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730E-8
Dump Truck
Serial # A40004 and up

Komatsu America Corp.


Lesson 7.1 Cartersville Georgia USA
wPTU 10 Copyright © 2017 All rights reserved.

Copyright © 2017 Technical Training ELTE0077717E0BK2


wPTU 10 Diagnostics for Quad chopper
Subject to 2017 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

2017 Terms of Use of Komatsu Training Materials

These training materials represent the confidential and proprietary information of


Komatsu America Corp. (Komatsu). These training materials have been issued to,
and may only be relied upon by, individuals authorized to participate in a Komatsu
sponsored training class and for use in the class. These training materials and their
contents may not be modified, copied, reproduced, published, uploaded, posted,
transmitted, distributed or otherwise used for any other purpose without prior written
authorization of a Komatsu officer. These training materials do not create,
supplement, amend or expand upon any warranties whatsoever concerning
Komatsu products. These training materials do not serve as a substitute for the
operation and maintenance manuals and technical supplements published by
Komatsu on the Komatsu products. These Terms of Use on the training materials
will be construed in accordance with and governed by the laws of the State of
Illinois, U.S.A. Any legal action filed by an individual or his employer or principal
against Komatsu arising out of or related to these training materials will be filed
exclusively within a State or Federal court located in the County of Du Page or the
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Slide 2
wPTU 10 Diagnostics for Quad chopper
Subject to 2017 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

Course Objectives
After successful completion of this lesson, the student will…..
● Understand the features and diagnostic functions of the General
Electric wPTUTM Tool Box
● Learn about operational aspects
● Utilization of the following features and menu’s,
 Software installation
 DSC Real time data and logic screens
 DSC Special tests, Load box, Capacitance and Digital I/O
 DSC Event and Statistical data collection and storage
 DSC Data Capture, single and multiframe snapshots
 Console configuration construction
 Programming Panels (INVERTER and DSC)

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Slide 3
wPTU 10 Diagnostics for Quad chopper
Subject to 2017 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

Disclaimer
● This class material is not
meant to replace the Service
Manual as a source of
technical/operational
information.
● It is always the operator’s
responsibility to read and
comprehend the Service
Manual furnished with the
equipment.

Technical Training ELTE0077717E0BK2


Slide 4
wPTU 10 Diagnostics for Quad chopper
Subject to 2017 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

WINDOWS based diagnostic PTU software


compatible with 32 and 64 bit O.S.

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Slide 5
wPTU 10 Diagnostics for Quad chopper
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Slide 6
wPTU 10 Diagnostics for Quad chopper
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wPTU Connections

Traditional
wPTU Diag.
Serial Port

PROGRAM
CONSOLE
PORT
PORTS

wPTU/Console
Ethernet Port Ethernet Port
192.168.3.1 192.168.0.1

Operators Cab Card Rack


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Slide 7
wPTU 10 Diagnostics for Quad chopper
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Launch Platform

choose

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Slide 8
wPTU 10 Diagnostics for Quad chopper
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DSC Menu

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Slide 9
wPTU 10 Diagnostics for Quad chopper
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DRIVE STATUS tab

PSC

TCI

N/A

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Slide 10
wPTU 10 Diagnostics for Quad chopper
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Real Time Data Screen


OPEN: 14.4v
SET: 9.7v
CANCEL: 4.4v
COAST/DECCEL: 2.5 v
RESUME/ACCEL: 0.9v
Out of range
values in BLUE are in spec

Composite of all
Individual temperatures
PEDAL; 1.00 = full 0.55 = 55%
CRUISE; 1= active 0= inactive CRUISE set point

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Slide 11
wPTU 10 Diagnostics for Quad chopper
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Analog Inputs

ROTOR GND. N/A

FB173 card,
rack ground

10V wire

Should read 10.00v


N/A

DIODE Fault
detection function
0 = NOT TRUE

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Slide 12
wPTU 10 Diagnostics for Quad chopper
Subject to 2017 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

System Temperatures

SYS. Temperature
as % of MAX

PT100 Sensor

All values except Ambient, CPU &


AFSE are CALCULATED

PT100 Sensor

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Slide 13
wPTU 10 Diagnostics for Quad chopper
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ENGINE DATA (CAN BROADCAST)

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Slide 14
wPTU 10 Diagnostics for Quad chopper
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FB173 card data

Ripple index -1800 = abs flat line


> +000 will cause FDP trip

ATOC = Alt Tertiary Current, (not shown anywhere else)

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Slide 15
wPTU 10 Diagnostics for Quad chopper
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Logic States

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Slide 16
wPTU 10 Diagnostics for Quad chopper
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CONFIGURATION, Parameters

Allows system parameter modification


which are lost at key off.

Not for general diagnostics

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Slide 17
wPTU 10 Diagnostics for Quad chopper
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Analog Options

Not designated for general


Trouble Shooting

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Slide 18
wPTU 10 Diagnostics for Quad chopper
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CONFIGURATION, Soft Ware

Provides details about the CPU


installed software

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Slide 19
wPTU 10 Diagnostics for Quad chopper
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CONFIGURATION, DSC Data Log Setup

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Slide 20
wPTU 10 Diagnostics for Quad chopper
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Data Logger set up

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Slide 21
wPTU 10 Diagnostics for Quad chopper
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Start / Stop DATA LOG

Typical Com error


NO RS232
available on PC

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Slide 22
wPTU 10 Diagnostics for Quad chopper
Subject to 2017 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

CONFIGURATION, Pedal Cal & Set Truck ID

Back up screens
forD.I.D.
for DID

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Slide 23
wPTU 10 Diagnostics for Quad chopper
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Loadbox Test

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Slide 24
wPTU 10 Diagnostics for Quad chopper
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TESTS Temperature

All, except AMB, CPU & AFSE


are calculated!

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Slide 25
wPTU 10 Diagnostics for Quad chopper
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Capacitance Test

Measurement
data of the last
test

Ave. of last 10 checks

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Slide 26
wPTU 10 Diagnostics for Quad chopper
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Slide 27
wPTU 10 Diagnostics for Quad chopper
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Slide 28
wPTU 10 Diagnostics for Quad chopper
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Event Data

System will take a multiframe snap shot of each EVENT


● The EVENT will be listed in the EVENT Summary with date and time of
occurrence and date and time of reset
● A Single frame snap shot of each EVENT will be stored as a multi-page
EVENT TRIGGER DATA file. This file will be as long as the number of
events that occurred since the last EVENT erasure
● A multi frame DATA PACK, (90 before and 30 after) will also be
captured.
● The maximum number of stored EVENTS/DATA PACKS is, 1000.
● The system will manage this storage (FIFO > 80% of memory)
● DATA PACKS can NOT be manually erased, but the system can be set
to automatically “clean up” the DATA PACK memory, by specifying the
maximum age (30 days or more) of data packs in memory.

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Slide 29
wPTU 10 Diagnostics for Quad chopper
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Event Summary

MAX 1000

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Slide 30
wPTU 10 Diagnostics for Quad chopper
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Event Trigger Data

#10 of 501 triggers

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Slide 31
wPTU 10 Diagnostics for Quad chopper
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Data Pack Summary

Maximum 1000

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wPTU 10 Diagnostics for Quad chopper
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RESET Active EVENTS

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Slide 33
wPTU 10 Diagnostics for Quad chopper
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RESET Active EVENTS

SAME AS A
STRONG RESET
via D.I.D. Panel

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Slide 34
wPTU 10 Diagnostics for Quad chopper
Subject to 2017 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

Erase All Events

COMMAND WILL
NOT ERASE
DATA PACKS

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Slide 35
wPTU 10 Diagnostics for Quad chopper
Subject to 2017 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

Event and Data Pack Up-load using wPTU

● All Reports Up-Loads


 Event Summary List
 Event Trigger Data
 Event Data Packs
 Statistics

● All Reports Up-Loads


 Lengthy process
 By Ticking Event Data
Packs, only the interesting
Data Packs can be
selected

● ACPSB9 provides a detailed


procedure to upload data

Take note of -- Upload STATUS Bar


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Slide 36
wPTU 10 Diagnostics for Quad chopper
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Windows Explorer View

All Reports Up-Loads


More than 100 mega bytes
System will assign unique
folder name with each
download
Truck#_date_upload time

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Slide 37
wPTU 10 Diagnostics for Quad chopper
Subject to 2017 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

Replay View
Open off line with either
● Replay PTU format
● Replay CSV format

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Slide 38
wPTU 10 Diagnostics for Quad chopper
Subject to 2017 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

Event and Data Pack Up-load using Thumb/Flash Drive


17FB187, DSC CPU cards offer a mass CSV data dump facility
to streamline the upload process, (converted / readable with wPTU).
● Ensure that the system has power and that Status LED’s are sequencing as normal.
● Insert a Thumb Drive into the 17FB187 USB slot and momentarily short the
Download and Ground pins, all LED’s turn ON.
● The Red Status 2 LED will start flashing, signifies that data is being copied.
● When data copy is complete, the Green Status LED will flash for 5 seconds to
signify that data upload is complete, and it is safe to remove Thumb Drive.
● Then the Status LED’s will resume their “system normal” sequence.
● Refer to the D.I.D. panel module for alternative methods of data dump.

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Slide 39
wPTU 10 Diagnostics for Quad chopper
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SPECIAL TASKS, Events and Parameters

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Slide 40
wPTU 10 Diagnostics for Quad chopper
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SPECIAL TASKS, REAL TIME Dispatch and IM Test

To view status of transmitted data to third party

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Slide 41
wPTU 10 Diagnostics for Quad chopper
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NOTE: STAT data is not erased during DSC config re-program

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Slide 42
wPTU 10 Diagnostics for Quad chopper
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DSC, Serial Config Report

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Slide 43
wPTU 10 Diagnostics for Quad chopper
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View Counters

STAT Resets are


executed via the
“CONSOLE” to be
explained later

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Slide 44
wPTU 10 Diagnostics for Quad chopper
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View Profiles

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Slide 45
wPTU 10 Diagnostics for Quad chopper
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Trip Monitor

Capture
with single
or multi

Launch / View when Launch and close


connected to DSC connection to DSC,
upload from Stat Data

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Slide 46
wPTU 10 Diagnostics for Quad chopper
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Slide 47
wPTU 10 Diagnostics for Quad chopper
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Slide 48
wPTU 10 Diagnostics for Quad chopper
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Digital Output Test

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Slide 49
wPTU 10 Diagnostics for Quad chopper
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Digital Output Test

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Slide 50
wPTU 10 Diagnostics for Quad chopper
Subject to 2017 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

FB187 CPU card special operation Commands


FB187 CPU card provides direct, command and feedback
monitoring similar to the wPTU DSC Manual Test menu.

● Connection to the FB187 CONSOLE is established in two ways


● via the card face mounted DB9 RS232 serial port
or
● via the card face mounted RJ45 Ethernet port.
● Full details of the connection procedure are provided later in this module
and also in the Vehicle Test Instructions GET-6908 and CTRLPSB035
(both included on class supplements disk).

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Slide 51
wPTU 10 Diagnostics for Quad chopper
Subject to 2017 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

FB187 CPU card special operation Commands

Punch ENTER until a


Controller prompt appears

ENTER Login <kac>


ENTER password <ka55C>

Type < imtest > at the


OHV-DSC prompt

● Returns a list of 7
Monitor Panel items
which can be turned
ON and OFF with the
left/right arrow keys

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Slide 52
wPTU 10 Diagnostics for Quad chopper
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FB187 CPU card special operation Commands

Type <io > at the OHV-


DSC prompt

● Returns a list of GE
Panel inputs for the
user to scroll with
arrow keys, Down
[D] and UP [U]

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Slide 53
wPTU 10 Diagnostics for Quad chopper
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FB187 CPU card special operation Commands


ACTIVE ONLY when Engine is STOPPED
Type < iotest > at the OHV-
DSC prompt

● Returns a list of inputs to


the GE Panel that can be
turned ON or OFF using the
0/1 key and restore original
with U key

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Slide 54
wPTU 10 Diagnostics for Quad chopper
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FB187 CPU card special operation Commands


Type < rec > at the OHV-DSC prompt

● Collects a serial report of the system and starts a 120 second data
recorder capturing system variables 50 times per second (0.020 interval)

● Data is erased after (3)


three days have elapsed

Up-load to Thumb Drive

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Slide 55
wPTU 10 Diagnostics for Quad chopper
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Product Service Bulletin, Inverter testing

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Slide 56
wPTU 10 Diagnostics for Quad chopper
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Description

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Slide 57
wPTU 10 Diagnostics for Quad chopper
Subject to 2017 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

Phase Module Test


Ensure that all fuses are in place on the Gate Drive Power Converter.

FL 454 PANEL

GDP Power Converter

To perform the phase module test.


Connect the laptop to the relevant inverter communications port.
For the FL454 Panel, connect directly to the Inverter Card
(17FB190) face diag. ports.

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Slide 58
wPTU 10 Diagnostics for Quad chopper
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FB190 card special operation Commands

● Connect to the relavent


Inverter card
● Start a Tera Term session
● Set Baud Rate 9600
● Hit the X key until the prompt
INVCPU > is displayed

● HIT;
● →T
● →G HIT “T” HIT “G”
● →N

HIT “N”

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Slide 59
wPTU 10 Diagnostics for Quad chopper
Subject to 2017 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

GE320, Dual IGBT

F = false
T = true
Move Curser to
desired module
and hit→ “T”

Always displays T

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Slide 60
wPTU 10 Diagnostics for Quad chopper
Subject to 2017 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

TeraTerminal
Command will show “T”
and Feedback will also
show “T” if the Phase
Module turns ON

Inverter 1, will control


both Choppers unless
the system detects a
problem with Inverter 1,
in which case control will
transition to Inverter 2

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Slide 61
wPTU 10 Diagnostics for Quad chopper
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Slide 62
wPTU 10 Diagnostics for Quad chopper
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Dual Inverter V I Test, launch and capture

● Used when to identify


incorrect results when a truck
fails an Inverter VI Test

● Start with, engine running and


with Drive System at “REST”

● Connect a Service PC to the


failed Inverter Card in the
same way as in Inverter
Testing Bulletin.

● Launch Tera Term, and


configure a Log file

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Slide 63
wPTU 10 Diagnostics for Quad chopper
Subject to 2017 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

Dual Inverter V I Test, launch and capture

● HIT;
● →T
● →F HIT “T” HIT “F”
● →K
HIT “K”

● Returns Inverter
detail and prompts
for an entry from any
key to start scrolling.

● Start log file


(next slide)

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Slide 64
wPTU 10 Diagnostics for Quad chopper
Subject to 2017 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

Dual Inverter V I Test, launch and capture

● Select Log.. from


File menu, assign a
name and location
for the log file which
is about to be
captured.

● Transition into
READY Mode
● Start screen
scrolling by
pressing {space}

It will be necessary to “cut’’ both


Inverters →Out→In to force a fresh
VI test if a Key Switch cycle has not
occurred since the last startup test.

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Slide 65
wPTU 10 Diagnostics for Quad chopper
Subject to 2017 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

Dual Inverter V I Test, launch and capture

● When the command to


“make READY” is
received, the system
makes routine checks
of the Inverter PM’s,
LEM’s, VAM’s and
Traction Motor circuits

● The first check is


performed at a very
low DC bus voltage.

● Both Inverter Stacks


(pairs) are monitored.

Hit {space bar} to


continue scrolling data

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Slide 66
wPTU 10 Diagnostics for Quad chopper
Subject to 2017 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

Dual Inverter V I Test, launch and capture

● The second series of


checks are performed
at a mid range of DC
bus voltage.

● During this step the


PM’s are monitored for
excessive pass thru
current.

● The LEM’s and


traction Motor circuits
are evaluated by
pulsing DC current in
both directions
Hit {space bar} to
continue scrolling data

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Slide 67
wPTU 10 Diagnostics for Quad chopper
Subject to 2017 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

Dual Inverter V I Test, launch and capture

● The second series of


checks are continued
at a mid range of DC
bus voltage.

● During this continued


step the two Inverter
Stack currents are
compared.

● The LEM’s and


traction Motor circuits
are further evaluated
by pulsing DC current
in both directions
Hit {space bar} to
continue scrolling data

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Slide 68
wPTU 10 Diagnostics for Quad chopper
Subject to 2017 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

Dual Inverter V I Test, launch and capture

● The third and final


series of checks are
continued at a high
range of DC bus
voltage.

● During this step the


PM’s are monitored for
pass thru current.

Refer to the Supplements


Disk for comprehensive
detail about interpreting
the test results

Hit {space bar} to


continue scrolling data to
end of report

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Slide 69
wPTU 10 Diagnostics for Quad chopper
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Slide 70
wPTU 10 Diagnostics for Quad chopper
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Snap Shot Activity

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Slide 71
wPTU 10 Diagnostics for Quad chopper
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Multiple Snap Controls

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Slide 72
wPTU 10 Diagnostics for Quad chopper
Subject to 2017 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

Snap Shot Options

Alternative drop down menus for


FREEZE and SNAPSHOTS

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Slide 73
wPTU 10 Diagnostics for Quad chopper
Subject to 2017 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

DATA STORE
CODE
98

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Slide 74
wPTU 10 Diagnostics for Quad chopper
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Replay Multi frame Snap Shot Files

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Slide 75
wPTU 10 Diagnostics for Quad chopper
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wPTU 10 Diagnostics for Quad chopper
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Slide 77
wPTU 10 Diagnostics for Quad chopper
Subject to 2017 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

INVERTEX II_FB187 CPU_CONFIGURATION


The new FB187 CPU holds all possible truck configurations in
the OHV_xxx.bin file for each particular software version
release (V5.03 etc)
● Therefore all commissioning, re-programming, CPU exchanges etc. will
require verification/modification to the “onboard” config file.
● Connection to the FB187 CONSOLE is established in two ways
● via the card face mounted DB9 RS232 serial port
or
● via the card face mounted RJ45 Ethernet port.
● Full details of the procedure are provided in Vehicle Test Instructions
GET-6908 and CTRLPSB035 (both included on class supplements disk).

Technical Training ELTE0077717E0BK2


Slide 78
wPTU 10 Diagnostics for Quad chopper
Subject to 2017 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

INVERTEX II_FB187 CPU_CONFIGURATION


Communication with the FB187 requires specific software that is
determined by the method of connection and service PC operating
system (XP or WINDOWS 7)
TM TM
● RS232 Terminal software such as HYPERTERM , PuTTY or
TM
TERATERM (note that Windows XP supports all but Windows 7 only supports
TERATERM TM ) must be installed before communication can be obtained.

● Alternatively the ethernet facility can be used, by making use of a RJ45 to


RJ45 cable, connected to any one of the available the ethernet ports on
the FL454 Panel.

● Ensure that your PC is set to obtain IP address automatically.


See following slide for this process

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INVERTEX II_FB187 CPU_CONFIGURATION using EtherNet

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INVERTEX II_FB187 CPU_CONFIGURATION

● Table identifies the IP address of the port which you have connected to;

● With Windows XP simply start a Telnet (Hyperterminal) session by typing


the IP address (above) into the WINDOWS; START/RUN line as follows

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INVERTEX II_FB187 CPU_CONFIGURATION

● Table identifies the IP address of the port which you have connected to;

● With Windows 7 simply start a


TERATERM session, select
TCP/IP, select TELNET type in
the IP address (above) into the
HOST dialog box as follows;

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INVERTEX II_FB187 CPU_CONFIGURATION


● When using Windows 7 through the RS232 port (or USB emulator) simply
start a TERATERM session, choose SERIAL and select the assigned
COM Port.

Punch ENTER until a


Controller prompt appears

ENTER Login <kac>


● The selected com port settings ENTER password <ka55C>
should be adjusted as shown;
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Create, View / Modify a system Configuration for INVERTEX II, config 1

current setting [min, max]

View Config &


Thumb drive
functions
● The basic “mine” password will
only allow the viewing of
parameters.

● For editing parameters, use the


config_password prompt and
enter <oemLeveL> password oemLeveL to modify config

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Create / View / Modify a system Configuration for INVERTEX II


At the OHV-DSC prompt, this will return the first configuration menu items for viewing ONLY..
OEM OPTIONS 1. Against each option line is the current setting, the description of the option and the possible range for
that option. Config 2….. will be likewise.
Version software (ver 5.03a) is an arrow key driven selection arrangement, using the arrow keys allows the user to move
up and down the list of options, when an option is highlighted the user can edit the value directly.
In order to make modifications to the Configuration a SECOND Password is required <oemLeveL>, this is entered at the
OHV-DSC> prompt using the following command;
------------------- config password<space>oemLeveL ---------------------, entry is case specific.
With the new password “accepted” type “config” and Enter to display the list of config items, select and highlight the line
to modify and make direct entries of values from the keyboard .
Ver 5.03a also allows the user to save the config file to a thumb drive using s, which can then be loaded into a sister truck
using the L key. (Password protect <ka55C>).
Note that the Thumb Drive MUST be inserted into the 17FB187 before CPS “ON”

OEM1 options details;


the first three choices are for hardwire “speed events”, example turn on a blue light when speed is above 30mph etc.,
next item “Dump Body Up speed limit” consult with the mine operators on how the truck should react to dump body up,
setting 0 in the first line will force the Operator to use the Over ride Button in order to Propel in Forward (only).
External OEM Accel Inhibit, provides the facility for the mine to “wire in” their own accelerator inhibit, for example an
interlock could be wired into the seat belt clasp to prevent propel unless the seat belt is worn.

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Create / View / Modify a system Configuration for INVERTEX II

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OEM OPTION 2
Set OEM2 options, For the most part the usual setup is as per the slide, The technician should physically check if a
pressure switch is added at the rear of the Control Cabinet in order to make the correct selection for Control Group
Pressure Sensor Present.
The choice for RP Strategy, this relates to how the RP contactors react to release of the Retard pedal. (0) RP1 will follow
the Retard Pedal, (1) RP1 is held closed for 20 seconds with minimal retardation, (2) ) RP1 is held closed for 20 seconds
with zero retardation. THIS IS NOT APPLICABLE TO 730E QUAD CHOPPER SYSTEM
Engine Warm Up feature is standard on 730E, for trucks which are equipped with a “Engine Warming” switch, option 1 or
2 should be chosen, option (1) will cause energy dissipation in the Grid, option (2) will add energy dissipation in the
Inverters and wheel windings by causing a small amount of DC to flow in the Traction Motor windings. Note that the truck
will NOT propel in this mode.
The Engine warm up mode speed must also be set, the minimum set speed is 1000 rpm, the default/recommended set
speed is 1200 rpm for general applications.
Link ON, minimum Engine speed allows this function to be SET from the DID panel when option (1) is selected.
The, Service Brake applied at speed event option can be selected at applications where excessive use of service brakes
is a concern, if set, an event 647 will be logged in the DSC, each and every time the operator makes use of service
brakes above 8 mph. Note that DSC also collects counter data for the same condition irrespective of the setting in this
box.
The technician should consult with the mine about the desired production reaction to Payload overload, select 0, for no
system reaction, 1 to impose a drive system speed limit and log Event 635, or select 2 for NO Propel and log Event 634.
Select option 0 for PLM payload monitor, in the Overload Input Sense field, note that this overloaded control signal is now
broadcast over CAN.

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Create / View / Modify a system Configuration for INVERTEX II

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OEM OPTION 3
OEM Options 3, ver5.00 and up has a new feature which deals with the management of Data Packs in memory, by
specifying a value between 30 and 9999 days the user can cause all “older than” <specified days> data packs to be
deleted from memory.
Grid Blower delta current of 10 Amp or more will set a Propel speed restriction when the option is set to (1)
Engine, is the facility to De-rate the Engine in special cases where an Engine is nearing its end of life.
Loaded and Unloaded speed limits must set with consultation with the Mine Owners.
Note the Overloaded Truck max speed option will only take effect if the correct choices were made on the OEM2 page.
Product Service is not essential information and can be left blank.
Wheel Motor Type is where the correct version/model Motorized wheel, selection is made.

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Create / View / Modify a system Configuration for INVERTEX II

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OEM OPTION

Choose the correct Language to display in DID panel


Extreme Cold weather option has been added to provide “Enhanced Drive Warm-up Mode”, with this option selected the
Inverters will transition into Drive Warming mode whenever the ambient temperature is less than -15 deg C and the
Inverters are not engaged in Traction Duty, that is whilst in Park or Neutral for extended periods, once active this feature
will remain in effect until temperatures rise above -10 degC
Movement restriction if truck is frozen, this mode which implements a temporary system restriction if a truck has been
parked for a long time in extreme cold weather. Should not be enabled without GE-Erie instruction
Activate Wheel Motor Oil Sump Heaters
License keys to allow to activation of GE controlled features. License key is specific to the FB187 card.

Fuel saver 2 package is ONLY available with an License Key


Selectable Komatsu Options;
Autonomous Operation should be set to 0 unless the truck is equipped to operate in Autonomous mode.
Set Mine Optional second speed limit bit to 1 if you require this feature to react to an external user input control.
Select Pre-shift brake test if desired

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INVERTEX II_FB187/FB190 CPU_PROGRAMMING


INVERTEX II with the new 17FB187 CPU and 17FB190 INV
Cards introduced a new method of down loading software and
onboard file systems; wPTU 7 and version release (V2.02 and up)
● Thus all commissioning, re-programming, CPU exchanges etc. require
individual programming and set up.
● Program connection to the FB187 and FB190 cards is via USB
Thumb/Flash Drive.
● Program SETUP is; (to be discussed later)
● via the card face mounted DB9 RS232 serial port
or
● via the card face mounted RJ45 Ethernet port.

● Full details of the procedure are provided in Vehicle Test Instructions


GET-6885 and CTRLPSB035 (both included on class supplements disk).

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INVERTEX II_FB187/FB190 CPU_PROGRAMMING


● The latest INVERTEX II, version release 5.xx requires
additional steps & software updates that improve the FB187
CPU card performance, the required updates are;
● Secondary Operating System (from v1.16 to v1.22)
● Application Software (v2.02~v4.00a to v5.03a / v5.10a / v5.12a)
● Primary Operating System (Boot soft ware) to v2.00
Full details of the procedure are provided in Software modification Information document
SMI41A322501MK and CTRLPSB035 (both included on class supplements disk)
Note: When updating the Primary Operating system, care must be taken to avoid
the loss of 24 volt power to the FB187 card.
If the Programming process is interrupted, the card will be rendered temporarily
unusable and will need to be sent back to the factory to be recovered.
Care should be taken to avoid the Disconnect switch, Key switch or CPS switch
being thrown during the process.
Also, if the Truck Batteries are weak, it is recommended that the Engine be
running and battery charging occurring during the Primary Operating System
update process.
Please follow the upgrade instructions carefully.
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INVERTEX II_FB187 /FB190 CPU_ver 5.03a / 5.10a / 5.12a updates

● Generally 17FB187 and 190 cards are shipped with the latest OS installed,
however v5.xx field updates require new application and OS codes that are
kept in; C:\GETrans\ wPTU_10.1\sw folder.
● Two (2) Thumb Drives must be prepared by
copying the correct software found in the
wPTU_10.1 SW folder.

Copy these files to a clean flash drive and name it


“V5 Application/OS Load Disk”

Copy these files to a clean flash drive and name it


“V5 FB187 Primary OS Load Disk”.

● OsDisk_FB190 is not required for this operation.


It is for FB190 Operating System repair only.

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Update (ver 5.xx) process for FB190 INV CPU_PROGRAMMING


V5.xx updates to FL454 (INVERTEX II) panels require that both
Inverter FB190 application codes be down loaded first before the
FB187 DSC CPU update is programmed.
● With Battery power ON and Key power ON, open the ICP Panel and turn OFF
Control Power Switch (CPS), insert the “V5 Application/OS Load Disk” thumb drive
into the front edge (face panel) USB port of the FB190 to be programmed.
● Turn CPS ON, the FB190 will recognize the thumb drive and flash the Yellow Status
2 LED for 5 seconds and the new application will start downloading, during which
the Yellow LED will be on solid, the FB190 will re-boot, the Yellow LED will turn off
and the Green Status 1 LED will turn on.
● Remove the Thumb drive and verify that the new application version has been
installed via the DID Panel or Service PC.
● Repeat the above steps for the second FB190.

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INVERTEX II_FB187 /FB190 CPU_ver 5.03a / 5.10a / 5.12a updates


Down load secondary OS and Application to 17FB187, DSC CPU.
● With Key ON, open the DSC Panel and turn OFF Control Power Switch (CPS), insert the [V5
Application/OS Load Disk] thumb drive into the front edge USB port of the FB187 DSC Card,
and jumper the Download pins.
● Turn CPS ON, remove the Jumper when the Red status 3 & 4 LED’s turn on, the FB187 will
recognize the thumb drive data and start data backup, only status 4 will blink.
● Status LED’s 3 & 4 turn ON during disk format, status 2 will also turn ON when App is copied
from Thumb Drive. Legacy data will restore from Thumb Drive when Status 2,3 & 4 flash.
● Installation is complete when all status lamps are ON solid, turn OFF CPS when status 1
blinks, then remove Thumb Drive, turn CPS back on and FB187 will re-boot.
● When status LED’s 2, 3 & 4 rotate and 1 is ON solid the card is functional and ready for the
next step, system SETUP verification and truck configuration. (discussed in earlier slides)

Proceed to Next Step,


SETUP & Configuration

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INVERTEX II_FB187 /FB190 CPU_ver 5.03a / 5.10a / 5.12a updates


After successful SETUP and Configuration, proceed to Installation of
FB187 Primary OS.
WARNING! The upgrade to the primary operating system can render the
FB187 card unusable if power is removed during this final upgrade step.
Carefully follow the instructions provided in SMI41A322501MK document.
● Turn OFF CPS and remove the FB187 card from the panel and locate the BTWR
pins at the lower front edge, insert jumper 58F-43-00410 and return card to panel.
● Insert the Thumb Drive labeled;
[V5 FB187 Primary OS Load Disk] into the
FB187 USB port on the front edge of the card.
● Short TP1 and TP2 at the top front edge of
the FB187 card and turn CPS ON.

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INVERTEX II_FB187 /FB190 CPU_ver 5.03a / 5.10a / 5.12a updates


Load 17FB187 Primary Operating System.
● With CPS ON, remove the TP.1/2 Jumper when the red status 3 & 4 LED’s turn on, the FB187
will recognize the thumb drive data, turn off red status 3 LED and test the new files.

● Status LED’s 3 & 4 will turn ON, Old Boot Flash will be erased (+/- 80 seconds )

● Installation and programming of new Boot Flash will start when red status LED 2 is also ON.

● After programming has completed, the status 1 LED will flash green.
● Switch CPS OFF, remove Thumb Drive, remove card and BTWR jumper then return card to panel.
● Switch CPS back on and system will boot up normally
● Using the DID panel, calibrate pedals, set truck ID and verify system time
● Perform new installation check out as specified in SMI41A322501xx

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INVERTEX II_FB187 /FB190 CPU general PROGRAMMING


For all earlier systems (pre V5) and for post V5.xx updates; the AppDisk
Thumb Drives should be prepared by copying only the Application software
found in the wPTU_x.xx SW (software) folder.

● INVERTEX II Application codes are


kept in; C:\GETrans\wPTU_xxx\sw\Ver_xxx\
● /AppDisk is the most common source, it
contains 3 files which will load the FB187
& FB190 apps.
● For INV II the FB187 will automatically
update the FB190 Inverter card software
at FIRST “Key ON”.
● OsDisk_187 &190 are to repair the Operating
System, only and will be rarely used

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INVERTEX II; FB187 Controller CPU general PROGRAMMING


Down load application for FL454 INVERTEX II panel, to
17FB187, DSC CPU.
● With Battery power ON and Key power ON, open the ICP Panel and turn OFF
Control Power Switch (CPS), insert the thumb drive into the front edge USB port of
the FB187 DSC Card, and jumper the Download and Ground pins.
● Turn CPS ON, when the Red Status 3 & 4 LED’s turn on, remove the Jumper, the
FB187 will recognize and mount the thumb drive, Status 2,3&4 turn ON. The new
application will start downloading, during which the Status 2,3 & 4 will flash.
● The App is installed when Status 2,3 & 4 rotate, cycle CPS and FB187 will re-boot.
● If all Status LED’s flash, the FB187 CPU requires App. version number, if so instruct
FB187 CPU to launch the new App. software in a Console session (next slide).

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INVERTEX II; FB187 Controller CPU general PROGRAMMING, cont.

Refer back to the INVERTEX CONSOLE section of this training module for details on
how to start a CONSOLE SESSION.
● At the OHV_xxx> type “list_apps”

● Select correct app. and type “OHV_xxx>change_app 303a.bin”


● Cycle CPS to Re-boot

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INVERTEX II; FB187 Controller CPU general PROGRAMMING cont.

FL454 (INVERTEX II) panel, down load application to 17FB187


DSC CPU cont.
● If status 2,3 &4 LED’s rotate but status 1 (green) is OFF, the FB187 CPU requires
SETUP to configure its principle role (DSC) and truck type (730E...960E) and
Control Group type (KG535//537/543), in this case complete a FB187 CPU SETUP
Console session (next slide).

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INVERTEX II; FB187 Controller CPU general PROGRAMMING, cont.


Refer back to the INVERTEX CONSOLE section of this training module for details on
how to start a CONSOLE SESSION.
● At OHV_xxx> type “setup” and then make selections.

● Cycle CPS after completing entries to Re-boot the system.


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Passwords

Use same password as wPTU

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Parent

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New CHILD

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730E-8
Dump Truck
Serial # A40004 and up

Komatsu America Corp.


End of Lesson 7.1 Cartersville Georgia USA
wPTU 10 Copyright © 2017 All rights reserved.

Copyright © 2017 Technical Training ELTE0077717E0BK2


wPTU 10 Diagnostics for Quad chopper
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OHV TRIP DATA, part of Statistical Report

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GE Lockout Option

The GE lockout option should only be turned on with


GE/KAC approval. It is meant to avoid a particular
engine speed range in propel and another range in
retard, to avoid excessive vibration/noise from the
tires which is transmitted through the frame to the
cab. In general, the quiet gears also help this so
this option is defaulted “off” and only turned on if a
site complains about excessive noise in the
operator’s cab.

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Multi frame DATA PACKS

Sequence of EVENTS

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