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Operation & Maintenance CEAM010301

Manual

DUMP TRUCK
with TROLLEY ASSIST

SERIAL NUMBER A30181 - A30211


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 Mining Systems, Inc. and is not to be reproduced, used, or disclosed except
in accordance with written authorization from Komatsu Mining Systems, Inc.
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 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


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OM4031.1 01/04 Maintenance - Section 4
Lubrication and Service Page 4-1

LUBRICATION AND SERVICE


Recommended Preventive Maintenance will contribute HYDRAULIC TANK SERVICE
to the long life and dependability of the truck and its
components. The use of proper lubricants and the per- There are two sight gauges on the side of the hydraulic
formance of checks and adjustments at recommended tank. With engine stopped, keyswitch "off", hydraulic
intervals is most important. system bled down and body down, oil should be visible
in the top sight gauge. If hydraulic oil is not visible in
Lubrication requirements are referenced to the lube the top sight gauge, follow "Adding Oil" instructions
key found in the Truck Lubrication Specifications Chart below.
(page 4-2). For detailed service requirements for spe-
cific components, refer to the Shop Manual Section for Adding Oil
that component (i.e. Section “H” for Suspensions, Sec-
tion "L" for Hydraulic System, etc.). Keep the system open to the atmosphere only as long
as absolutely necessary to lessen chances of system
Refer to manufacturer's service manual when servicing contamination.
any components of the General Electric System.
Service the tank with clean Type C-4 hydraulic oil only.
Refer to engine manufacturer's service manual when All oil being put into the hydraulic tank should be fil-
servicing the engine or any of its components. tered through 3 micron filters.
1. With engine stopped, keyswitch "off", hydraulic
system bled down and body down, check to see
730E SERVICE CAPACITIES that hydraulic oil is visible in the top or lower sight
gauge.
Crankcase: Liters U.S.
(including lube oil filters). Gal- 2. If hydraulic oil is not visible in the top sight gauge,
lons remove the tank fill cap and add clean, filtered C-
Komatsu SSA16V159 Engine 4 hydraulic oil (Lubrication Chart, Lube Key "D")
214 56.6
until oil is visible in the top sight gauge.
Cooling System: 409 108
3. Replace fill cap.
Komatsu SSA16V159 Engine
4. Start engine. Raise and lower the dump body
Hydraulic System: 731 193
three times.
Refer to "Hydraulic Tank Ser-
5. Repeat steps 1 through 4 until oil is maintained in
vice".
the top sight gauge with engine stopped, body
Wheel Motor Gear Box 39.7 10.5 down, and hydraulic system bled down
(each side)
Fuel Tank (Diesel Fuel Only) 3217 850

The service intervals presented here are in hours of


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

Many Komatsu trucks are equipped with an Automatic


Lubrication System option. The initial setup for this sys-
tem provides for nominal amounts of lubricant to be
delivered to each serviced point. The lubrication injec-
tors can be adjusted to vary the amount of lubricant
delivered. In addition, the timer for lubrication intervals
is normally adjustable. Consult the "Options and
Accessories", Section "M", of the truck service manual
for adjustments to these devices.
Maintenance - Section 4 OM4031.1 01/04
Page 4-2 Lubrication and Service

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

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


steps 1 through 4. Any excess coolant will be dis-
charged through the vent hose after the engine
reaches normal operating temperature.
OM4031.1 01/04 Maintenance - Section 4
Lubrication and Service Page 4-3
Maintenance - Section 4 OM4031.1 01/04
Page 4-4 Lubrication and Service

10 HOUR (DAILY) INSPECTION

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

COMMENTS CHECKED INITIALS


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

2. RADIATOR - Check coolant level and fill with proper


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

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


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

4. FUEL FILTER - Drain water from bottom of filter


housing.

5. FUEL STRAINER - Drain water and sediment at


drain cock.

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


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

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


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

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


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

NOTE: After service, push the reset button on face


of gauge to allow the gauge to return to zero.
OM4031.1 01/04 Maintenance - Section 4
Lubrication and Service Page 4-5

10 HOUR (DAILY INSPECTION (continued)

COMMENTS CHECKED INITIALS


9. AIR CLEANERS

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


cleaner elements. Empty air cleaner dust caps.

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


equipped) to allow the needle to return to zero.

10. WHEELS AND TIRES -

a. Inspect tires for proper inflation and wear.

b. Inspect for debris embedded in cuts or tread.

After each wheel mounting operation, recheck wheel


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

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


ing area of any dirt accumulation.

12. FUEL TANK - Fill as required.

13. HOIST LIMIT SWITCH (NOT SHOWN) - Clean


sensing area of any dirt accumulation.

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


operating conditions, clean every 250 hours. In
extremely dusty conditions, service as frequently as
required. Clean filter element with mild soap and water,
rinse completely clean and air dry with maximum of 40
psi (275 kPa). Reinstall filter.
Maintenance - Section 4 OM4031.1 01/04
Page 4-6 Lubrication and Service

50 HOUR LUBRICATION AND MAINTENANCE CHECKS


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

COMMENTS CHECKED INITIALS


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

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


automatic lube system) - Add one or two applications
of grease at grease fitting. Lube Key "D".
OM4031.1 01/04 Maintenance - Section 4
Lubrication and Service Page 4-7

100 HOUR LUBRICATION AND MAINTENANCE CHECKS


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

COMMENTS CHECKED INITIALS

1.REAR HYDRAIR® SUSPENSION PIN JOINTS - (If


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

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


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

3. HOIST CYLINDER - (If not equipped with automatic


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

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


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

5. HYDRAULIC OIL FILTERS - Change filter elements


after the initial 100 hours of operation; then at 250
hours; and then each 500 hours of operation thereafter.
Maintenance - Section 4 OM4031.1 01/04
Page 4-8 Lubrication and Service

250 HOUR LUBRICATION AND MAINTENANCE CHECKS


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

1. ENGINE - Refer to Cummins Operation & Mainte- COMMENTS CHECKED INITIALS


nance manual for complete specifications regarding
engine lube oil specifications.

NOTE: If engine is equipped with the CENTINEL ∗ oil


system and/or the ELIMINATOR filter system, engine
oil and filter change intervals are extended beyond 250
hours. Refer to Cummins Operation & Maintenance
manual for specific oil & filter change intervals.

a. Change engine oil. Lube Key “A”.

b. Replace lube oil filters.

NOTE: When installing spin-on filter elements, follow


the instructions as specified by the filter manufacturer.
The tightening instructions are normally printed on the
outside of the filter. Do not use a wrench or strap to
tighten filter elements.

c. If truck is equipped with a Reserve Engine Oil Tank,


change the reserve tank oil filter.

d. Check the fan belt tension.Refer to Cummins Opera-


tion & Maintenance manual for specific fan belt adjust-
ment instructions.

2. HYDRAULIC SYSTEM FILTERS - Change filter ele-


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

3. FUEL FILTER AND STRAINER - Change filter and


strainer element.

4. MOTORIZED WHEEL GEAR CASE - Refer to the


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

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


matic lube system) - Add one or two applications of
grease to each grease fitting for pin and bearing.
Check torque on steering pin nuts 343 ± 34 ft. lbs. (465
± 46 N.m) torque. Use Lube Key "E".

∗The Centinel system is a duty-cycle-dependent


lubrication management system whereby oil is
blended with the fuel and burned and an extension of
oil change intervals can occur.
OM4031.1 01/04 Maintenance - Section 4
Lubrication and Service Page 4-9

250 HOUR LUBRICATION AND MAINTENANCE CHECKS (continued)

COMMENTS CHECKED INITIALS


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

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


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

8. FRONT WHEEL BEARINGS - Check oil level.

9. FUEL TANK - Drain H2O and sediment.

10. AXLE BLOWER MOTOR (If equipped with trolley


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

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


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

12. CHASSIS LUBE LEVEL - Check the level of grease


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

13. BATTERIES (NOT SHOWN) - Check electrolyte


level and add water if necessary.
Maintenance - Section 4 OM4031.1 01/04
Page 4-10 Lubrication and Service

500 HOUR LUBRICATION AND MAINTENANCE CHECKS


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

1. FINAL DRIVE CASE BREATHERS - Remove


breather elements for motorized wheels and clean or
replace elements.

2. HYDRAULIC SYSTEM FILTERS - Replace filter ele-


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

3. HYDRAIR® SUSPENSION - Check for proper piston


extension (front and rear).

4. THROTTLE AND BRAKE PEDAL (NOT SHOWN) -


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

5. HYDRAULIC TANK BREATHER - Replace breather.

6. FRONT WHEELS - Check front wheel bearing pre-


load 500 hours after truck commissioning (and at 500
hours after each rebuild) as per Section G (in the ser-
vice manual for Disassembly and Assembly proce-
dures) and every 5,000 hours there after.
OM4031.1 01/04 Maintenance - Section 4
Lubrication and Service Page 4-11

1000 HOUR LUBRICATION AND MAINTENANCE CHECKS


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

1. HYDRAULIC TANK - Drain hydraulic oil and clean


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

2. RADIATOR - Clean cooling system with a quality


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

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


vent. Dry with air pressure and reinstall.

4. ENGINE - Remove, clean and dry crankcase


breather elements.

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


Use Lube Key "D".
Maintenance - Section 4 OM4031.1 01/04
Page 4-12 Lubrication and Service

5000 HOUR LUBRICATION AND MAINTENANCE CHECKS


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

1.FRONT WHEELS - Drain oil and completely disas-


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

2. AIR CLEANERS - Clean the Donaclone Tubes in the


pre-cleaner section of the air filter. Use low pressure
cold water or low pressure air to clean tubes. Refer to
Section "C" of the service manual.

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


sure air to clean tubes, high pressure causes pre-
cleaner tubes to distort.
OM4031.2 Maintenance - Section 4
Automatic Lube System Page 4- 13

AUTOMATIC LUBRICATION SYSTEM


Simultaneously, grease is discharged through the outlet
GENERAL DESCRIPTION (9) of the pump. The volume of grease during intake is
The Lincoln Automatic Lubrication System is a pressur- twice the amount of grease output during one cycle.
ized lubricant delivery system which delivers a controlled During the upstroke, the inlet check valve closes, and
amount of lubricant to designated lube points. The sys- one half the grease taken in during the previous stroke
tem is controlled by an electric timer which signals a is transferred through the outlet check and discharged
solenoid valve to operate a hydraulic motor powered to the outlet port.
grease pump. Hydraulic oil for pump operation is sup-
plied by the truck steering circuit.
Grease output is proportional to the hydraulic motor
input flow. A pump control manifold (4, Figure 3-1),
mounted on top of the hydraulic motor (2), controls input
flow and pressure. A 24VDC Solenoid (5) mounted on
the manifold turns the pump on and off.
The pump is driven by the rotary motion of the hydraulic
motor, which is then converted to reciprocating motion
through an eccentric crank mechanism. The reciprocat-
ing action causes the pump cylinder to move up and ! " # # $
down. The pump is a positive displacement, double-
acting type as grease output occurs on both the up and
the down stroke.
During the down stroke, the pump cylinder is extended
into the grease. Through the combination of shovel
action and vacuum generated in the pump cylinder
chamber, the grease is forced into the pump cylinder.
% $

& '

( $

"
)#
$

$
&

$
* $
+
FIGURE 3-1. PUMP COMPONENTS " #

1. Orifice Fitting 6. Pressure Guage


2. Hydraulic Motor 7. Pump Assembly
3. Pressure Reducing Valve 8. Flow Control Valve
4. Manifold 9. Grease Outlet
5. Solenoid Valve 10. Grease Pickup Tube
Maintenance - Section 4 OM4031.2
Page 4- 14 Automatic Lube System

FIGURE 3-2. AUTO LUBE SYSTEM INSTALLATION

1. Reservoir (Torque Tube) 8. Hyd. Oil Supply 15. R.H. Body Pivot Pin 22. L.H. Top Hoist Cyl.
2. Grease Supply From Filter 9. Hyd. Oil Return 16. R.H. Top Hoist Cyl. 23. L.H. Body Pivot Pin
3. Grease Pump/Motor 10. Reservoir Vent Line 17. R.H. Bottom Hoist Cyl 24. L.H. Top Susp.
4. Relay Box 11. Lube Injectors (each side)18. Rear Axle Pivot Pin 25. L.H. Lower Susp.
5. Pressure Gauge 12. Rear Lube Injectors 19. R.H. Anti-Sway Bar 26. Grease Supply
6. Vent Valve Assy. 13. R.H. Lower Suspension 20. L.H. Bottom Hoist Cyl.
7. Reservoir Fill Hose (To Filter) 14. R.H. Top Suspension 21. L.H. Anti-Sway Bar
OM4031.2 Maintenance - Section 4
Automatic Lube System Page 4- 15

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


The flow control valve mounted on the manifold, controls
Filter (2, Figure 3-6) the amount of oil flow to the hydraulic motor.
A filter assembly mounted on the right front upright filters "
the grease prior to refilling the reservoir from the shop
supply. A bypass indicator alerts service personnel
when the filter requires replacement. Solenoid Valve (5, Figure 3-1)
The solenoid valve, when energized, allows oil to flow to
Hydraulic Motor and Pump (2 & 7, Figure 3-1) the hydraulic motor.

Vent Valve (6, Figure 3-2)


!" With the vent valve closed, the pump continues to oper-
Specifications are as follows: ate until maximum grease pressure is achieved. As this
occurs, the vent valve opens and allows the grease
•Max. hydraulic oil inlet pressure: pressure to drop to 0, so the injectors can recharge for
.............................................. 3,000 psi (20 685 kPa) their next output cycle.
•Hydraulic oil operating pressure:
..................................325-350 psi (2 240-2 415 kPa) 24 VDC Lubrication Cycle Timer (Not Shown)
•Hydraulic inlet flow The lube cycle timer provides a 24 VDC timed-interval
............................................ up to 7 GPM (28 L/min.) signal to operate the solenoid valve (5, Figure 3-1),
causing the grease pump motor to operate. This timer is
•Pump ratio: approx. 9:1 mounted in the cab (in the housing under the passenger
...@300 to 350 psi (2 068 to 2 415 kPa) oil pressure seat) to insure temperature stability.
............................ @less than 2 GPM (7 L/min.) flow
•Operating temperature Pressure Switch (N.O. 2500 psi [17 237 kPa])
....................................-20 to +150 °F (-10 to +65°C) (Not Shown)
The pressure switch, mounted on the front pump outlet
port, energizes the normally closed pump solenoid relay
when the grease line pressure reaches the switch pres-
sure setting, turning off the motor and pump.

Unloader Valve (Not Shown)


, # The unloader valve is mounted on a “tee” fitting with the
-... /0.123$4 5 )# pressure switch described above. This valve will relieve
grease pressure in the pump if pressure exceeds 4000
psi (27.6 MPa). This valve has been factory adjusted
and is not repairable.
Grease Reservoir (1, Figure 3-2)
The reservoir has an approximate capacity of 214 lbs. Pressure Gauge (6, Figure 3-1)
(97 kg) of grease. When the grease supply is replen- The pressure gauge monitors hydraulic oil pressure to
ished by filling the system at the service center, the the inlet of the hydraulic motor.
grease is passed through the filter to remove contami-
nants before it flows into the reservoir. Relay Box (4, Figure 3-2)
Pressure Reducing Valve (3, Figure 3-1) The relay box houses the 24V relay used to control the
solenoid valve controlling the hydraulic motor.
The pressure reducing valve, located on the manifold
reduces the hydraulic supply pressure (from the truck Injectors (11, Figure 3-2)
steering circuit) to a suitable operating pressure, [325-
350 psi (2 240-2 415 kPa)] for the hydraulic motor used Each injector delivers a controlled amount of pressur-
to drive the lubricant pump. ized lubricant to a designated lube point. Refer to Figure
3-2 for locations.
Maintenance - Section 4 OM4031.2
Page 4- 16 Automatic Lube System

System Operation 5. During this period, the injectors will meter the ap-
propriate amount of grease to each lubrication
Refer to Figure 3-3 & 3-4: point.
1. During truck operation, with the pump and timer 6. When grease pressure reaches the pressure switch
systems in a rest state, a preset time interval oc- setting, the switch contacts will close and energize
curs. the relay (3, Figure 3-4), removing power from the
2. The lubrication cycle timer (1, Figure 3-4) provides hydraulic motor/pump solenoid and the the pump
a 24 VDC signal through the normally closed relay will stop. The relay will remain energized until
(3) used to energize the pump solenoid valve (4), grease pressure drops and the pressure switch
allowing hydraulic oil provided by the truck steering opens again or until the timer turns off.
pump circuit to flow to the pump motor and initiate 7. After the pump solenoid valve (3) is de-energized,
a pumping cycle. hydraulic pressure in the manifold drops and the
3. The hydraulic oil pressure from the steering circuit vent valve will open, releasing grease pressure in
is reduced to 325 to 350 psi (2 240 to 2 413 kPa) the lines to the injector banks. When this occurs,
by the pressure reducing valve (4, Figure 3-3) the injectors are then able to recharge for the next
before entering the motor. In addition, the amount lubrication cycle.
of oil supplied to the pump is limited by the flow 8. The unloader valve (10) prevents excessive grease
control valve (6). Pump pressure can be read using pressure if the pressure switch fails to close and
the gauge (5) mounted on the manifold. shut off the hydraulic supply to the pump. The
4. With oil flowing into the hydraulic motor, the grease unloader will open at approximately 4000 psi (27.6
pump will operate, pumping grease from the reser- MPa).
voir to the injectors (13), and to the vent valve (11)
and the normally open pressure switch (9).

FIGURE 3-3. HYDRAULIC SCHEMATIC


1. Hydraulic Oil Return 6. Flow Control Valve 10. Unloader Valve
2. Hydraulic Oil Supply 7. Hydraulic Motor 11. Vent Valve
3. Pump Solenoid Valve 8. Grease Pump 12. Orifice
4. Pressure Reducing Valve 9. Pressure Switch (N.O.) 13. Injector Bank
5. Motor Pressure Gauge
OM4031.2 Maintenance - Section 4
Automatic Lube System Page 4- 17

FIGURE 3-4. ELECTRICAL SCHEMATIC


1. 24VDC Timer 4. Pump Solenoid Valve
2. Pressure Switch; N.O., 2500 psi (17 237 kPa) 5. Manual Test Switch (If Equipped)
3. Relay
Maintenance - Section 4 OM4031.2
Page 4- 18 Automatic Lube System

INJECTOR OPERATION

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

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

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

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

Injector is now ready for the next cycle.


OM4031.2 Maintenance - Section 4
Automatic Lube System Page 4- 19

GENERAL INSTRUCTIONS

LUBRICANT REQUIRED FOR SYSTEM Pump Pressure Control


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

LUBRICANT PUMP

Pump Housing Oil Level


The pump housing must be filled to the proper level with
SAE 10W-30 motor oil. Oil level should be checked at
1000 hour intervals. To add oil, remove pipe plug (4,
Figure 3-5) and fill housing to bottom of plug hole.
FIGURE 3-5. PUMP CONTROLS

1. Pump Pressure Control 4. Oil Level Plug


2. Manifold 5. Flow Control Valve
3. Pressure Gauge 6. Outlet Port
Maintenance - Section 4 OM4031.2
Page 4- 20 Automatic Lube System

FILTER AND RESERVOIR Filter Assembly


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

FIGURE 3-7. FILTER ASSEMBLY


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

FIGURE 3-6. FILTER AND RESERVOIR

1. R.H. Upright 5. Grease Reservoir


2. Filter Assembly 6. Cap
3. Filter Outlet Hose 7. Vent Hose
4. Filter Inlet Hose 8. Pump Access Door
OM4031.2 Maintenance - Section 4
Automatic Lube System Page 4- 21

INJECTORS (SL-1 Series “H”)

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

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


3
The injectors may be adjusted to supply from 0.008 in 1. Adjusting Screw 12. Plunger
to 0.08 in3 (0.13 cc to 1.31 cc) of lubricant per injection 2. Locknut 13. Viton Packing
cycle. The injector piston travel distance determines the 3. Piston Stop Plug 14. Inlet Disc
amount of lubricant supplied. This travel is in turn con- 4. Gasket 15. Viton Packing
trolled by an adjusting screw in the top of the injector 5. Washer 16. Washer
housing. 6. Viton O-Ring 17. Gasket
7. Injector Body Assy. 18. Adapter Bolt
Turn the adjusting screw (1, Figure 3-8) counterclock- 8. Piston Assembly 19. Adapter
wise to increase lubricant amount delivered and clock- 9. Fitting Assembly 20. Viton Packing
wise to decrease the lubricant amount. 10. Plunger Spring
11. Spring Seat
When the injector is not pressurized, maximum injector
delivery volume is attained by turning the adjusting
screw (1) fully counterclockwise until the indicating pin NOTE: The Piston Assembly (8) has a visible indicator
(8) just touches the adjusting screw. At the maximum pin at the top of the assembly to verify the injector oper-
delivery point, about 0.38 inch (9.7 mm) adjusting screw ation.
threads should be showing. Decrease the delivered
lubricant amount by turning the adjusting screw clock-
wise to limit injector piston travel. If only half the lubricant
is needed, turn the adjusting screw to the point where
about 0.19 inch (4.8 mm) threads are showing. The
injector will be set at minimum delivery point with about
0.009 inch (0.22 mm) thread showing.
/ 0 )
) )

) / )
! .
Maintenance - Section 4 OM4031.2
Page 4- 22 Automatic Lube System

SYSTEM CHECKOUT
To check system operation (not including timer), pro-
ceed as follows:
1. Lift the passenger seat and connect a jumper wire
between “SOL” terminal and “LUBE SW” terminal
on the lube cycle timer or activate test switch if
installed.
2. Turn keyswitch “ON” and start the engine. The
pump should operate.
3. Keep system activated until the pump stalls or
pressure switch closes.
4. Disconnect jumper wire or release test switch.
System should vent.
Turn keyswitch “OFF”. FIGURE 3-9. TIMER (TOP COVER REMOVED)
1. Timer Enclosure
24 VDC TIMER CHECK 2. Red LED (Light Emitting Diode)
3. Time Selector
To check the timer operation without waiting for the
normal timer setting, proceed as follows:
1. Remove timer dust cover.
/ 0 1

. Lubrication Cycle Timer Adjustment


2. Adjust timer selector (3, Figure 3-9) to 5 minute The timer is factory set for a nominal 2.5 minute (off time)
interval setting. interval. Dwell time is approximately 1 minute, 15 sec-
3. The timer should cycle in five minutes if the truck is onds. A longer interval (off time) is obtained by turning
operating. the Selector knob (3, Figure 3-9) to the desired position .
/ 0 / 0 4 4 $"'
2 %( 4 !
3 1 !
. 2 .
4. Voltage checks at the timer should be accomplished "
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 be-
tween positive and negative posts on the solid
state timer with the truck keyswitch “ON”.
Normal reading should be 18-26 VDC, depend-
ing upon whether or not the engine is running.
OM4031.2 Maintenance - Section 4
Automatic Lube System Page 4- 23

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

12. Unscrew the wrist pin anchor (14) from the recipro-
cating tube (21) and pull the plunger assembly (9
through 20) from the tube.
13. Using a .50 in. (13 mm) diameter wooden or plastic
rod, push the cup seal (22) and the pump cylinder
(24) from the reciprocating tube.
Maintenance - Section 4 OM4031.2
Page 4- 24 Automatic Lube System

FIGURE 3-10. LUBE PUMP ASSEMBLY


1. Screw 17. Plunger Rod 33. Screw 49. O-Ring
2. Outer Weight 18. Spring 34. Valve Cartridge 50. Nut
3. Inner Weight 19. Steel Ball 35. Solenoid Valve 51. Bronze Bearing
4. Retaining Ring 20. Plunger 36. Connector 52. O-Ring
5. Crankrod 21. Reciprocating Tube 37. manifold 53. Backup Washer
6. Retaining Ring 22. Cup Seal 38. Press. Reducing Valve 54. O-Ring
7. Eccentric Crank 23. O-Ring 39. Flow Control Valve 55. Housing Tube
8. Ball Bearing 24. Cylinder 40. O-Ring 56. Shovel Plug
9. Outlet Pin 25. Ball Cage 41. Gasket 57. Retaining Ring
10. O-Ring 26. Steel Ball 42. Hydraulic Motor 58. Orifice Fitting
11. Plunger Tube 27. O-Ring 43. Washer
12. Screw 28. Check Seat 44. Screw
13. Wrist Pin Bushing 29. Screw 45. Pipe Plug
14. Wrist Pin Anchor 30. Housing Cover 46. Pump Housing
15. Backup Washer 31. Cover Gasket 47. Backup Ring
16. Cup Seal 32. Guage 48. O-Ring
OM4031.2 Maintenance - Section 4
Automatic Lube System Page 4- 25

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


7 ings (13) and button head screws (12). Tighten
6 - %8%$ 1 '
screws to 100 - 110 in. lbs. (11.3 - 12.4 N.m)
1 6 2
torque.
)
3 9. Place pump subassembly (parts 1 through 28) into
" pump housing (46).
10. Install new O-ring (54), backup washer (53) and O-
ring (52) and bronze bushing (51) into housing tube
1. Support ball bearing (8, Figure 3-10) inner race and
(55).
press eccentric (7) into bore. Install small retaining
rings (6). 11. Install housing tube assembly onto pump housing
(46). Be certain reciprocating tube (21) is inserted
2. Assemble crankrod assembly parts; large retaining
through both bushings. Using a .75 in. (19 mm)
rings (4), inner weights (3), outer weights (2) and
diameter rod through the inlet holes at bottom of
install flat head screws (1). Tighten to 100 - 110 in.
tube, tighten to 20 - 25 ft. lbs. (27.1 - 33.9 N.m)
lbs. (11.3 - 12.4 N.m) torque.
torque.
3. Using a new O-ring (10), install install plunger tube
12. Install shovel plug (56) and retainer (57).
(11) on outlet pin (9). Tighten to 100 - 110 in. lbs.
(11.3 - 12.4 N.m) torque. 13. Install new backup rings (47), O-rings (48 & 49), and
outlet pin nuts (50). Tighten to 30 - 35 ft. lbs. (40.7
4. Assemble the wrist pin anchor (14), backup washer
- 47.5 N.m) torque.
(15), cup seal (16) and plunger link rod (17) onto
plunger tube (11). Tighten to 100 - 110 in. lbs. (11.3 14. Install gasket (41) and motor (42) on pump housing
- 12.4 N.m) torque. (46). Install washers (43) and socket head screws
(44).
5. Assemble spring (18), ball (19), and plunger (20) on
plunger link rod (17). Tighten plunger to 100 - 110 15. Install shovel plug (56) in housing tube (55). Install
in. lbs. (11.3 - 12.4 N.m) torque. retaining ring (57).
6. Install reciprocating tube (21) onto wrist pin anchor 16. Install gasket (31), cover (30) and six self-tapping
(14). Tighten to 20 - 25 ft. lbs. (27.1 - 33.9 N.m) screws (29), on pump housing.
torque.
17. Using new O-rings (40), install manifold (37) on
7. Install cup seal (22), O-ring (23), cylinder (24), ball motor (42). Install socket head screws (33).
cage (25), ball (26), O-ring (27) and check seat (28)
18. With the pump assembly in its normal operating
into reciprocating tube (21). Tighten check seat
position, add SAE 10W-30 motor oil to pump hous-
housing to 20 - 25 ft. lbs. (27.1 - 33.9 N.m) torque.
ing until oil is level with bottom of pipe plug (45) hole.
Install pipe plug.
Maintenance - Section 4 OM4031.2
Page 4- 26 Automatic Lube System

SYSTEM TROUBLESHOOTING CHART


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

POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION

TROUBLE: Pump Does Not Operate

Lube system not grounded. Correct grounding connections to pump assembly and
truck chassis.
Electrical power loss. Locate cause of power loss and repair. 24VDC power
required. Be sure keyswitch is “ON”.

Timer malfunction. Replace timer assembly.

Solenoid valve malfunctioning. Replace the solenoid valve assembly.

Relay malfunctioning Replace relay.

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

/ 0 /

4 1

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

/ 0 ) )
$ ' )
.

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

All injectors inoperative - pump build up not sufficient Service and/or replace pump assembly.
to cycle injectors.
OM4031.2 Maintenance - Section 4
Automatic Lube System Page 4- 27

SYSTEM TROUBLESHOOTING CHART


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

TROUBLE: Pressure Gauge Does Not Register Pressure

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

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

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

24V Relay may be defective. Replace relay.

TROUBLE: Pump Pressure Builds Very Slowly Or Not At All

No signal at 24V relay. Check Timer.

Pressure switch may be defective Replace pressure switch.

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

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

Pump inlet check or outlet check may have foreign Remove, inspect and clean, if necessary.
matter trapped causing leakage. Inspect sealing surfaces between checks. Replace if
rough or pitted.
Lubricant supply line leaks or is broken. Repair lubricant supply line

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

TROUBLE: 24VDC Timer Not Operating

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

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

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

TROUBLE: Timer Stays Timed Out


Commutation failure in timer caused by damaged Replace Timer.
component.

Output relay contacts welded shut caused by Replace Timer


extended short to ground.
Solenoid valve connected to LUBE SW terminal of Correct wiring hook-up.
timer instead of terminal marked SOL.
Maintenance - Section 4 OM4031.2
Page 4- 28 Automatic Lube System

POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION

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

Electrical noise is being introduced into the power sup- *%4 7"&!"8 *
ply to the timer overcoming suppressor capacitor
causing uncontrolled turn-on of its output relay.

* 03. 9... %:
93. -3.; ( 6&"/<5
6&" /5

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.
OM4031.2 Maintenance - Section 4
Automatic Lube System Page 4- 29

Preventative Maintenance Procedures

The following maintenance procedures should be used This will indicate if there are any frozen or plugged
to insure proper system operation. bearings, and will help flush the bearings of con-
taminants.
Daily Lubrication System Inspection
5. System Checkout
1. Check grease reservoir level. a. Remove all SL-1 injector cover caps to allow
Inspect grease level height after each shift of oper- visual inspection of the injector cycle indicator
ation. Grease usage should be consistent from day- pins during system operation.
to-day operations. b. Start truck engine.
•Lack of lubricant usage would indicate an inopera- c. Lift the passenger seat and connect a jumper
tive system. Excessive usage would indicate a bro- wire between “SOL” and “LUBE SW” on the lube
ken supply line. cycle timer or activate test switch if installed.
The hydraulic grease pump should operate.
2. Check filter bypass indicator when filling reservoir.
Replace element if bypassing. d. Keep the system activated until the pump stalls
out or the pressure switch closes.
3. Check all grease feed line hoses from the SL-1
e. With the pump in the stalled-out mode, check
Injectors to the lubrication points.
each SL-1 injector assembly.
a. Repair or replace all damaged feed line hoses. The cycle indicator pin should be retracted inside
b. Make sure that all air is purged and all new feed the injector body.
line hoses are filled with grease before sending f. Once all of the SL-1 injectors have been inspect-
the truck back into service. ed under pressure remove the jumper wire be-
4. Inspect key lubrication points for a bead of lubricant tween the “SOL” terminal and “LUBE SW”
around seal. If a lubrication point appears dry, terminal on the timer assembly or open test
troubleshoot and repair problem. switch. The pump should shut off and the pres-
sure in the system should drop to zero, venting
250 Hour Inspection back to the grease reservoir.
g. With the system vented, check all of the SL-1
1. Check all grease feed line hoses from the SL-1
injector indicator pins; all of the pins should be
Injectors to the lubrication points (see, Figure 3-2).
visible. Replace or repair injectors, if defective.
a. Repair or replace all worn / broken feed line
h. Reinstall all injector cover caps.
hoses.
i. Check timer operation.
b. Make sure that all air is purged and all new feed
line hoses are filled with grease before sending
the truck back into service. ( % %(
%(!8
2. Check all grease supply line hoses from the pump
to the SL-1 injectors. j. If the system is working properly, the machine is
ready for operation.
a. Repair or replace all worn / broken supply lines.
k. If the system is malfunctioning, refer to the trou-
b. Make sure that all air is purged and all new supply
bleshooting chart.
line hoses are filled with grease before sending
the truck back into service.
3. Check grease reservoir level. 1000 Hour Inspection
a. Fill reservoir if low.
1. Check pump housing oil level.
b. Check reservoir for contaminants.
Clean, if required.
c. Check that all filler plugs, covers and breather
vents on the reservoir are intact and free of
contaminants.
4. Inspect all bearing points for a bead of lubricant
around the bearing seal.
It is good practice to manually lube each bearing
point at the grease fitting provided on each Injector.
Maintenance - Section 4 OM4031.2
Page 4- 30 Automatic Lube System

NOTES
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OM6008 Optional Equipment - Section 6
Payload Meter 3 Page 6-1

PAYLOAD METER 3
INDEX

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


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

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


PC Overview ...............................................................................................................................................16
System Configuration ..................................................................................................................................16
Installing the Payload Meter 3 Software ..................................................................................................... 16
DOWNLOADING DATA ................................................................................................................................ 17
PLM3 SYSTEM CONFIGURATION ............................................................................................................... 18
Starting Communications ........................................................................................................................... 18
Displayed Payload Units........................................................................................................................... 18
Time Units ................................................................................................................................................ 18
Connection Menu ....................................................................................................................................... 18
Connecting to the Payload Meter ............................................................................................................... 19
Configure the Payload Meter ...................................................................................................................... 19
Setting the Date and Time ....................................................................................................................... 19
Setting the Truck Type ............................................................................................................................ 20
Setting the Gauge Display Units .............................................................................................................. 20
Setting the Frame Serial Number ............................................................................................................ 20
Setting the Truck Number ........................................................................................................................ 20
Setting the KMS Distributor ..................................................................................................................... 20
Setting the KMS Customer ...................................................................................................................... 20
Clean Truck Tare ........................................................................................................................................ 21
Inclinometer Calibration .............................................................................................................................. 21
DATA ANALYSIS .........................................................................................................................................22
Creating a Query ........................................................................................................................................ 22
Sorting on Truck Unit Number ................................................................................................................. 22
Sorting on Truck Type .............................................................................................................................22
Sorting on Date Range ............................................................................................................................ 23
Sorting on Time Range ............................................................................................................................ 23
Payload Detail Screen ................................................................................................................................ 24
Creating Reports ........................................................................................................................................ 24
Summary - one page report ..................................................................................................................... 25
Detailed - multi-page report ..................................................................................................................... 25
Creating Graphs .........................................................................................................................................26
Exporting Data ............................................................................................................................................ 26
CSV Export .............................................................................................................................................. 26
Compressed ............................................................................................................................................ 27
Importing Data ............................................................................................................................................ 28
Deleting Haul Cycle Records ...................................................................................................................... 28
Viewing Alarms ........................................................................................................................................... 29
Deleting Alarm Records .............................................................................................................................. 29
OM6008 Optional Equipment - Section 6
Payload Meter 3 Page 6-3

OPERATION SECTION Data Gathering


Windows 95/98/NT software is available to
INTRODUCTION download, store and view payload and fault
Payload Meter 3 (PLM3) measures, displays and information. The PC software will download an entire
records the weight of material being carried by an off- truck fleet into one Paradox database file. Users can
highway truck. The system generally consists of a query the database by date, time, truck type and
payload meter, a gauge display, deck-mounted lights, truck number to produce reports, graphs and export
and sensors. The primary sensors are four the data. The software can export the data in ' .CSV'
suspension pressures and an inclinometer. Other format that can be easily imported into most
inputs include a body up signal, brake lock signal, spreadsheet applications. The Windows software is
and speed. not compatible with the Payload Meter 2 system.

It is important that each payload meter be configured


Data Summary for each truck using the PC software. The
5208 haul cycles can be stored in memory. The information for frame serial number and truck
following information is recorded for each haul cycle: number is used by the database program to organize
• Payload the payload data. In addition, the payload meter
• Operator ID number (0000-9999) must be configured to make calculations for the
• Distance traveled loaded and empty proper truck model. Improper configuration can lead
• The amount of time spent empty run/stop, to data loss and inaccurate payload calculations.
loading, loaded run/stop, and dumping
• Maximum speed loaded and empty with time of
day
• Average speed loaded and empty
• Empty carry-back load
• Haul-cycle, loading, dumping start time of day.
• Peak positive and peak negative frame torque
with time of day
• Peak sprung load with time of day
• Tire ton-mph for each front and average per rear
tires

The payload meter stores lifetime data that cannot be


erased. This data includes:
• Top 5 maximum payloads and time stamps.
• Top 5 positive and negative frame torque and
time stamps
• Top 5 maximum speeds and time stamps
Optional Equipment - Section 6 OM6008
Page 6-4 Payload Meter 3

Component Description
System Diagram

Suspension Pressure Sensors Operator Display


PLM3 uses a two-wire pressure sensor. The range The speedometer/display gauge is used as a
for the pressure sensor is 4000 psi (281 kg/cm2) and speedometer and payload display. The top display is
used for speed and can display metric (km/h) or
the overload limit is 10,000 psi (700 kg/cm2). One
English (mph) units. Grounding terminal #4 on the
wire to the sensor is the supply voltage and the other
back of the speedometer will switch the meter to
is the signal. The 0-4000 psi range is converted into
display metric units. Leaving terminal #4
an electrical current between 4-20 ma. The supply
unconnected will cause the gauge to display English
voltage for the sensor is nominally +18vdc. Each
units. The speedometer can be adjusted using a
pressure sensor has an 90" length of cable that is
calibration potentiometer in the back just like existing
terminated with #10 ring terminals. The cable is
speedometers.
specially shielded and reinforced to provide
mechanical strength and electronic noise immunity.
The payload meter uses the lower display for
A typical part number for the pressure sensor is
payload information. The normal display mode
PC0328.
shows the current payload. The display can be
changed to show the load and total tons counter or
Inclinometer the Operator ID. Using the operator switch on the
dash panel, the current suspension pressures and
The inclinometer is used to increase the accuracy of
incline can be displayed. The units for display are
load calculations on an incline. The inclinometer
set using the PC software. Payloads can be
uses three wires. For the sensor, red is the +18vdc
displayed in Short Tons, Long Tons or Metric Tons. A
supply voltage, black is ground and the white is the
typical part number for this gauge is the PC0550.
signal. The incline signal is a voltage between 1 and
4 volts. Zero degrees of incline is represented by
2.6vdc on the signal line. The voltage signal will be
decreased by 0.103vdc for every degree of nose up
incline. A typical part number for the inclinometer
assembly is 7861-92-5330.
OM6008 Optional Equipment - Section 6
Payload Meter 3 Page 6-5

Operator Switch Payload Meter


The payload operator switch is used to set, view and The payload meter is housed in a black aluminum
clear the Total Load Counter and Total Ton Counter. housing. There is a small window on the face of the
It is also used to enter the Operator ID number (0- unit. Status and active alarm codes can be viewed
9999). This switch can also be used to view the through the window. During normal operation, a two-
suspension pressures and inclinometer. The digit display flashes 0 back and forth. Active fault
payload meter operator switch is located on the codes will be displayed for two seconds. These
dashboard. It is a two-way momentary switch. The codes are typically viewed using the laptop computer
top position is the SELECT position. The SELECT connected to the serial communications port.
position is used step through the different displays.
The lower position is the SET position. The SET There is one 40-pin connector on the payload meter.
position is used to set the Operator ID or clear the A jack-screw is used to hold the payload meter and
load and total ton counters. Normally the inputs from wire harness connector housings together. This
the switch to the payload meter are open circuit. The screw requires a 4mm or 5/32 hex wrench. The
switch momentarily connects the circuit to ground. correct tightening torque for this screw is 25 lb-in.
Four bolts hold the payload meter housing to its
mounting bracket in the cab.
Speed Input
PLM3 uses a speed signal to calculate speed, The circuit board inside the payload meter housing is
distance, and other performance data. This input is made from multi-layer, dual-sided surface-mount
critical to the proper operation of the system. PLM3 electronics. There are no field serviceable
receives this signal from the speedometer/operator components inside. The electronics are designed to
display on the dashboard. The same signal withstand the harsh operating environment of the
displayed to the operator is used by the system. mining industry. Opening the payload meter housing
Distance calculations are made based on the rolling will result in voiding the warranty.
radius of the tires for a particular truck.

Communications Ports
Body-Up Switch The payload meter has two RS232 serial
The Body-Up input signal is received from a communications ports and two CAN ports.
magnetic switch located on the inside of the truck Connections for the two serial ports are available
frame, forward the pivot pin of the truck body. This is inside the payload meter junction box. The two CAN
the same switch typically used for input to the drive ports are available for future electronics systems.
system. When the body is down, the switch closes
and completes the circuit to 71-Control Power. Serial port #1 is used to communicate with the
24vdc indicates the body is down. Open circuit dashboard display. It is also used to connect to the
indicates that the body is up. laptop computer. The display gauge will remain blank
when the PC is using the serial port. This port
initially operates with serial settings at 9600,8,N,1.
Brake Lock Switch These settings change automatically to increase the
The brake lock is used to lock the rear brakes on the communications rate when the PC is using the port.
truck. It is necessary for the accurate calculation of This serial port uses a 3-wire hardware connection.
swingloads during the loading process. Without the
brake lock applied, the payload meter will not Serial port #2 is used to communicate to other on-
calculate swingloads during the loading process. board electronics like Modular Mining' s Dispatch®
Without the brake lock, the payload meter will system or the Scoreboard from KMS. This port uses
assume that the truck was loaded using a continuous a 3-wire hardware connection. Connections to this
loader and flag the haul cycle record. All other serial port need to be approved by KMS. Several
functions will be normal regardless of brake lock protocol options are available and detailed technical
usage. The brake lock input comes from the switch information is available depending on licensing.
located on the dash panel. The brake lock switch
connects the circuit to ground. Open circuit indicates
brake lock off. Ground indicates brake lock on.
Optional Equipment - Section 6 OM6008
Page 6-6 Payload Meter 3

Keyswitch Input Load Lights


PLM3 monitors the status of the keyswitch. 24vdc PLM3 uses load lights to indicate to the shovel
indicates that the keyswitch is on, open indicates the operator the approximate weight of the material in
keyswitch is off. The payload meter does not receive the truck. The load lights are illuminated only when
its electrical power from the keyswitch circuit. The the brake lock is applied. The lights are controlled by
payload meter will remain on for several seconds the payload meter through a series of relays in the
after keyswitch is removed. When the keyswitch junction box. The payload meter controls the relays
power is removed, payload meter performs a series with 24vdc outputs. A 24vdc signal from the payload
of internal memory operations before turning itself meter powers the relay coil and connects battery
off. To allow for these operations, the keyswitch power to the load light. When the relay is not
should be turned off for at least 15 seconds before powered by the payload meter, a pre-warm resistor
turning the keyswitch back on. The payload meter connects the load light to a reduced voltage. This
will automatically reset itself without error if not circuit pre-warms the load light filaments and
enough time is given for these operations. The reduces the inrush current when the light is fully
display may blink briefly. illuminated. This lengthens the operating life of the
load lights.

Payload Meter Power


The payload meter receives its power from the The load lights progressively indicate to the shovel
battery circuit on the truck. Removing battery power operator the approximate weight of the material in
from the payload meter before removing keyswitch the truck.
and waiting 15 seconds may result in lost haul cycle
data. The payload meter turns itself off approximately A flashing green light indicates the next swingload
15 seconds after the keyswitch power is removed. will make the measured load greater than 50% of
Some haul cycle data will be lost if battery power is rated load. A solid green light indicates that the
removed before waiting 15 seconds. The payload current load is greater than 50% of rated capacity.
meter system operates at a nominal voltage of 24vdc
at 1 to 2 amps depending on options. The payload A flashing amber light indicates the next swingload
meter is designed to turn itself off if the supply will make the measured load greater than 90% of
voltage rises above 36vdc. The payload meter is also rated load. A solid amber light indicates that the
protected by a 5 amp circuit breaker located in the current load is greater than 90% of rated capacity.
junction box.
Power to the load lights comes from the same battery A flashing red light indicates the next swingload will
circuit. The load lights are powered through a relay. make the measured load greater than 105% of rated
The keyswitch circuit controls the relay. The load load. A solid red light indicates that the current load
lights are also protected by a 15 amp circuit breaker is greater than 105% of rated capacity.
in the junction box.
The optimal loading target is a solid green and amber
lights with a flashing red light. This indicates that the
load is between 90% and 105% of rated load for the
truck and the next swingload will load the truck over
105%.
OM6008 Optional Equipment - Section 6
Payload Meter 3 Page 6-7

Wiring and Termination


Most of the PLM3 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 PLM3 system are made in the
payload meter junction box.

TCI Outputs
The GE drive system on the 930E requires
information from the payload meter regarding the
loaded condition of the truck. There are three
outputs from the payload meter to GE to indicate the
relative load in the truck. 24 vdc on the 73MSL
circuit indicates that the load is 70% of rated load. 24
vdc on the 73FSL circuit indicates the truck is 100%
loaded. The 73OSL circuit is not currently used.
Optional Equipment - Section 6 OM6008
Page 6-8 Payload Meter 3

Operator's Display and Switch Using the Operator ID


The current Operator ID number is recorded with
each haul cycle. The number can be between 0 and
Reading the Speedometer 9999.
The top window of the speedometer/display gauge is
the speedometer section. The display shows the To set the Operator ID:
speed indicated by the frequency being received by 1. Press the “SELECT” switch until is dis-
the gauge. This can be adjusted using the played.
potentiometer on the back of the gauge. In addition,
2. Hold the “SET” button until is displayed.
the units for the display can be changed. Terminal #4
The first digit should be flashing.
controls the displayed units. If #4 is grounded, the
display will be metric. If terminal #4 is left open, the 3. Press the “SET” button again to change the
display will be in English units. digit.
4. Press the “SELECT” button once to adjust the
second digit.
Reading the Load Display
The lower display on the speedometer/display gauge 5. Use the “SET” button again to change the digit.
is used for payload information. The SELECT 6. Press the “SELECT” button once to adjust the
position on the operator switch allows the user to third digit.
scroll through a number of useful displays. The order
7. Use the “SET” button again to change the digit.
for the displays is as follows:
8. Press the “SELECT” button once to adjust the
fourth digit.
9. Use the “SET” button again to change the digit
• = Payload
10. Press the “SELECT” button one more time to
• = Operator ID enter the ID.
• = Total Shift Tons If no buttons are pressed for 30 seconds, the display
• = Shift Load Counter will return to normal operation. The number being
entered will be lost and the ID number returns to the
• = Left Front Suspension Pressure previous ID number.
• = Right Front Suspension Pressure
• = Left Rear Suspension Pressure Using the Load and Ton Counter
PLM3 allows the truck operator to monitor and track
• = Right Rear Suspension Pressure
the total tons hauled and the number of haul cycles
• = Inclinometer during the shift. This display can be cleared at the
beginning of each shift to allow the operator to record
The display holds the displayed information until the how many loads and tons have been hauled during
SELECT switch is pressed again. The suspension the shift.
pressures, inclinometer, and payload displays are
Total Ton Counter
based on current sensor inputs.
Communications to the display use the same serial The Total Ton Counter records the number of tons
link as the download connection. Whenever another hauled since the last time it was cleared. This
computer is connected to serial port #1 to download display is in 100’s of tons. For example, if the display
or configure the system, the lower display will blank. shows the total tons is 43,200. This display
This is not the same connection used by mine
can be cleared at the beginning of each shift to allow
dispatch systems.
the operator to record how many tons have been
hauled during the shift. The units are selected using
the PC software.
• To view the Total Ton Counter press and release
the “SELECT” switch until is displayed on
the gauge.
OM6008 Optional Equipment - Section 6
Payload Meter 3 Page 6-9

Total Load Counter The inclinometer displays whole degrees of incline.


The Total Load Counter records the number of loads Positive incline is truck nose up. The gauge will
hauled since the last time it was cleared. This quickly display the type of information shown every
display can be cleared at the beginning of each shift 10 seconds. For example, if the left-front pressure is
to allow the operator to record how many loads have being displayed, will flash on the display
been hauled during the shift.
every minute. Only the payload display,
• To view the Total Load Counter press and does not display this information.
release the “SELECT” switch until is • Left Front Pressure - To display the pressure in
the left-front suspension, press and release the
displayed on the gauge.
“SELECT” switch until is displayed.
• Right Front Pressure - To display the pressure in
Clearing the Counters the right-front suspension, press and release the
Clearing the Total Ton Counter or Total Load Counter
“SELECT” switch until is displayed.
clears both records.
• Left Rear Pressure - To display the pressure in
the left-rear suspension, press and release the
To clear the total ton and total load counter:
“SELECT” switch until is displayed.
1. Press the “SELECT” switch until or • Right Rear Pressure - To display the pressure in
the right-rear suspension, press and release the
is displayed.
“SELECT” switch until is displayed.
2. Hold the “SET” button until the display clears. • Inclinometer - To display the truck incline, press
and release the “SELECT” switch until is
Viewing Live Sensor Data displayed.
The display can also be used to quickly show the
current readings from the four suspension pressure
sensors and the inclinometer. This can be used
Other Display Messages
during regularly scheduled service periods to check
the state of the suspensions. These displays are live On startup of the payload meter system, the gauge
and will update as the values change. display will scroll the truck type that the PLM3 is
configured for. For example, on a 930E, the gauge
The live displays cannot be cleared and the SET will scroll,
button will have no effect.
If the PLM3 encounters memory problems, it will
The units for the display are controlled by the
configuration of the payload meter. If the payload display where 88 is the specific memory
meter is set to display metric units, the pressures will error. In this very rare circumstance, the system
be displayed in tenths of kg/cm2. For example, if the should be turned off for 30 seconds and restarted.

display shows the actual value is 20.2 kg/


2
cm . If the payload meter is set to display short tons,
the pressures will be displayed in psi (lbs/in2). To
convert from kg/cm2 to psi, multiply by 14.2. 1 1kg/
cm2 = 14.2 psi. There is no way to detect the units
setting for the gauge without the PC software.
Optional Equipment - Section 6 OM6008
Page 6-10 Payload Meter 3

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

2. If the average payload is greater than 20% of Sources for Payload Error
rated load and the final payload has been cal-
culated, the payload meter will switch back to
the hauling state. The false_body_up flag will Payload Error
be recorded in the haul cycle record.
The number one source of error in payload
3. If the average payload is less than 20% of rated calculation is improperly serviced suspensions. The
load, the payload meter will switch to the payload meter calculates payload by measuring
tare_zone and begin to calculate a new empty differences in the sprung weight of the truck when it
tare. is empty and when it is loaded. The sprung weight is
the weight of the truck supported by the suspensions.
The only method for determining sprung weight is by
Load Calculation measuring the pressure of the nitrogen gas in the
The final load calculation is different from the last suspensions. If the suspensions are not properly
swingload calculation. The accuracy of the swing maintained, the payload meter cannot determine an
load calculation depends on loading conditions and accurate value for payload. The two critical factors
the position of the truck during loading. The last are proper oil height and proper nitrogen charge.
swingload calculation is not the value recorded in
memory as the final load. The final load is If the suspensions are overcharged, the payload
determined by a series of calculations made while meter will not be able to determine the empty sprung
the truck is traveling to the dump site. weight of the truck. The suspension cylinder must be
able to travel up and down as the truck drives empty.
The pressure in an overcharged suspension can
Carry Back push the suspension rod to full extension. In this
Carry back is calculated as the difference between case, the pressure inside the cylinder does not
the current truck tare and the clean truck tare. The accurately represent the force necessary to support
clean truck tare is calculated using the PC software. that portion of the truck.
When the suspensions are serviced or changes are
made that may affect the sprung weight of the truck,
a new clean truck tare should be calculated. If the suspensions are undercharged, the payload
meter will not be able to determine the loaded sprung
weight of the truck. The suspension cylinder must be
Measurement Accuracy able to travel up and down as the truck drives loaded.
Payload measurements are typically repeatable If the pressure in an undercharged suspension
within 1%. Accuracy for a particular scale test cannot support the load, the suspension will collapse
depends on specific combinations of pressure and make metal-to-metal contact. In this case, the
sensors and payload meters as well as the specifics pressure inside the cylinder does not accurately
of each scale test. Comparisons from different scale represent the force necessary to support that portion
tests are often made without considering the of the truck.
differences introduced by the specific installation and
operation of the scales for each test. In addition, Low oil height can also introduce errors by not
each pressure sensor and payload meter introduces correctly supporting a loaded truck. This is why the
it'
s own non-linearity. Each truck becomes an correct oil height and nitrogen charge are the most
individual combination of sensors and payload meter. critical factors in the measurement of payload. If the
Errors from these sources can introduce up to a ±7% suspensions are not properly maintained, accurate
bias in the payload meter calculations for a specific payload measurement is not possible. In addition,
scale test, for an individual truck. suspension maintenance is very important to the life
of the truck.
Because the PLM3 calculates a new empty tare for
each payload, a detailed scale test must weigh the
trucks empty and loaded for each haul cycle. Using
a simple average of 2 or 3 empty truck weights as an
empty tare for the entire scale test will introduce
significant error when comparing scale weights to
PLM3 weights.
Optional Equipment - Section 6 OM6008
Page 6-12 Payload Meter 3

Loading Conditions HAUL CYCLE DATA


The final load calculation of the PLM3 system is not PLM3 records and stores data in its on-board flash
sensitive to loading conditions. The final load is memory. This memory does not require a separate
calculated as the truck travels away from the shovel. battery. The data is available through the download
Variations in road conditions and slope are software.
compensated for in the complex calculations
performed by the payload meter. PLM3 can store 5208 payload records. When the
memory is full, the payload meter will erase the
oldest 745 payload records and continue recording.
Pressure Sensors
Small variations in sensors can also contribute to PLM3 can store 512 alarm records in memory. When
payload calculation error. Every pressure sensor is the memory is full, the payload meter will erase the
slightly different. The accuracy differences of oldest 312 alarm records and continue recording.
individual sensors along the range from 0 to 4000 psi All data is calculated and stored in metric units within
can add or subtract from payload measurements. the payload meter. The data is downloaded and
This is also true of the sensor input circuitry within stored in metric units within the Paradox database on
individual payload meters. These differences can the PC. The analysis program converts units for
stack up 7% in extreme cases. These errors will be displays, graphs and reports.
consistent and repeatable for specific combinations
of payload meters and sensors on a particular truck. The units noted in the Table 1 are the actual units
stored in the data file. The value for the haul cycle
start time is the number of seconds since January 1,
Swingloads
1970 to the start of the haul cycle. All other event
Swingload calculations can be affected by conditions times are referenced in seconds since the haul cycle
at the loading site. Parking the truck against the start time. The PC download and analysis program
berm or large debris can cause the payload meter to converts these numbers into dates and times for
inaccurately calculate individual swingloads. While graphs and reports.
the PLM3 system uses an advanced calculation
algorithms to determine swingloads, loading site
conditions can affect the accuracy.

Speed and Distance


The payload meter receives the same speed signal
as the speedometer. This signal is a frequency that
represents the speed of the truck. The payload
meter uses this frequency to calculate speeds and
distances. The meter assumes a single value for the
rolling radius of the tire. The rolling radius may
change at difference speeds by growing larger at
higher speeds. The actual rolling radius of the tire
will also change between a loaded and empty truck.
The payload meter does not compensate for these
changes.
OM6008 Optional Equipment - Section 6
Payload Meter 3 Page 6-13
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 PLM3 system and
should be ignored
Optional Equipment - Section 6 OM6008
Page 6-14 Payload Meter 3

Haul Cycle Warning Flags F: Final Zone to Dumping Transition


The payload meter expects haul cycles to progress in This message is generated when the payload meter
a particular way. When something unexpected takes senses a Body-Up while it is calculating the final
place, the system records a warning flag. Several payload indicating that the operator has dumped the
events within the haul cycle can cause a warning flag load. It may also be generated if the Body-Up signal
to be generated. Each one indicates an unusual is not properly reaching the payload meter and the
occurrence during the haul cycle. They do not weight in the truck falls dramatically while the truck is
necessarily indicate a problem with the payload calculating the final payload.
meter or payload calculation.

G: False Body Up
A: Continuous Loading This message indicates that the body was raised
This message is generated when the truck is loaded during the haul cycle without the load being dumped.
over 50% full without the payload meter The Body-Up signal indicated that the truck was
sensing swingloads. This indicates that a continuous dumping, but the weight of the truck did not fall below
loading operation was used to load the truck. It may 20% of the rated load.
also indicate that the payload meter did not receive
the Brake Lock input while the truck was being
loaded. There may be a problem with the wiring or H: Body Up Signal Failed
the Brake Lock was not used. The payload meter will This message indicates that the load was dumped
not measure swingloads unless the Brake Lock is without a Body-Up signal being received by the
used during the loading process. payload meter. The weight of the truck fell below
20%, but the payload meter did not receive a Body-
Up signal from the sensor.
B: Loading to Dumping Transition
This message is generated when the payload meter
senses a body up input during the loading process. I: Speed Sensor Failed
This message is usually accompanied by a This message indicates that the payload meter
no_final_load flag. sensed the truck loading and dumping without
receiving a speed signal.

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

D: Maneuvering to Dumping Transition


This message is generated when the payload meter K: Incomplete Haul Cycle
senses a Body-Up input during the maneuvering or The payload meter did not have proper data to start
repositioning process indicating that the operator has the haul cycle with after powering up. When the
dumped the load. It may also be generated if the PLM3 powers off, it records the data from the haul
Body-Up signal is not properly reaching the payload cycle in progress into memory. This flag indicates
meter and the weight in the truck falls dramatically that this data was not recorded the last time the
while the truck is maneuvering or repositioning. payload meter was shut down. This can happen
when the main battery disconnect is used to shut the
truck down instead of the keyswitch. A haul cycle
E: Average Load or Tare Used with this warning flag should not be considered
This message indicates that the recorded payload accurate. Haul cycles with this warning are displayed
may not be as accurate as a typical final load in red on the Payload Summary window and are not
calculation. Typically, this is recorded when loading included in the summary statistics for reports or
begins before an accurate tare is calculated or the display.
load is dumped before the load can be accurately
measured.
OM6008 Optional Equipment - Section 6
Payload Meter 3 Page 6-15

L: Haul Cycle Too Long Alarm Records


The haul_cycle_too_long flag indicates that the haul The payload meter stores alarm records to give
cycle took longer than 18.2 hours to complete. The service personnel a working history of the system.
times stored for particular events may not be All codes are viewed using the PC connected to the
accurate. This does not affect the payload payload meter. Active codes are also displayed on
calculation. the two-digit display on the meter itself. Each code
has a specific cause and should lead to an
investigation for correction. Some failures can be
M: Sensor Input Error overcome by the payload meter. Haul cycle data will
An alarm was set for one of the 5 critical sensor indicate if an alarm condition was present during the
inputs during the haul cycle. The five critical sensors cycle. Failures with the suspension or inclinometer
are the four pressure sensors and the inclinometer. sensors cannot be overcome.
Without these inputs, the payload meter cannot
calculate payload. A haul cycle with this warning flag
should not be considered accurate. Haul cycles with
this warning are displayed in red on the Payload
Summary window and are not included in the
summary statistics for reports or display.
Table 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. the longitudinal centerline. In this case, the payload
Positive frame torque is measured when the meter will record a positive frame torque.
suspension forces on the front of the truck act to twist
the frame in the clockwise direction as viewed from The 5 highest values in the positive and negative
the operator' s seat. Negative frame torque is direction are stored in permanent memory within the
measured when the forces from the suspensions act payload meter.
in the opposite direction.
Optional Equipment - Section 6 OM6008
Page 6-16 Payload Meter 3

Sprung Weight Data System Configuration


The payload meter is constantly monitoring the live PLM3 needs to be configured for operation when it is
payload calculation. This value naturally rises and 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 PLM3 system.
• Starting communications
• Setting the time & date
Maximum Speed Data • Setting the truck type
The payload meter records the top 5 highest speeds • Setting the truck ID
• Setting the speedometer/display gauge units
and the time they occurred. This information is
stored in permanent memory inside the meter.
Installing the PLM3 Software
The CD ROM containing the Payload Data
Management (PDM) Software will automatically
begin installation when it is inserted into the drive on
the PC. If this does not happen, the software can be
PC Software Overview installed by running the Setup.exe program on the
CD ROM.
PC Overview
The PC software has several basic functions: The minimum PC requirements for running the
• Configure the PLM3 system on the truck. software is a Pentium 133Mhz with 64 MB of ram and
• Troubleshoot and check the PLM3 system.
at least 300 MB of free hard drive space available.
• Download data from the PLM3 system.
• Analyze data from the payload systems. For improved performance, the recommended PC
would be a Celeron, AMD K6-2 or better processor
Configuration, troubleshooting and downloading with 128 MB of ram running at 400 Mhz. The PDM
require a serial connection to the payload meter on Software uses a powerful database to manipulate the
the truck. Analysis can be done at any time without a large amounts of data gathered from the PLM3
connection to the payload meter. system. Using a more powerful computer and added
memory to run the software can result in a significant
Payload data is downloaded from several trucks into improvement in performance. The software is written
one database on the PC. The database can be to use a minimum 800x600 screen resolution.
queried to look at the entire fleet, one truck or truck
model. The data can be graphed, reported, imported
or exported. The export feature can take payload
data and save it in a format that spreadsheet
programs like Excel or word processing programs
can easily import.
OM6008 Optional Equipment - Section 6
Payload Meter 3 Page 6-17

Downloading Data
To download the payload meter:
PLM3 records many types of data. The PLM3 PC
software is designed to download the data from a
whole truck fleet. Instead of creating one data file for 1. Connect to the payload meter and start the PC
each truck, the PC software combines all the data software.
from many trucks into one database on the hard 2. From the main menu, select "Connect to Pay-
drive of the computer. The software then allows load Meter". The PC will request the latest sta-
users to query the database to create custom reports tus information from the payload meter. The
and graphs. Data for individual trucks or groups of number of haul cycles and alarms will be dis-
trucks can be easily analyzed. This same data can played.
be exported for use in other software applications like
word processors and spreadsheet applications. 3. Select the " Begin Download" button. The PC
will request the payload and alarm data from
As the database grows, performance of the PC the payload meter and save it into the data-
software for analysis will slow down. It may be base. This may take several minutes. A
helpful to periodically export data. For example, progress bar at the bottom will show the
query the database to show the oldest quarter, approximate time left.
month, or half year and print out a summary report.
Then export the data to a compressed format and
save the file in a secure location. Once the data is
exported, delete the entire query results from the
database. If necessary, the data can easily be
imported back into the main database for analysis at
a future date. Removing this older data will improve
performance.

The PC software downloads the data from the


payload meter into a single Paradox database. The
data from all the trucks is added to the same
database. Downloading the payload meter can take
several minutes. The data is added to the database
on the laptop used to download.
To move the data to another computer, a query must
be run to isolate the particular data for export. Do not
press the operator switch on the dashboard while
downloading
Optional Equipment - Section 6 OM6008
Page 6-18 Payload Meter 3

PLM3 System Configuration Short Tons: Payload is displayed in short tons,


distances and speeds will be displayed in
Starting Communications
Miles
The PDM software allows users to download and
configure the system.
Metric Tons: Payload is displayed in metric
tons, distances and speeds are displayed in
Kilometers
Long Tons: Payload is displayed in long tons,
distances and speeds are displayed in Miles

Time Units
Minutes and Seconds Example:
Five minutes and thirty-two seconds = 5:32
Decimal Minutes Example:
Five minutes and thirty-two seconds = 5.53

Connection Menu
Before connecting to the payload meter, select
"Change Program Options" and confirm that the
program has selected the correct laptop serial port.
Most laptops use Comm 1 for serial communications.
The units displayed for reports and graphs by the PC
software can be set on this form. Click “Done” to
return to the main menu.

The connection screen displays basic system


information to the user.
• Frame S/N should agree with the truck serial
number from the serial plate located on the truck
frame.
• Truck Number is an ID number assigned to the
From the main menu, click the "Connect to Payload truck by the mine.
Meter" button. The PC will try to connect to the • The Payload Meter Date / Time values come
payload meter and request basic information from from the payload meter at the moment of
the system. In the event of communications trouble, connection.
the PC will try 3 times to connect before "timing-out". • Number of Haul Cycle Records is the number of
This may take several seconds. haul cycles records stored in memory and
available for download.
• Number of Active Alarms shows how many
Displayed Payload Units alarms are currently active in the system at the
time of connection. If there are active alarms,
the "Display Active Alarms" button is available.
• Number of Inactive Alarms shows how many
alarms have been recorded in memory and are
available for download.
Three options are available for the display of units in • PLM Software Version displays the current
the PC software, reports, and graphs: version of software in the payload meter.
The information on the connection menu comes from
the configuration of the payload meter system on the
truck.
OM6008 Optional Equipment - Section 6
Payload Meter 3 Page 6-19

There are also many configuration and download Setting the Date and Time
options available from this screen. The Connection
Menu is updated only when the connection is first
made. It does not update automatically. To view
changes made while connected, the user must close
the window and reconnect to the payload meter.

The connection menu is displayed after a serial The time shown on the form is the time transmitted
connection has been established and the PC from the payload when the connection was first
software has connected to the payload meter. established.

Connecting to the Payload Meter


Communications to the PLM3 requires a laptop
computer running the PDM software. The software
connects to the payload meter through the meter' s
serial port #1. This is the same port used by the
speedometer/display gauge. When the laptop is
using the serial port, the lower display on the
operator gauge on the dashboard will be blank. This The date and time are maintained by a special chip
does not affect the operation of the speedometer. on the PLM3 circuit board. The memory for this chip
is maintained by a very large capacitor when the
• Connect the laptop to the system using the power is removed from the payload meter. This will
EF9160 communications harness. The download maintain the date and time settings for approximately
connector is typically located on the housing 30 days. After this time, it is possible for the payload
mounted in the cab to the back wall. The PLM3 meter to lose the date and time setting. It is
system uses the same connection as the recommended that the system be powered every 20
Payload Meter 2 system. days to maintain the date and time. If the date and
time is lost, simply reset the information using this
Configure the Payload Meter procedure. It takes approximately 90 minutes to
Configuration of the payload meter requires a serial recharge the capacitor.
connection to the PLM3 system. Clicking the
"Configure Payload Meter" button will bring up the Changing the date and time will affect the haul cycle
Truck Configuration screen and menu. This screen in progress and may produce unexpected results in
displays the latest configuration information stored the statistical information for that one haul cycle.
on the payload meter.
To change the time:
When changes are made to the configuration, the
1. Click on the digit that needs to be changed.
"Save Changes" button must be pressed to save the
changes into the payload meter. To confirm the 2. Use the up/down arrows to change or type in
changes, exit to the main menu and re-connect to the the correct value.
payload meter. 3. Press the "Save Changes" button to save the
new time in the payload meter.

To change the date:


1. Click on the digit that needs to be changed.
2. Type in the correct value or use the pull-down
calendar to select a date.
3. Press the "Save Changes" button to save the
new time in the payload meter.
Optional Equipment - Section 6 OM6008
Page 6-20 Payload Meter 3

Setting the Truck Type Setting the Truck Number


Most mining operations assign a number to each
piece of equipment for quick identification. This
number or name can be entered in the Truck Number
field. It is very important to enter a unique truck
1. From the Truck Configuration screen, use the number for each truck using the PLM3 system. This
pull-down menu to select the truck type that the number is one of the key fields used within the haul
payload meter is installed on. cycle database. The field will hold 20 alpha-numeric
2. Press the "Save Changes" button to program characters.
the change into the meter.
1. On the Truck Configuration screen, enter the
truck number in the appropriate field.
Setting the Gauge Display Units
The Payload Meter Speedometer / Display Gauge 2. Press the "Save Changes" button to program
displays the speed on the upper display. The units the change into the payload meter.
for the speed display are selected using a jumper on
the rear of the case.
Setting the KMS Distributor
The payload units on the lower display can be This field in the haul cycle record can hold the name
changed from metric to short tons or long tons using of the Komatsu Mining Systems distributor that
the Truck Configuration screen. This selection also helped install the system. KMS also assigns a
distributor number to each distributor. This number is
switches between metric (kg/cm2) and psi (lbs/in2) used on all warranty claims. This KMS distributor
for the live display of pressure on the gauge. number can also be put into this field. The field will
hold 20 alpha-numeric characters.
1. From the Truck Configuration screen, select the
payload units to be used on the lower display of 1. On the Truck Configuration screen, enter the
the speedometer/display gauge. distributor name or number in the appropriate
2. Press the "Save Changes" button to program field.
the change into the payload meter. 2. Press the "Save Changes" button to program
the change into the payload meter.
Setting the Frame Serial Number
Setting the KMS Customer
This field in the haul cycle record can hold the name
of the mine or operation where the truck is in service.
KMS also assigns a customer number to each
customer. This number is used on all warranty
claims. This KMS customer number can also be put
The frame serial number is located on the plate into this field. The field will hold 20 alpha-numeric
mounted to the truck frame. The plate is outboard on characters.
the lower right rail facing the right front tire. It is very
important to enter the correct frame serial number.
This number is one of the key fields used within the 1. On the Truck Configuration screen, enter the
haul cycle database. The field will hold 20 alpha- customer name or number in the appropriate
numeric characters. field.
2. Press the "Save Changes" button to program
1. On the Truck Configuration screen, enter the the change into the payload meter.
truck frame serial number in the appropriate
field.
2. Press the "Save Changes" button to program
the change into the payload meter.
OM6008 Optional Equipment - Section 6
Payload Meter 3 Page 6-21

Clean Truck Tare Inclinometer Calibration

The payload meter uses the clean truck tare value to


calculate carry-back load for each haul cycle. The The inclinometer calibration procedure is designed to
carry-back stored in the haul cycle record is the new compensate for variations in the mounting attitude of
empty tare minus the clean truck tare. the inclinometer. The inclinometer input is critical to
the payload calculation.
This procedure should be performed after service to
the suspensions or when significant changes are This procedure should be performed on relatively flat
made to the sprung weight of the truck. Before ground. Often the maintenance area is an ideal
performing this procedure, be sure the suspensions location for this procedure.
are properly filled with oil and charged. It is critical to 1. After cleaning debris from the truck and check-
payload measurement that the proper oil height and ing to see that the suspensions are properly
gas pressure be used. serviced, use the PLM3 software to connect to
the payload meter.
Once the clean tare process is started, the payload
2. From the "Truck Configuration" screen, select
meter will begin to calculate the clean empty sprung
"Inclinometer".
weight of the truck. This calculation continues while
the truck drives to the next loading site. Once the 3. With the truck stopped and the brake lock on,
procedure is started, there is no reason to continue press the “Start” button. This instructs the pay-
to monitor the process with the PC. The truck does load meter to sample the inclinometer once.
not need to be moving to start this procedure. 4. Turn the truck around. Drive the truck around
1. After cleaning debris from the truck and check- and park in the exact same spot as before, fac-
ing to see that the suspensions are properly ing the other direction.
serviced, use the PLM3 software to connect to 5. With the truck stopped and the brake lock on,
the payload meter. press the “Start” button. This instructs the pay-
2. From the "Truck Configuration" screen, select load meter to sample the inclinometer again.
"Clean Truck Tare". The payload meter will average the two sam-
ples to determine the average offset.
3. Be sure to follow the screen instructions.
6. Be sure to follow the screen instructions.
Optional Equipment - Section 6 OM6008
Page 6-22 Payload Meter 3

Data Analysis Sorting on Truck Unit Number


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

Payload Summary Form

Creating a Query Sorting on Truck Type


The program defaults to show all trucks, all types, all The truck type is the size of the truck from the family
dates and all times for the initial query. The display of Komatsu trucks. This allows the user to quickly
can be narrowed by selecting which trucks or types view results from different types of trucks on the
to view and for what dates and times. property. For example, a separate report can be
generated for 830E and 930E trucks.
The query items are added in the "AND" condition. If
the user selects a truck # and date range, the query
will sort the data for that truck number AND the date
range.
OM6008 Optional Equipment - Section 6
Payload Meter 3 Page 6-23

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


The default query starts in 1995 and runs through the
current date on the PC. To narrow the range to a
specific date, change the “From” and “To” dates.
For example, to view the haul cycle reports from
truck 374 for the month of July, 2000:

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


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

6. Press the "Query Database and Display" to view


the results.
2. Change the “From” date to July 1, 2000.
This query will display haul cycles from January 5 to
January 8, from 6:00 AM to 6:00 PM.
D ate
T im e
Jan 5, 2000 Jan 6, 2000 Jan 7, 2000 Jan 8, 2000 Jan 9, 2000
0:00

6:00

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


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

Sorting on Time Range 18:00

The time range sorts the times of the day for valid
dates. Changing the time range to 6:00AM to
6:00PM will limit the payloads displayed to the loads 24:00

that occurred between those times for each day of


Query : Date: 1/5/00 to 1/8/00
the date range. Times are entered in 24:00 format. Daily Shift Tim e: 6:00 to 18:00
Haul Cycles Included in the Query

To view the haul cycle reports from the first shift for
truck 374 from January 5, 2000 to January 8, 2000: The shift times selected can extend the query past
the original date. If the dates set for the query are
January 5 to January 8 and the times were changed
1. Select truck 374 from the Truck Unit pull-down to query the 6:00 PM (18:00) to 6:00 AM (06:00) shift,
menu. the results would extend into the morning of the 9th.
This can been seen in the following example:
Optional Equipment - Section 6 OM6008
Page 6-24 Payload Meter 3

Date Creating Reports


T im e

0:00
Jan 5, 2000 Jan 6, 2000 Jan 7, 2000 Jan 8, 2000 Jan 9, 2000
Reports can be generated and viewed on the screen
or printed. These reports are generated from the
query displayed on the Payload Summary Screen.
From the example in "Sorting on Time Range", the
6:00
report printed would only contain data from truck 374
during the month of July 2000, from 8:00 AM to 5:00
PM.
12:00
It is important to carefully select the query data and
press the "Query Database & Display" button before
printing a report.
18:00

24:00

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


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

Payload Detail Screen


The Payload Detail screen gives the details for any
individual haul cycle. From the “Payload Summary”
screen, double-click on any haul cycle to display the
detail.
OM6008 Optional Equipment - Section 6
Payload Meter 3 Page 6-25

NOTE: Some haul cycles may contain the Sensor


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

Summary - one page report


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

Detailed - multi-page report


The detail report starts with the summary report and
follows with pages of data for each haul cycle. The
detailed report prints date, time, payload, cycle
times, and cycle distances, speeds and the number
of swing loads.
Optional Equipment - Section 6 OM6008
Page 6-26 Payload Meter 3

Creating Graphs Exporting Data


The PLM3 software can generate graphs that quickly
summarize payload data. These graphs can be
customized for printing. Just like the reports, the
graphs are generated from the query displayed on
the “Payload Summary” screen. From the "Sorting
on Time Range" example, the graph that is printed
would only contain data from truck 374 during the
month of July 2000, from 8:00 AM to 5:00 PM.

It is important to carefully select the query data and


press the "Query Database & Display" button before
creating a graph. The data from the database can be exported for use
with other software applications. The data is
1. From the Payload Summary Screen select the
selected from the currently displayed query. The
“Graph” button at the bottom. The Histogram
exported data can be put into a ".CSV" file or a
Setup screen will display
compressed ".zip" file.

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


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

CSV Export

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


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

The graph will be displayed based on the query


settings from the Payload Summary screen. The
graph can be customized and printed.
OM6008 Optional Equipment - Section 6
Payload Meter 3 Page 6-27

. • Reserved 1-5, 7-10: These values are internal


calculations used in the continued development
of PLM3 and should be ignored.
• Reserved 6: This value is the payload estimate
at the shovel just before the truck begins to
move.

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


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

• Truck number
• Haul cycle start date The second series of data below the haul cycle data
• Haul cycle start time is the alarms. The alarm columns, left to right are:
• Payload
• Swingloads • The alarm type
• Operator ID • The date the alarm was set
• Warning Flags • The time the alarm was set
• Carry Back • Alarm description
• Total Haul Cycle time • The date the alarm was cleared
• Empty Running Time • The time the alarm was cleared
• Empty stop time
• Loading time
• Loaded running time Compressed
• Loaded stopped time
• Dumping time
• Loading start time
• Dumping start time
• Loaded haul distance
• Empty haul distance
• Loaded maximum speed
• Time when loaded maximum speed occurred
• Empty maximum speed
• Time when loaded maximum speed occurred
• Maximum + frame torque
• Time when the maximum + frame torque
occurred This export function allows the data from one laptop
• Maximum - frame torque
to be transferred to another computer. This can be
• Time when the maximum - frame torque
occurred useful when a service laptop is used to download
• Maximum sprung weight calculation multiple machines and transfer the data to a central
• Time when the maximum sprung weight computer for analysis. This can also be used to copy
calculation occurred haul data from a particular truck onto a diskette for
• Left Front Tire-kilometer-hour analysis.
• Right Front Tire-kilometer-hour
• Average Rear Tire-kilometer-hour The file format is a compressed binary form of the
• Frame serial number displayed query. The file can only be imported by
another computer running the PDM Software.
Optional Equipment - Section 6 OM6008
Page 6-28 Payload Meter 3

To export data in ZIP format: Deleting Haul Cycle Records


1. Confirm that the data displayed is the query To delete haul cycle records from the main database,
data that needs to be exported. press the "Delete" button at the bottom of the
“Payload Summary” screen. The program will
2. From the payload summary screen, press the display a summary of the records from the displayed
"EXPORT" button and select "To ZIP". query. To delete a record, select one at a time and
3. The program will ask for a filename and loca- press the "Delete" button. It is recommended that
tion. records be exported to a zip file for archival purposes
before deletion. Multiple records may be selected by
holding down the Shift key. Pressing the "Delete All"
Importing Data button will select all the records from the current
This import function allows the data from one laptop query and delete them.
to be transferred to another computer. This can be
useful when a service laptop is used to download NOTE: There is no recovery for records that have
multiple machines and transfer the data to a central been deleted from the main database. It is highly
computer for analysis. This can also be used to copy recommended that all records be exported and
haul data from a particular truck from a diskette into a archived in a compressed file format for future
database for analysis. reference before being deleted.

To import data, press the "IMPORT" button at the


bottom of the “Payload Summary” screen. The
program will ask for a ".zip" file to import, locate the
file and press "Open". The program will only import
".zip" files created by another computer running the
PDM Software.
OM6008 Optional Equipment - Section 6
Payload Meter 3 Page 6-29

Viewing Alarms Deleting Alarm Records


From the Payload Summary screen, click the To delete alarm records from the main database,
“Alarms” button to display the alarm screen. The press the "Delete" button at the bottom of the “Alarm
alarms are sorted by the query settings from the Display” screen. The program will display a
Payload Summary screen. Alarms can be displayed summary of the alarms from the query. To delete an
as Active or Inactive. alarm, select one at a time and press the "Delete"
button. It is recommended that the query data be
exported to a “.zip” file for archival purposes before
deletion. Multiple records may be selected by
holding down the Shift key. Pressing the "Delete All"
button will select all the alarms from the current
query and delete them.

NOTE: There is no recovery for alarms that have


been deleted from the main database. It is highly
recommended that all records be exported and
archived in a compressed file format for future
reference before being deleted.
OM6008 Optional Equipment - Section 6
Payload Meter 3 Page 6-30

NOTES:
OM7001 Optional Equipment - Section 7
Cab Radio Page 7-1

FIGURE 7-1. CAB RADIO

SETTING THE TIME GENERAL RECEIVER FUNCTIONS


1. Turn the key switch "ON". The receiver is equipped with two FM radio bands,
FM1 and FM2. The two bands are identical, however,
2. Press and hold DSPL/TM SET (9) for 2 sec-
each one allows the operator to set 6 preset
onds. When the number display flashes, time
channels for a total of 12 FM presets overall.
set mode is active.
3. Press TUNE / SEEK (7 & 8) to change the hour TURNING THE POWER "ON" AND "OFF"
setting.
1. Turn the key switch to "ON".
4. Press the DSPL/TM button to switch to min-
2. Press PWR (1) to turn the receiver "ON" and
utes. The minute digits will flash when in this
"OFF". Pushing ON/AUDIO (6) may also be
mode.
used to turn the receiver power "ON".
5. Press TUNE / SEEK to change the minute set-
ting. 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.
Optional Equipment - Section 7 OM7001
Page 7-2 Cab Radio

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

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

PROGRAMMING PRESET STATIONS

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

PROGRAMMABLE EJECT DEFAULT PLAYING A CASSETTE

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

2. Press button (3) to toggle between


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

BAD TAPE DETECT CASSETTE PLAYER CLEANING

If the receiver detects a bad cassette, “BAD TAPE” After 35 hours of cassette play, the display will read
will appear on the display, and the tape will be "TP CLEAN" for 5 seconds. This indicates that it is
ejected. If this occurs, the cassette should be time to clean the cassette player.
removed from the player and should not be re- 1. Turn the key switch to "ON", and turn the
inserted. receiver "OFF".

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

NOTES
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