is used to calculate the empty and loaded
8. After Dump sprung weights. The payload meter will switch from
the final_zone to the dumping state if the Body-Up
signal is received. If the truck has moved for less
Haul Cycle Description
than 1 minute in the final_zone, the payload meter
A new haul cycle is started after the load has been will calculate the final payload using an averaging
dumped from the previous cycle. The payload meter technique which may be less accurate. If this hap-
will stay in the after_dump state for 10 seconds to pens, the average_load flag will be recorded in the
confirm that the load has actually been dumped. If haul cycle.
the current payload is less than 20% of rated load,
The payload meter switches to the dumping state
the payload meter will switch to the tare_zone and
when the dump body rises. The payload meter will
begin calculating a new empty tare. If, after dump-
switch from dumping to after_dump when the dump
ing, the payload has not dropped below 20% of rated
body comes back down.
load the meter will return to the maneuvering or haul-
ing states. In this case, the false_body_up flag will
be recorded in the haul cycle record.
From the after_dump, the payload meter will switch
While in the tare_zone state, and moving faster than to one of three states:
5 km/h (3 mph), the payload meter calculates the
empty sprung weight of the truck. This tare value will
be subtracted from the loaded sprung weight to cal- 1. If the average payload is greater than 20% of
culate the final payload. The payload meter will rated load and no final payload has been calcu-
switch from the tare_zone or empty to the loading lated, the payload meter will return to the
state if swingloads are detected. By raising the maneuvering state. After the truck travels
dump body while in the empty state the payload 160m (0.1 mile) the meter will switch to the
meter can be manually switched back to the final_zone and attempt to calculate the payload
tare_zone to calculate a new tare. again. The false_body_up flag will be recorded
in the haul cycle record.
From the empty state, the payload meter will switch
to the loading state through one of two means. If the 2. If the average payload is greater than 20% of
brake lock is applied, the payload meter will be ana- rated load and the final payload has been calcu-
lyzing the suspension pressures to detect a swing- lated, the payload meter will switch back to the
load. If a swingload is detected, the meter will switch hauling state. The false_body_up flag will be
to the loading state. The minimum size for swingload recorded in the haul cycle record.
detection is 10% of rated load. Swingload detection 3. If the average payload is less than 20% of rated
usually takes 4-6 seconds. The second method to load, the payload meter will switch to the
switch from empty to loading is through continuous tare_zone and begin to calculate a new empty
loading. This can happen if the brake lock is not tare.
used during loading. If the load increases above
50% of rated load for 10 seconds without the brake
OM6009 Payload Meter III - Section 60
Page 60-11
Load Calculation SOURCES FOR PAYLOAD ERROR
The final load calculation is different from the last
swingload calculation. The accuracy of the swing
load calculation depends on loading conditions and Payload Error
the position of the truck during loading. The last
The number one source of error in payload calcula-
swingload calculation is not the value recorded in
tion is improperly serviced suspensions. The pay-
memory as the final load. The final load is deter-
load meter calculates payload by measuring
mined by a series of calculations made while the
differences in the sprung weight of the truck when it
truck is traveling to the dump site.
is empty and when it is loaded. The sprung weight is
the weight of the truck supported by the suspensions.
The only method for determining sprung weight is by
Carry Back measuring the pressure of the nitrogen gas in the
suspensions. If the suspensions are not properly
Carry back is calculated as the difference between
maintained, the payload meter cannot determine an
the current truck tare and the clean truck tare. The
accurate value for payload. The two critical factors
clean truck tare is calculated using the PC software.
are proper oil height and proper nitrogen charge.
When the suspensions are serviced or changes are
made that may affect the sprung weight of the truck, If the suspensions are overcharged, the payload
a new clean truck tare should be calculated. meter will not be able to determine the empty sprung
weight of the truck. The suspension cylinder must be
able to travel up and down as the truck drives empty.
Measurement Accuracy The pressure in an overcharged suspension can
push the suspension rod to full extension. In this
Payload measurements are typically repeatable case, the pressure inside the cylinder does not accu-
within 1%. Accuracy for a particular scale test rately represent the force necessary to support that
depends on specific combinations of pressure sen- portion of the truck.
sors and payload meters as well as the specifics of
each scale test. Comparisons from different scale If the suspensions are undercharged, the payload
tests are often made without considering the differ- meter will not be able to determine the loaded sprung
ences introduced by the specific installation and weight of the truck. The suspension cylinder must be
operation of the scales for each test. In addition, able to travel up and down as the truck drives loaded.
each pressure sensor and payload meter introduces If the pressure in an undercharged suspension can-
it's own non-linearity. Each truck becomes an indi- not support the load, the suspension will collapse
vidual combination of sensors and payload meter. and make metal-to-metal contact. In this case, the
Errors from these sources can introduce up to a ±7% pressure inside the cylinder does not accurately rep-
bias in the payload meter calculations for a specific resent the force necessary to support that portion of
scale test, for an individual truck. the truck.

Because the PLMIII calculates a new empty tare for Low oil height can also introduce errors by not cor-
each payload, a detailed scale test must weigh the rectly supporting a loaded truck. This is why the cor-
trucks empty and loaded for each haul cycle. Using rect oil height and nitrogen charge are the most
a simple average of 2 or 3 empty truck weights as an critical factors in the measurement of payload. If the
empty tare for the entire scale test will introduce sig- suspensions are not properly maintained, accurate
nificant error when comparing scale weights to payload measurement is not possible. In addition,
PLMIII weights. suspension maintenance is very important to the life
of the truck.
Payload Meter III - Section 60 OM6009
Page 60-12

Loading Conditions HAUL CYCLE DATA

The final load calculation of the PLMIII system is not PLMIII records and stores data in its on-board flash
sensitive to loading conditions. The final load is cal- memory. This memory does not require a separate
culated as the truck travels away from the shovel. battery. The data is available through the download
Variations in road conditions and slope are compen- software.
sated for in the complex calculations performed by
the payload meter. PLMIII can store 5208 payload records. When the
memory is full, the payload meter will erase the old-
est 745 payload records and continue recording.

Pressure Sensors PLMIII can store 512 alarm records in memory.

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

Speed and Distance

The payload meter receives the same speed signal
as the speedometer. This signal is a frequency that
represents the speed of the truck. The payload
meter uses this frequency to calculate speeds and
distances. The meter assumes a single value for the
rolling radius of the tire. The rolling radius may
change at difference speeds by growing larger at
higher speeds. The actual rolling radius of the tire
will also change between a loaded and empty truck.
The payload meter does not compensate for these
changes.
 OM6009 Payload Meter III - Section 60
Page 60-13
Haul Cycle Data
The following information is recorded for each haul cycle:

Table 1. Haul Cycle Data

Data Unit Remark
Truck # alpha- Up to 22 characters can be stored in this field to identify the truck. Typically this field will be just the
numeric truck number.
Haul Cycle Start Date/Time seconds Number of seconds from 1/1/70 to the start of the haul cycle, haul cycle starts when the meter transi-
tions from dumping to empty state after the previous haul cycle, download program converts seconds
into date and time for display
Payload tons Stored as metric, download program allows for conversion to short or long tons.
Number of Swingloads number The number of swingloads detected by the payload meter
Operator ID number This is a 4 digit number that can be entered by the operator at the start of the shift.
Warning Flags alpha Each letter represents a particular warning message about the haul cycle, details are located on page
19.
Carry-back load tons The difference between the latest empty tare and the clean truck tare
Empty haul time seconds Number of seconds in the tare_zone and empty states with the truck moving
Empty stop time seconds Number of seconds in the tare_zone and empty states with the truck stopped
Loading time seconds Number of seconds in the loading state
Loaded haul time seconds Number of seconds in the maneuvering, final_zone and loaded states with the truck moving
Loaded stop time seconds Number of seconds in the maneuvering, final_zone and loaded states with the truck stopped
Dumping time seconds Number of seconds in the dumping state
Loading start time seconds Number of seconds from the start of the haul cycle to when the meter transitions from empty to loading
state
Dump start time seconds Number of seconds from the start of the haul cycle to the time when the meter switches from loaded to
dumping state
Loaded haul distance m Distance traveled while loaded
Empty haul distance m Distance traveled while empty
Loaded max speed km/h Maximum speed recorded while the truck is loaded
Loaded max speed time seconds Number of seconds from the start of the haul cycle to the time when the max speed occurred
Empty max speed km/h Maximum speed recorded while the truck is empty
Empty max speed time seconds Number of seconds from the start of the haul cycle to the time when the max speed occurred
Peak positive frame torque ton-meter Positive frame torque is measured as the frame twists in the clockwise direction as viewed from the
operator’s seat.
Peak frame torque time seconds Number of seconds from the start of the haul cycle to the peak torque, download program converts to
time for display
Peak negative frame torque ton-meter Negative frame torque is measured as the frame twists in the counter-clockwise direction as viewed
from the operator's seat.
Peak frame torque time seconds Number of seconds from the start of the haul cycle to the peak torque, download program converts to
time for display
Peak sprung load tons Peak dynamic load calculation
Peak sprung load time seconds Number of seconds from the start of the haul cycle to the peak instantaneous load calculation
Front-left tire-ton-km/h t-km/h Tire ton-km/h for haul cycle
Front-right tire-ton-km/h t-km/h Tire ton-km/h for haul cycle
Average rear tire-ton-km/h t-km/h Tire ton-km/h for haul cycle
Truck Frame Serial Number alpha The truck serial number from the nameplate on the truck frame
Reserved 1-10 number These values are internal calculations used in the continued development of the PLMIII system and
should be ignored
Payload Meter III - Section 60 OM6009
Page 60-14

Haul Cycle Warning Flags F: Final Zone to Dumping Transition

The payload meter expects haul cycles to progress in This message is generated when the payload meter
a particular way. When something unexpected takes senses a Body-Up while it is calculating the final pay-
place, the system records a warning flag. Several load indicating that the operator has dumped the
events within the haul cycle can cause a warning flag load. It may also be generated if the Body-Up signal
to be generated. Each one indicates an unusual is not properly reaching the payload meter and the
occurrence during the haul cycle. They do not nec- weight in the truck falls dramatically while the truck is
essarily indicate a problem with the payload meter or calculating the final payload.
payload calculation.
H: False Body Up
A: Continuous Loading
This message indicates that the body was raised dur-
This message is generated when the truck is loaded ing the haul cycle without the load being dumped.
over 50% full without the payload meter sensing The Body-Up signal indicated that the truck was
swingloads. This indicates that a continuous loading dumping, but the weight of the truck did not fall below
operation was used to load the truck. It may also 20% of the rated load.
indicate that the payload meter did not receive the
Brake Lock input while the truck was being loaded. I: Body Up Signal Failed
There may be a problem with the wiring or the Brake This message indicates that the load was dumped
Lock was not used. The payload meter will not mea- without a Body-Up signal being received by the pay-
sure swingloads unless the Brake Lock is used dur- load meter. The weight of the truck fell below 20%,
ing the loading process. but the payload meter did not receive a Body-Up sig-
nal from the sensor.
B: Loading to Dumping Transition
This message is generated when the payload meter J: Speed Sensor Failed
senses a body up input during the loading process. This message indicates that the payload meter
This message is usually accompanied by a sensed the truck loading and dumping without
no_final_load flag. receiving a speed signal.
C: No Final Load K: New Tare Not Calculated
This message is generated when the payload meter The payload meter was not able to accurately calcu-
is unable to determine the final payload in the truck. late a new empty sprung weight for the truck to use
Typically, this means that the payload meter switched as the tare value for the haul cycle. The tare value
from a loaded state to the dumping state before the from the last haul cycle was used to calculate pay-
load could be accurately measured. load.
D: Maneuvering to Dumping Transition L: Incomplete Haul Cycle
This message is generated when the payload meter The payload meter did not have proper data to start
senses a Body-Up input during the maneuvering or the haul cycle with after powering up. When the
repositioning process indicating that the operator has PLMIII powers off, it records the data from the haul
dumped the load. It may also be generated if the cycle in progress into memory. This flag indicates
Body-Up signal is not properly reaching the payload that this data was not recorded the last time the pay-
meter and the weight in the truck falls dramatically load meter was shut down. This can happen when
while the truck is maneuvering or repositioning. the main battery disconnect is used to shut the truck
down instead of the keyswitch. A haul cycle with this
E: Average Load or Tare Used
warning flag should not be considered accurate. Haul
This message indicates that the recorded payload cycles with this warning are displayed in red on the
may not be as accurate as a typical final load calcula- Payload Summary window and are not included in
tion. Typically, this is recorded when loading begins the summary statistics for reports or display.
before an accurate tare is calculated or the load is
dumped before the load can be accurately mea-
sured.
OM6009 Payload Meter III - Section 60
Page 60-15

M: Haul Cycle Too Long Alarm Records

The haul_cycle_too_long flag indicates that the haul The payload meter stores alarm records to give ser-
cycle took longer than 18.2 hours to complete. The vice personnel a working history of the system. All
times stored for particular events may not be accu- codes are viewed using the PC connected to the
rate. This does not affect the payload calculation. payload meter. Active codes are also displayed on
the two-digit display on the meter itself. Each code
N: Sensor Input Error has a specific cause and should lead to an investi-
An alarm was set for one of the 5 critical sensor gation for correction. Some failures can be over-
inputs during the haul cycle. The five critical sen- come by the payload meter. Haul cycle data will
sors are the four pressure sensors and the inclinom- indicate if an alarm condition was present during the
eter. Without these inputs, the payload meter cycle. Failures with the suspension or inclinometer
cannot calculate payload. A haul cycle with this sensors cannot be overcome.
warning flag should not be considered accurate.
Haul cycles with this warning are displayed in red on
the Payload Summary window and are not included
in the summary statistics for reports or display.

Table 2. Fault Code Data

Fault
Name Description
Code
1 Left front pressure high Input current > 22 ma
2 Left front pressure low Input current < 2 ma
3 Right front pressure high Input current > 22 ma
4 Right front pressure low Input current < 2 ma
5 Left rear pressure high Input current > 22 ma
6 Left rear pressure low Input current < 2 ma
7 Right rear pressure high Input current > 22 ma
8 Right rear pressure low Input current < 2 ma
9 Inclinometer high Input voltage < 0.565 vdc
10 Inclinometer low Input voltage > 5.08 vdc
13 Body-up input failure Payload meter detected dumping activity without receiving a body up signal
16 Memory write failure Indicates possible memory problem at power start up. Cycle power and recheck.
17 Memory read failure Indicates possible memory problem at power start up. Cycle power and recheck.
24 System key-on status Payload Meter failed to correctly start at power up. Cycle power and recheck.
26 User switch fault - SELECT Select switch on for more than 2 minutes, may indicate short to ground
27 User switch fault - SET Set switch on for more than 2 minutes, may indicate short to ground

Frame Torque Data

Payload meter records the top 5 peak positive and For example, if the left front and right rear pressure
negative frame torque values and the time they rises as the right front and left rear pressure drops,
occurred. The frame torque is a measure of the the truck frame experiences a twisting motion along
twisting action along the centerline of the truck. Pos- the longitudinal centerline. In this case, the payload
itive frame torque is measured when the suspension meter will record a positive frame torque.
forces on the front of the truck act to twist the frame
The 5 highest values in the positive and negative
in the clockwise direction as viewed from the opera-
direction are stored in permanent memory within the
tor's seat. Negative frame torque is measured when
payload meter.
the forces from the suspensions act in the opposite
direction.
Payload Meter III - Section 60 OM6009
Page 60-16

Sprung Weight Data System Configuration

The payload meter is constantly monitoring the live PLMIII needs to be configured for operation when it
payload calculation. This value naturally rises and is first installed on the truck. This process requires
falls for a loaded truck depending on road and driving several steps and uses the laptop computer to make
conditions. The payload meter records the top 5 the necessary settings. The setup procedure can be
highest payload calculations and the time they broken down into several steps:
occurred. This information is stored in permanent
memory inside the meter.
• Connecting the laptop to the PLMIII system.
• Starting communications
Maximum Speed Data
• Setting the time & date
The payload meter records the top 5 highest speeds • Setting the truck type
and the time they occurred. This information is
stored in permanent memory inside the meter. • 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-
PC SOFTWARE OVERVIEW lation when it is inserted into the drive on the PC. If
this does not happen, the software can be installed
PC Overview by running the Setup.exe program on the CD ROM.
The PC software has several basic functions: The minimum PC requirements for running the soft-
ware is a Pentium 133Mhz with 64 MB of ram and at
• Configure the PLMIII system on the truck.
least 300 MB of free hard drive space available. For
• Troubleshoot and check the PLMIII system. improved performance, the recommended PC would
• Download data from the PLMIII system. be a Celeron, AMD K6-2 or better processor with 128
MB of ram running at 400 Mhz. The PDM Software
• Analyze data from the payload systems. uses a powerful database to manipulate the large
amounts of data gathered from the PLMIII system.
Using a more powerful computer and added memory
Configuration, troubleshooting and downloading
to run the software can result in a significant
require a serial connection to the payload meter on improvement in performance. The software is written
the truck. Analysis can be done at any time without a to use a minimum 800x600 screen resolution.
connection to the payload meter.
Payload data is downloaded from several trucks into
one database on the PC. The database can be que-
ried to look at the entire fleet, one truck or truck
model. The data can be graphed, reported, imported
or exported. The export feature can take payload
data and save it in a format that spreadsheet pro-
grams like Excel or word processing programs can
easily import.
OM6009 Payload Meter III - Section 60
Page 60-17

DOWNLOADING DATA To download the payload meter:

PLMIII records many types of data. The PLMIII PC
software is designed to download the data from a 1. Connect to the payload meter and start the PC
whole truck fleet. Instead of creating one data file for software.
each truck, the PC software combines all the data
2. From the main menu, select "Connect to Pay-
from many trucks into one database on the hard
load Meter". The PC will request the latest sta-
drive of the computer. The software then allows
tus information from the payload meter. The
users to query the database to create custom reports
number of haul cycles and alarms will be dis-
and graphs. Data for individual trucks or groups of
played.
trucks can be easily analyzed. This same data can
be exported for use in other software applications like 3. Select the " Begin Download" button. The PC
word processors and spreadsheet applications. will request the payload and alarm data from
the payload meter and save it into the data-
As the database grows, performance of the PC soft- base. This may take several minutes. A
ware for analysis will slow down. It may be helpful to progress bar at the bottom will show the
periodically export data. For example, query the approximate time left.
database to show the oldest quarter, month, or half
year and print out a summary report. Then export
the data to a compressed format and save the file in
a secure location. Once the data is exported, delete
the entire query results from the database. If neces-
sary, the data can easily be imported back into the
main 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 data
from all the trucks is added to the same database.
Downloading the payload meter can take several
minutes. The data is added to the database on the
laptop used to download.
To move the data to another computer, a query must
be run to isolate the particular data for export. Do not
press the operator switch on the dashboard while
downloading
Payload Meter III - Section 60 OM6009
Page 60-18

PLMIII SYSTEM CONFIGURATION Short Tons: Payload is displayed in short tons,

distances and speeds will be displayed in
Starting Communications
Miles
The PDM software allows users to download and Metric Tons: Payload is displayed in metric
configure the system. tons, distances and speeds are displayed in
Kilometers
Long Tons: Payload is displayed in long tons,
distances and speeds are displayed in Miles
Time Units
Minutes and Seconds Example:
Five minutes and thirty-two seconds = 5:32
Decimal Minutes Example:
Five minutes and thirty-two seconds = 5.53

Connection Menu

Before connecting to the payload meter, select

"Change Program Options" and confirm that the pro-
gram has selected the correct laptop serial port.
Most laptops use Comm 1 for serial communications.
The units displayed for reports and graphs by the PC
software can be set on this form. Click “Done” to
return to the main menu.

The connection screen displays basic system infor-

mation to the user.
• Frame S/N should agree with the truck serial
number from the serial plate located on the truck
frame.
• Truck Number is an ID number assigned to the
truck by the mine.
From the main menu, click the "Connect to Payload • The Payload Meter Date / Time values come
Meter" button. The PC will try to connect to the pay- from the payload meter at the moment of
load meter and request basic information from the connection.
• Number of Haul Cycle Records is the number of
system. In the event of communications trouble, the
haul cycles records stored in memory and
PC will try 3 times to connect before "timing-out". available for download.
This may take several seconds. • Number of Active Alarms shows how many
alarms are currently active in the system at the
time of connection. If there are active alarms,
Displayed Payload Units the "Display Active Alarms" button is available.
• Number of Inactive Alarms shows how many
alarms have been recorded in memory and are
available for download.
• PLM Software Version displays the current
version of software in the payload meter.
Three options are available for the display of units in
the PC software, reports, and graphs:
OM6009 Payload Meter III - Section 60
Page 60-19
The information on the connection menu comes from Setting the Date and Time
the configuration of the payload meter system on the
truck.
There are also many configuration and download
options available from this screen. The Connection
Menu is updated only when the connection is first
made. It does not update automatically. To view
The time shown on the form is the time transmitted
changes made while connected, the user must close
from the payload when the connection was first
the window and reconnect to the payload meter.
established.
The connection menu is displayed after a serial con-
nection has been established and the PC software
has connected to the payload meter.

Connecting to the Payload Meter

Communications to the PLMIII requires a laptop
computer running the PDM software. The software
connects to the payload meter through the meter's
serial port #1. This is the same port used by the
speedometer/display gauge. When the laptop is The date and time are maintained by a special chip
using the serial port, the lower display on the opera- on the PLMIII circuit board. The memory for this chip
tor gauge on the dashboard will be blank. This does is maintained by a very large capacitor when the
not affect the operation of the speedometer. power is removed from the payload meter. This will
• Connect the laptop to the system using the maintain the date and time settings for approximately
EF9160 communications harness. The download 30 days. After this time, it is possible for the payload
connector is typically located on the housing meter to lose the date and time setting. It is recom-
mounted in the cab to the back wall. The PLMIII mended that the system be powered every 20 days
system uses the same connection as the to maintain the date and time. If the date and time is
Payload Meter 2 system. lost, simply reset the information using this proce-
dure. It takes approximately 90 minutes to recharge
Configure the Payload Meter the capacitor.
Configuration of the payload meter requires a serial Changing the date and time will affect the haul cycle
connection to the PLMIII system. Clicking the "Con- in progress and may produce unexpected results in
figure Payload Meter" button will bring up the Truck the statistical information for that one haul cycle.
Configuration screen and menu. This screen dis-
plays the latest configuration information stored on To change the time:
the payload meter. 1. Click on the digit that needs to be changed.
When changes are made to the configuration, the 2. Use the up/down arrows to change or type in
"Save Changes" button must be pressed to save the the correct value.
changes into the payload meter. To confirm the 3. Press the "Save Changes" button to save the
changes, exit to the main menu and re-connect to the new time in the payload meter.
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.
Payload Meter III - Section 60 OM6009
Page 60-20

Setting the Truck Type Setting the Truck Number

Most mining operations assign a number to each
piece of equipment for quick identification. This num-
ber or name can be entered in the Truck Number
field. It is very important to enter a unique truck num-
1. From the Truck Configuration screen, use the
ber for each truck using the PLMIII system. This
pull-down menu to select the truck type that the
number is one of the key fields used within the haul
payload meter is installed on.
cycle database. The field will hold 20 alpha-numeric
2. Press the "Save Changes" button to program characters.
the change into the meter.
1. On the Truck Configuration screen, enter the
truck number in the appropriate field.
Setting the Gauge Display Units 2. Press the "Save Changes" button to program
the change into the payload meter.
The Payload Meter Speedometer / Display Gauge
displays the speed on the upper display. The units
for the speed display are selected using a jumper on
the rear of the case.
Setting the Komatsu Distributor
The payload units on the lower display can be
changed from metric to short tons or long tons using This field in the haul cycle record can hold the name
the Truck Configuration screen. This selection also of the Komatsu distributor that helped install the sys-
switches between metric (kg/cm2) and psi (lbs/in2) tem. Komatsu also assigns a distributor number to
for the live display of pressure on the gauge. each distributor. This number is used on all warranty
claims. This Komatsu distributor number can also be
1. From the Truck Configuration screen, select the put into this field. The field will hold 20 alpha-
payload units to be used on the lower display of numeric characters.
the speedometer/display gauge.
1. On the Truck Configuration screen, enter the
2. Press the "Save Changes" button to program
distributor name or number in the appropriate
the change into the payload meter.
field.
2. Press the "Save Changes" button to program
the change into the payload meter.
Setting the Frame Serial Number

Setting the Komatsu Customer

This field in the haul cycle record can hold the name
of the mine or operation where the truck is in service.
Komatsu also assigns a customer number to each
customer. This number is used on all warranty
The frame serial number is located on the plate claims. This Komatsu customer number can also be
mounted to the truck frame. The plate is outboard on put into this field. The field will hold 20 alpha-
the lower right rail facing the right front tire. It is very numeric characters.
important to enter the correct frame serial number.
This number is one of the key fields used within the 1. On the Truck Configuration screen, enter the
haul cycle database. The field will hold 20 alpha- customer name or number in the appropriate
numeric characters. field.
2. Press the "Save Changes" button to program
1. On the Truck Configuration screen, enter the
the change into the payload meter.
truck frame serial number in the appropriate
field.
2. Press the "Save Changes" button to program
the change into the payload meter.
OM6009 Payload Meter III - Section 60
Page 60-21
Clean Truck Tare Inclinometer Calibration

The payload meter uses the clean truck tare value to

calculate carry-back load for each haul cycle. The The inclinometer calibration procedure is designed to
carry-back stored in the haul cycle record is the new compensate for variations in the mounting attitude of
empty tare minus the clean truck tare. the inclinometer. The inclinometer input is critical to
the payload calculation.
This procedure should be performed after service to
the suspensions or when significant changes are This procedure should be performed on relatively flat
made to the sprung weight of the truck. Before per- ground. Often the maintenance area is an ideal loca-
forming this procedure, be sure the suspensions are tion for this procedure.
properly filled with oil and charged. It is critical to 1. After cleaning debris from the truck and check-
payload measurement that the proper oil height and ing to see that the suspensions are properly
gas pressure be used. serviced, use the PLMIII software to connect to
Once the clean tare process is started, the payload the payload meter.
meter will begin to calculate the clean empty sprung 2. From the "Truck Configuration" screen, select
weight of the truck. This calculation continues while "Inclinometer".
the truck drives to the next loading site. Once the 3. With the truck stopped and the brake lock on,
procedure is started, there is no reason to continue press the “Start” button. This instructs the pay-
to monitor the process with the PC. The truck does load meter to sample the inclinometer once.
not need to be moving to start this procedure. 4. Turn the truck around. Drive the truck around
1. After cleaning debris from the truck and check- and park in the exact same spot as before, fac-
ing to see that the suspensions are properly ing the other direction.
serviced, use the PLMIII software to connect to 5. With the truck stopped and the brake lock on,
the payload meter. press the “Start” button. This instructs the pay-
2. From the "Truck Configuration" screen, select load meter to sample the inclinometer again.
"Clean Truck Tare". The payload meter will average the two sam-
3. Be sure to follow the screen instructions. ples to determine the average offset.
6. Be sure to follow the screen instructions.
Payload Meter III - Section 60 OM6009
Page 60-22

DATA ANALYSIS Sorting on Truck Unit Number

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

Payload Summary Form

Creating a Query Sorting on Truck Type

The program defaults to show all trucks, all types, The truck type is the size of the truck from the family
all dates and all times for the initial query. The dis- of Komatsu trucks. This allows the user to quickly
play can be narrowed by selecting which trucks or view results from different types of trucks on the
types to view and for what dates and times. property. For example, a separate report can be
generated for 830E and 930E trucks.
The query items are added in the "AND" condition.
If the user selects a truck # and date range, the
query will sort the data for that truck number AND
the date range.
OM6009 Payload Meter III - Section 60
Page 60-23
Sorting on Date Range 2. Change the “From” date to July 1, 2000.
The default query starts in 1995 and runs through the
current date on the PC. To narrow the range to a
specific date, change the “From” and “To” dates.
For example, to view the haul cycle reports from
truck 374 for the month of July, 2000:

1. Select truck 374 from the Truck Unit pull-down

menu. 3. Change the “To” date to July 31, 2000.
4. Change the “From” time to 06:00.
5. Change the “To” time to 18:00.

6. Press the "Query Database and Display" to

view the results.

2. Change the “From” date to July 1, 2000.

This query will display haul cycles from January 5 to
January 8, from 6:00 AM to 6:00 PM.
Date
Time
Jan 5, 2000 Jan 6, 2000 Jan 7, 2000 Jan 8, 2000 Jan 9, 2000
0:00

6:00

3. Change the “To” date to July 31, 2000.

4. Press the "Query Database and Display" to 12:00

view the results.

18:00

Sorting on Time Range

The time range sorts the times of the day for valid
dates. Changing the time range to 6:00AM to 24:00

6:00PM will limit the payloads displayed to the loads Query : Date: 1/5/00 to 1/8/00
Haul Cycles Included in the Query
Daily Shift Time: 6:00 to 18:00
that occurred between those times for each day of
the date range. Times are entered in 24:00 format.
To view the haul cycle reports from the first shift for
truck 374 from January 5, 2000 to January 8, 2000:
The shift times selected can extend the query past
the original date. If the dates set for the query are
1. Select truck 374 from the Truck Unit pull-down January 5 to January 8 and the times were changed
menu. to 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:
Payload Meter III - Section 60 OM6009
Page 60-24

Creating Reports
Date
Time
Jan 5, 2000 Jan 6, 2000 Jan 7, 2000 Jan 8, 2000 Jan 9, 2000
Reports can be generated and viewed on the screen
0:00 or printed. These reports are generated from the
query displayed on the Payload Summary Screen.
From the example in "Sorting on Time Range", the
report printed would only contain data from truck 374
6:00
during the month of July 2000, from 8:00 AM to 5:00
PM.

12:00
It is important to carefully select the query data and
press the "Query Database & Display" button before
printing a report.

18:00

24:00

Query : Date: 1/5/00 to 1/8/00

Haul Cycles Included in the Query
Daily Shift Time: 18:00 to 6:00

Payload Detail Screen

The Payload Detail screen gives the details for any
individual haul cycle. From the “Payload Summary”
screen, double-click on any haul cycle to display the
detail.
OM6009 Payload Meter III - Section 60
Page 60-25

NOTE: Some haul cycles may contain the Sensor

Input warning flag. This indicates that one of the
four pressure sensors or inclinometer was not
functioning properly during the haul cycle. Haul
cycles with this warning are displayed in red on the
Payload Summary window and are not included in
the summary statistics for reports or display.

Summary - one page report

A summary of the queried data can be printed onto
1 page. The cycle data is summarized onto one
sheet. Displayed is the speeds, cycle times, load
statistics, frame and tire data.

Detailed - multi-page report

The detail report starts with the summary report and
follows with pages of data for each haul cycle. The
detailed report prints date, time, payload, cycle
times, and cycle distances, speeds and the number
of swing loads.
Payload Meter III - Section 60 OM6009
Page 60-26

Creating Graphs Exporting Data

The PLMIII software can generate graphs that
quickly summarize payload data. These graphs can
be customized for printing. Just like the reports, the
graphs are generated from the query displayed on
the “Payload Summary” screen. From the "Sorting
on Time Range" example, the graph that is printed
would only contain data from truck 374 during the
month of July 2000, from 8:00 AM to 5:00 PM.
It is important to carefully select the query data and
press the "Query Database & Display" button before
creating a graph.
The data from the database can be exported for use
1. From the Payload Summary Screen select the with other software applications. The data is
“Graph” button at the bottom. The Histogram selected from the currently displayed query. The
Setup screen will display. exported data can be put into a ".CSV" file or a com-
pressed ".zip" file.

• The “.CSV” format allows data to be easily

imported into spreadsheet applications and word
processing applications.
• The “.Zip” format allows data to be transferred
from one computer to the PDM Software
database on another computer. This offers a
compact way to transfer data from one computer
to another.

CSV Export

2. Enter the "Lowest Value". This will be the low-

est payload on the graph. Any payloads less
than this value will be summed in the first bar.
3. Enter the "Highest Value". This will be the high-
est value on the graph. Payloads over this
value will be summed in the last bar.
4. Enter the "Incremental Change". This will
determine the number of bars and the distance
between them. The program limits the number
of bars to 20. This allows graphs to fit on the
CSV stands for Comma Separated Value. This is an
screen and print onto 1 page.
ASCII text file format that allows spreadsheet appli-
5. Press the “Create Graph” button. cations like Excel and Lotus 123 to import data eas-
The graph will be displayed based on the query set- ily. To export the data into a ".csv" file, press the
tings from the Payload Summary screen. The graph "Export" button at the bottom of the payload sumary
can be customized and printed. screen and select "To CSV". The program will
request a filename and location for the file.
OM6009 Payload Meter III - Section 60
Page 60-27
. • Reserved 1-5, 7-10: These values are internal
calculations used in the continued development
of PLMIII and should be ignored.
• Reserved 6: This value is the payload estimate
at the shovel just before the truck begins to
move.

Two sets of data are exported. At the top of the file

will be the haul cycle data. The columns, left to right
are:

• Truck number The second series of data below the haul cycle data
• Haul cycle start date is the alarms. The alarm columns, left to right are:
• Haul cycle start time
• Payload
• Swingloads • The alarm type
• Operator ID • The date the alarm was set
• Warning Flags • The time the alarm was set
• Carry Back • Alarm description
• Total Haul Cycle time • The date the alarm was cleared
• Empty Running Time • The time the alarm was cleared
• Empty stop time
• Loading time
• Loaded running time
• Loaded stopped time
• Dumping time Compressed
• 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 This export function allows the data from one laptop
• Maximum sprung weight calculation to be transferred to another computer. This can be
• Time when the maximum sprung weight useful when a service laptop is used to download
calculation occurred multiple machines and transfer the data to a central
• Left Front Tire-kilometer-hour computer for analysis. This can also be used to copy
• Right Front Tire-kilometer-hour haul data from a particular truck onto a diskette for
• Average Rear Tire-kilometer-hour analysis.
• Frame serial number
The file format is a compressed binary form of the
displayed query. The file can only be imported by
another computer running the PDM Software.
Payload Meter III - Section 60 OM6009
Page 60-28

To export data in ZIP format: Deleting Haul Cycle Records

1. Confirm that the data displayed is the query To delete haul cycle records from the main database,
data that needs to be exported. press the "Delete" button at the bottom of the “Pay-
2. From the payload summary screen, press the load Summary” screen. The program will display a
"EXPORT" button and select "To ZIP". summary of the records from the displayed query. To
delete a record, select one at a time and press the
3. The program will ask for a filename and loca-
"Delete" button. It is recommended that records be
tion.
exported to a zip file for archival purposes before
deletion. Multiple records may be selected by hold-
ing down the Shift key. Pressing the "Delete All" but-
Importing Data ton will select all the records from the current query
This import function allows the data from one laptop and delete them.
to be transferred to another computer. This can be
useful when a service laptop is used to download
multiple machines and transfer the data to a central NOTE: There is no recovery for records that have
computer for analysis. This can also be used to copy been deleted from the main database. It is highly
haul data from a particular truck from a diskette into a recommended that all records be exported and
database for analysis. archived in a compressed file format for future
reference before being deleted.
To import data, press the "IMPORT" button at the
bottom of the “Payload Summary” screen. The pro-
gram will ask for a ".zip" file to import, locate the file
and press "Open". The program will only import
".zip" files created by another computer running the
PDM Software.
OM6009 Payload Meter III - Section 60
Page 60-29
Viewing Alarms Deleting Alarm Records
To delete alarm records from the main database,
From the Payload Summary screen, click the
press the "Delete" button at the bottom of the “Alarm
“Alarms” button to display the alarm screen. The
Display” screen. The program will display a
alarms are sorted by the query settings from the Pay-
summary of the alarms from the query. To delete an
load Summary screen. Alarms can be displayed as
alarm, select one at a time and press the "Delete"
Active or Inactive.
button. It is recommended that the query data be
exported to a “.zip” file for archival purposes before
deletion. Multiple records may be selected by
holding down the Shift key. Pressing the "Delete All"
button will select all the alarms from the current
query and delete them.

NOTE: There is no recovery for alarms that have

been deleted from the main database. It is highly
recommended that all records be exported and
archived in a compressed file format for future
reference before being deleted.
Payload Meter III - Section 60 OM6009
Page 60-30

NOTES

PORTIONS OF THIS PRODUCT RELATING TO PAYLOAD MEASURING SYSTEMS ARE

MANUFACTURED UNDER LICENSE F ROM

L.G. HAGENBUCH holder of

U.S. Patent Numbers 4,831,539 and 4,839,835
OM7004 Cab Radio - Section 70
Page 70-1

RADIO, AM / FM STEREO CASSETTE

FIGURE 70-1. CAB RADIO

SETTING THE TIME GENERAL RECEIVER FUNCTIONS

1. Turn the key switch ON. The receiver is equipped with two FM radio bands,
FM1 and FM2. The two bands are identical, however,
2. Press and hold DSPL/TM SET (9) for 2 sec-
each one allows the operator to set 6 preset
onds. When the number display flashes, time
set mode is active. channels for a total of 12 FM presets overall.

3. Press TUNE / SEEK (7 & 8) to change the Turning The Power On And Off
hour setting. 1. Turn the key switch to ON.
4. Press the DSPL/TM button to switch to minutes. 2. Press PWR (1) to turn the receiver on and off.
The minute digits will flash when in this mode. Pushing ON/AUDIO (6) may also be used to
turn the receiver power on.
5. Press TUNE / SEEK to change the minute
setting. Display
After 5 seconds of inactivity has elapsed, the display
will return to the default mode. The clock will now With the receiver off, the clock will be displayed.
display the correct time of day. Momentarily pressing DSP/TM SET (9) with the
receiver on will allow the operator to toggle between
displays.

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

the display will toggle between the frequency and
the clock.
• When the receiver is in an active satellite mode
and the provider is transmitting the available
information, the display will toggle between the
clock, frequency, station name, artist, song title
and music type.
Cab Radio - Section 70 OM7004
Page 70-2

• When the receiver is in the cassette mode, the When in satellite mode, press and release either the
display will toggle between TP SIDE 1 or TP TUNE or the SEEK buttons to navigate to the
SIDE 2, and the clock.
next channel. Pressing and holding either of the two
buttons for more than 0.5 seconds will increase the
Setting The Default Display cycle speed through the channels. The increase
cycle speed is approximately 10 channels per sec-
1. Press and hold DSPL/TM (9) for 2 seconds until ond.
the hour digits flash.
2. Press push-button 6/FF (15) to change the SEEK Mode
default display.
Hold either the TUNE or SEEK buttons for more
After 5 seconds of inactivity has elapsed, the
than 0.5 seconds to enter the seek mode. SEEK will
selected default will display.
appear on the display when this mode is activated. In
this mode, the radio will scroll through stations and
Adjusting Display Brightness stop on the next station with a strong signal.

1. Press and hold DIM (14) until DIM appears on NOTE: If the receiver can not find a strong enough
the display. signal after two band cycles, the seek mode will
discontinue and the receiver will return to the initial
2. Rotate ON/AUDIO knob (6) clockwise or coun- starting point.
terclockwise until the desired brightness is
obtained. When in satellite mode, press TUNE or SEEK to
navigate through the channels. Pressing and holding
either of the two buttons for more than two seconds
will increase the cycle speed through the channels.
The increase cycle speed is approximately 10 chan-
nels per second.
OPERATING THE RADIO SCAN
BAND Press SCAN button (10) to scan all stations on the
current band. When a strong frequency is found, the
Press BAND (2) to switch between FM1, FM2, AM,
receiver will pause on that station for about 5 sec-
and WX Weather (US) and Satellite (XM1, XM2 or
onds and then continue scanning. Scan will appear
SR1, SR2). If a separate satellite receiver is not con-
on the display along with the frequency when this
nected to your radio and operational, the satellite
mode is active. To stop scanning, press the SCAN
bands will not appear in the display.
button again.
TUNE/SEEK AUTO
TUNE (7) / SEEK (8) allows you to move up or AUTO (12) allows the receiver to store the 6 stron-
down in frequency to other stations. There are two gest stations onto push-buttons 1 through 6. Press
modes of operation for finding other stations, manual AUTO until AUTO and AS appear on the display. The
tuning and seek mode. presets on the current band only will now be pro-
grammed with the 6 strongest frequencies. Presets
Press and hold both TUNE (8) and BAND (2) for 2 on the other inactive bands will not be changed.
seconds to toggle between the two modes. The dis- Pressing AUTO again will delete the stations and
play will read either MANUAL or SEEK to indicate the default to the original preset stations.
mode the receiver is in.
NOTE: The AUTO function is not functional on the
Manual Tuning satellite band.

Press TUNE (8) to tune to the next higher fre-

quency. Press SEEK (7) to tune to the next lower
frequency. Holding either of the buttons for more than
0.5 seconds will activate fast tuning for increased
speed.
OM7004 Cab Radio - Section 70
Page 70-3

ADJUSTING THE RECEIVER SETTINGS OPERATION OF THE WEATHERBAND

VOLUME: Rotate ON/AUDIO (6) knob clockwise to (U.S.)
increase the volume and counter-clockwise to NOAA - Weather Radio is a service of the National
decrease the volume. VOL will be displayed along Weather Service. It provides continuous broadcasts
with the volume level. of the latest weather information directly from the
National Weather Service offices. Taped weather
BASS: Push and release ON/AUDIO (6) knob until
messages are repeated every four to six minutes and
BASS and the current bass level is displayed. Rotate
are routinely revised every one to three hours, or
the knob clockwise to increase the bass and counter-
more frequently if needed. Most of the stations oper-
clockwise to decrease the bass.
ate 24 hours, daily.
TREBLE: Push and release ON/AUDIO (6) knob
The weather for the area you are in may be found on
until TREB and the current treble level is displayed.
one of 7 stations. When in the Weatherband mode,
Rotate the knob clockwise to increase the treble and
the display will show the WX icon and CHAN # to
counter-clockwise to decrease the treble.
indicate the channel. The channel may be adjusted
FADE: Push and release ON/AUDIO (6) knob until through the TUNE /SEEK buttons, and may be
FADE and the current level is displayed. Rotate the preset as in the radio mode.
knob clockwise to move the sound to the front speak- The frequency associated with each channel is as
ers and counter-clockwise to move the sound to the follows:
rear speakers.
BALANCE: Push and release ON/AUDIO (6) knob 1. 162.550 MHz 5. 162.450 MHz
until BAL and the present level is displayed. Rotate 2. 162.400 MHz 6. 162.500 MHz
the knob clockwise to move the sound to the right 3. 162.475 MHz 7. 162.525 MHz
speakers and counter-clockwise to move the sound 4. 162.425 MHz
to the left speakers.
SPEAKER: Push and release ON/AUDIO (6) knob
until SPKR and the current setting is displayed. The National Weather Service operates approxi-
Rotate the ON/AUDIO knob to select 2-speaker or 4- mately 372 stations. Close to 90 percent of the
speaker operation. When 2-speaker operation active, nation's population is within the listening range of a
the rear speakers are muted and the FADE option NOAA Weather Radio broadcast.
will not appear on the menu.

PROGRAMMING PRESET STATIONS

Presets are stations that are stored on each of the 6
push-buttons. After a station has been programmed
into one of the preset buttons, pushing the preset
provides a quick return to that station. The six but-
tons can each store a preset channel per band.
Perform the following steps for programming 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 2 seconds. During the 2 second period,
receiver output will be muted and the push-but-
ton number will not show on the display. When
the station has been committed to memory, the
audio and the preset icon will return.
4. Repeat steps 1 through 3 for the remaining
available presets.
Cab Radio - Section 70 OM7004
Page 70-4

SATELLITE RADIO
In order to use the satellite radio function on your Operating Satellite Radio
radio, a subscription must be ordered from a pro-
vider. There are two providers in the U.S. currently, 1. Use the BAND button to select the proper satel-
XM and Sirius Satellite Radio. When a subscription is lite radio band. (XM1, XM2, SR1, SR2)
ordered, an additional receiver and antenna will need 2. Use the TUNE and SEEK buttons to navi-
to be obtained from your provider. gate through the channels.
To activate the external satellite receiver, you must
supply the provider with your Electronic Serial Num-
ber (ESN). To find the ESN, first install the satellite Program Type Search (PTY)
receiver per instructions from the your provider. Next,
XM and Sirius both allow you to search by music
follow the instructions below.
type. Program Type Search (PTY) allows you to per-
XM Satellite Radio: form a music search by type. Perform the following
1. Turn both the radio and the satellite receiver on. steps in order to do a PTY search.
Press the BAND button on the radio and select
either XM1 or XM2.
1. Press SCAN and push-button 1 at the same
2. Tune your satellite receiver to channel 0 to see time. PTY will appear on the display.
the ESN display.
2. Continue to press push-button 1 until the
Record the ESN. desired genre of programming is displayed.
The display will return to the default setting after 3. Once the desired genre has been selected,
5 seconds. press the TUNE and SEEK buttons to scroll
Sirius Satellite Radio: through the different channels in that genre.
Station names will appear on the display as
1. Turn the radio on and with the display showing your scroll.
the clock, press and hold the DSPL/TM SET
button until the hours segment is flashing. You may also scan through the channels using
the scan feature. Press the SCAN button to
2. Press the BAND button and the ESN will be dis-
begin scanning the channels. Press the SCAN
played.
button again to stop at the desired channel.
Record the ESN.
The display will return to the default setting after
5 seconds.

NOTE: Only one satellite receiver can be installed

and connected to your receiver at one time.
NOTE: Obstructions in the satellite signal may impair
your satellite radio reception. Contact your provider
for satellite radio reception problems.
OM7004 Cab Radio - Section 70
Page 70-5

CASSETTE PLAYER Cassette Functions

The cassette player that the radio is equipped with 4/REV (17): This button rewinds the cassette. The
works best with cassettes that range from 30 to 90 cassette will continue to rewind until the button is
minutes long. Cassettes that are longer than 90 min- pressed again, or until the cassette reaches the end
utes have thinner tape, and do not work well in this of the tape. <REW will appear on the display as the
model cassette player. cassette is rewinding.
It is also important to only use cassettes that are in 6/FF (15): This button fast forwards the cassette. The
good condition. Cassettes that are dirty, damaged, or cassette will continue to fast forward until the button
have been exposed to excessive heat and/or sunlight is pressed again, or until the cassette reaches the
could cause damage to the cassette player and pos- end of the tape. FWD> will appear on the display as
sible failure. the cassette is fast forwarding.
The cassette player is equipped with automatic
equalization and metal tape sensing functions. An M Eject (5): Press this button to eject the cassette
will appear on the display when a metal tape is from the player. When the eject button is held, it acts
sensed. as a stop button.
Cleaning the cassette player is a recommended
maintenance item. It should be performed at 35 hour (4): This button causes the cassette player to
(cassette play) intervals. Failure to clean the cassette reverse directions and play the opposite side of the
player may diminish sound quality and cause cas- cassette. Pressing the button a second time will
sette player failure. reverse the cassette back to the original side.
NOTE: The cassette will automatically flip to the
Playing A Cassette
opposite side when the end of the tape is reached.
1. Turn the receiver ON.
2. Insert a cassette into the player. The cassette
icon will appear on the display. The tape will
begin to play when the icon appears.
PROGRAMMABLE EJECT DEFAULT
Press button (3) to change from the radio The cassette player has been pre-programmed to
to a cassette. TP SIDE 1 or TP SIDE 2 will return to the radio after a tape has been ejected. This
appear on the display depending on which side default may be changed to an “eject audio mute”
of the cassette is currently being played. If a mode. This mode will mute the radio after a cassette
cassette is not loaded in the player, NO TAPE has been ejected. When this occurs, “NO TAPE” will
will appear on the display. appear on the display and the radio will remain
NOTE:A tape may be inserted when the receiver is muted until BAND (2) is pressed. Pressing this button
off by pressing the eject button and inserting the tape will enable the radio.
within 25 seconds. Perform the following steps to change the eject
default mode:
1. Press and hold DSP/TM SET (9) for at least 2
seconds until the hour digits flash.

2. Press button (3) to toggle between

“P.PLAY” and “EJMUTE”. After 5 seconds of
inactivity, the receiver will return to the default
display.
Cab Radio - Section 70 OM7004
Page 70-6

Bad Tape Detect CASSETTE PLAYER CLEANING

If the receiver detects a bad cassette, “BAD TAPE” After 35 hours of cassette play, the display will read
will appear on the display, and the tape will be TP CLEAN for 5 seconds. This indicates that it is
ejected. If this occurs, the cassette should be time to clean the cassette player.
removed from the player and should not be re-
1. Turn the key switch to ON, and turn the receiver
inserted.
off.
If it is desired to use a cleaning tape or a CD adapter 2. Disable BAD TAPE DETECT mode. Press and
in the cassette player, the bad tape detector must be
turned OFF. Perform the following steps in order to hold button (3) for 5 seconds. “BAD TAPE
disable this mode: DETECT OFF” will appear on the display. When
this is displayed, the detector has been dis-
1. Turn the receiver off and turn the key switch to abled.
OFF.
3. Turn the receiver on.
2. Press and hold button (3) for 5 seconds. 4. Insert a wet-type, non-abrasive, scrubbing cas-
“BAD TAPE DETECT OFF” will appear on the sette cleaner. Follow the instructions provided
display. When this is displayed, the detector has with the cleaner.
been disabled. 5. Reset the clean tape timer. With the receiver on,
Repeat this procedure to reactivate the bad press and hold the eject button for 5 seconds.
tape detector. “BAD TAPE DETECT ON” will TP CLEAN will appear on the display and the
appear on the display after the detector has tape icon will flash after 3 seconds has elapsed.
been activated. After 5 seconds CLN RST will appear on the
display. When this occurs, the clean tape timer
will be reset to zero hours. If the button was
released before CLN RST was displayed, the
timer will not be reset.