PT UNITED TRACTORS Tbk

on KOMATSU DUMP TRUCK

 02
Komatsu Pay Load Meter Card Type 02

SYSTEM
SYSTEMOVERVIEW
OVERVIEW
5. Suspension pressure sensor
6. Suspension pressure sensor
7. Suspension pressure sensor
8. Suspension cylinder
9. Pay Load Meter Controller
10. Lamp drive relay
11. External display lamp
12. Battery
13. Fuse for external display lamp

1. Shift lever neutral detection switch 14. Fuse for PLM Controller
(relay) 15. Memory Card
2. Body float detection switch 16. Travel signal sensor
3. Clinometer 17. RS232C output
4. Suspension pressure sensor 18. Battery charge signal
By. WIED_JULY-04
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Komatsu Pay Load Meter Card Type 03

PRINCIPLE
PRINCIPLEOF
OFCALCULATION
CALCULATION

The dump truck is supported by four

PB suspension cylinders. By measuring the
total for load bearing on each cylinder, it
is possible to know how the load on the
spring of the machine.
ST PT The payload can be calculated by
subtracting the unladen machine weight
from the laden machine weight

The load each cylinder can be calculated

from cross sectional area and internal
SB pressure of the suspension cylinder.

W = PB SB - PT (SB - ST)
By. WIED_JULY-04
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Komatsu Pay Load Meter Card Type 03

PAY
PAYLOAD
LOADMETER
METERBLOCK
BLOCKDIAGRAM
DIAGRAM Unladen
weight (results
of calibration)

-
Front right Calculate + + +
pressure sensor load

Convert to pressure value

(PxA) + +

Compensat
ion factor
Front left Calculate
load
pressure sensor
(PxA)

Rear right Calculate + PAY LOAD

A/D converter

load
pressure sensor
(PxA) +

Compensat
ion factor
Rear left Calculate
load
pressure sensor
(PxA)

Convert to angle of
Clinometer inclination

Gain adjustment Product when

multipled by link
trimmer
factor (inside ROM)

By. WIED_JULY-04
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Komatsu Pay Load Meter Card Type 04

PLM
PLMCONTROLLER
CONTROLLER

1 2 3 4

DISPALY

5 Display panel
5

SWITCH
6 7 8
1 MODE switch MODE
INDICATOR
CAL
2 Receive data Indicator 6 CALIBRATION/CLEAR switch
CLR

TOTAL
3 Transmit data Indicator 7 TOTAL/SHIFT switch
SFT
LIGHT
4 Download data to memory card Indicator 8 LIGHT/INCREMENT switch
INC

By. WIED_JULY-04
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Komatsu Pay Load Meter Card Type 05

CONTROLLER
CONTROLLERSIDE
SIDESWITCH
SWITCH

1. Payload gain adjustment trimmer

2. Speed regulation switch
3. Distance regulation switch
4. Model selection switch
5. Use of memory card
6. Use of clinometer switch
7. Weight unit setting
8. Not used
B. Buzzer volume regulation

Left switches

< Blue font : can be adjusted > By. WIED_JULY-04

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Komatsu Pay Load Meter Card Type 06

DISPLAY
DISPLAYWHEN
WHENTURN
TURNON
ON

Display flow of
payload meter display
after starting switch
turned ON, if the
engine is started
during this flow of
displays, even if there
are items which
should still be
displayed the display
switches after several
seconds to display
during normal
operation.

By. WIED_JULY-04
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Komatsu Pay Load Meter Card Type 07

OPERATION NORMAL DISPLAY

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Komatsu Pay Load Meter Card Type 08

SUSPENSION
SUSPENSIONPRESSURE
PRESSURESENSOR
SENSOR
FL pressure FR pressure
sensor sensor

Pressure sensor is
installed at the
bottom end of the
suspension
cylinder, and acts
to measure the
pressure at the
cylinder bottom.

RL pressure RR pressure
sensor sensor
By. WIED_JULY-04
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Komatsu Pay Load Meter Card Type 09

SUSPENSION
SUSPENSIONPRESSURE
PRESSURESENSOR
SENSOR

When replacing pressure

sensor (1), leave the valve
installed to the suspension
and remove only pressure
sensor.

1 : PRESSURE SENSOR
2 : VALVE
3 : VALVE CORE

SIGNAL OUTPUT
CHARACTERISTICS

By. WIED_JULY-04
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Komatsu Pay Load Meter Card Type 10

CLINOMETER
CLINOMETER

Clinometer measures the front-rear

angle of the machine to carry out
compensation on slopes. Clinometer
When loading is carried out on
slopes, the weight of the load is
different from the value measured
on flat ground, so the front-rear
angle of the machine is detected and
compensation is carried out
according to the angle (within + 5o)

SIGNAL OUTPUT CHARACTERISTICS

By. WIED_JULY-04
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Komatsu Pay Load Meter Card Type 11

EXTERNAL DISPLAY LAMP

External display HD 785-5

lamps
50 – 67 tons
67 – 85 tons
85 – 92 tons
92 – 96 tons
96 – up tons

HD 465-7
41.4 – 51.6 tons
51.6 – 55.2 tons
55.2 tons & above
By. WIED_JULY-04
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Komatsu Pay Load Meter Card Type 12

DUMPING
DUMPINGFULLFILLED
FULLFILLEDCONDITION
CONDITION

On the previous occasion, when the

dump lever was moved from a position
other than FLOAT to FLOAT (after
dumping, lever was returned from YES
LOWER to FLOAT), was load after 5
seconds less than 1/5 of rated ?

On the previous occasion, when the

dump lever was moved from a position
other than FLOAT to FLOAT, did it stay YES RECORD
at FLOAT for 5 seconds ?

This time, when the dump lever was

moved from a position other than
FLOAT to FLOAT ( after dumping, lever YES
was returned from LOWER to FLOAT ),
was load more than ½ of rated ?

By. WIED_JULY-04
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Komatsu Pay Load Meter Card Type 12

PLM
PLMCALIBRATION
CALIBRATION
Kapan KALIBRASI dilakukan ???
Bagaimana Prosedur KALIBRASI ???
 Selesai assembly / saat delivery
1. Kosongkan vessel (tidak ada muatan)
 Dilakukan adjustment suspensi
2. Pastikan Hoist Lever di posisi FLOAT
 Berat unit berubah >100 kg CAL
3. Hidupkan engine, kemudian tekan tombol CLR
setidaknya selama 2 detik.
 Ganti Suspension Pressure Sensor
Pada display panel akan muncul tulisan : CAL (berkedip)
 Ganti PLM Controller
4. Jalankan unit maju, lurus dengan kecepatan 5 - 10 km/jam
CAL
 Ganti / repair suspension cylinder 5. Dalam keadaan unit berjalan, tekan tombol CLR
sampai tulisan CAL tidak berkedip (menyala terus).
6. Jalankan unit terus sampai display CAL berubah menjadi
tampilan “waktu” (jam dunia).
7. Kalibrasi selesai.
CAL

CATATAN ;
Tempat dilakukannya kalibrasi hendaknya datar dan lurus
CAL
CLR

By. WIED_JULY-04
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Komatsu Pay Load Meter Card Type 13

DISPLAY
DISPLAYTHE
THEDATA
DATA

Data yang tersimpan di dalam PLM Bagaimana caranya ???

Controller dapat ditampilkan secara 1. Unit kondisi parkir dengan aman, engine stop,
manual (tanpa menggunakan computer) hoist lever posisi FLOAT, starting switch posisi
pada Display Panel yang terdapat di PLM
ON, transmisi NETRAL.
Controller.
2. Tekan tombol TOTAL sesaat, maka akan
SFT
muncul angka yang menunjukkan NUMBER OF
Data yang dapat ditampilkan adalah ;
CYCLE.
 Total Pay Load
3. Tekan lagi tombol TOTAL , maka akan muncul
SFT
 Error code
TOTAL PAY LOAD.
 Number of cycle Total pay load = DISPLAY x 1OO TON
TOTAL
4. Tekan lagi tombol SFT , maka akan muncul
ERROR CODE jika ada. Jika system dalam kondisi
baik maka display panel akan menampilkan “ : “.
5. Tekan lagi tombol TOTAL , maka akan kembali
SFT
ke NORMAL DISPLAY.

Detail/deskripsi
Detail/deskripsierror
errorcode
code(jika
(jikamuncul)
muncul)dapat
dapat
dilihat di SHOP MANUAL, dan untuk mengatasinya
dilihat di SHOP MANUAL, dan untuk mengatasinya
TOTAL ikuti
SFT ikutitroubleshooting
troubleshootingstep
steppada
padaSHOP
SHOPMANUAL
MANUALpula.
pula.

By. WIED_JULY-04
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Komatsu Pay Load Meter Card Type 14

DATA
DATACLEAR
CLEAR

PLM controller memiliki kapasitas memory terbatas. Bagaimana cara menghapus data ???
Jika unit terus dioperasikan suatu saat memory TOTAL PAY LOAD & OVERALL NUMBER
akan PENUH. Jika memory penuh controller akan A
ngomong dengan cara memunculkan tulisan pada
OF CYCLE DATA CLEAR
Display Panel. 1. Tekan tombol TOTAL sesaat.
SFT
2. Ulangi langkah no.1
DISPLAY DESKRIPSI CAL
3. Tekan tombol CLR setidaknya selama
E.FUL Memory ENGINE ON/OFF DATA
penuh. Kapasitas memory 115. 2 detik.
F.FUL ERROR memory penuh. Kapasitas 4. Ulangi langkah no. 3 hingga Display Panel
memory 230.
menampilkan “ 0000 “
L.FUL Memory CYCLE DATA penuh. B DATA ALL CLEAR
LIGHT
Kapasitas memory 2900. 1. Tekan tombol MODE dan INC bersa-
H.FUL Memory TOTAL PAY LOAD, ma-sama.
OVERALL NUMBER OF CYLCLE LIGHT CAL
2. Tekan tombol INC dan CLR bersa-
penuh. Kapasitas memory 999900
ton. ma-sama.
3. Tekan tombol CAL
CLR
PERINGATAN
PERINGATAN!!!
!!!
Sebelum menghapus data pada PLM NOTE ;
controller, lakukan down load data lebih
Saat menghapus data ; unit parkir, engine stop, starting
dulu, agar Anda tidak kehilangan data.
switch ON, hoist lever FLOAT, transmisi NETRAL

By. WIED_JULY-04
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Komatsu Pay Load Meter Card Type 15

TIME,
TIME,DATE
DATE&&SPEED
SPEEDLIMIT
LIMITSETTING
SETTING

Agar PLM controller dapat menyimpan data
kejadian sesuai dengan tanggal dan jam dunia,
maka harus dilakukan setting jika belum sesuai.
Setting tidak perlu dilakukan jika tanggal dan jam
sudah sesuai. Dengan demikian produksi unit dari
menit ke menit setiap hari dapat diketahui.
Safety operation merupakan hal yg sangat vital. Salah
satu wujudnya adalah pembatasan laju unit. Agar speed
limit yang diterapkan di tambang dapat ditaati maka PLM
dapat diset agar bisa memberikan peringatan kepada
OPERATOR pada saat laju unit melebihi ketentuan.
Peringatan tersebut berupa BUZZER dan melalui Display
Panel PLM.

PROSEDUR SETTING
PROSEDUR SETTING
1. Tekan tombol MODE dan tahan hingga pada
1. Tekan tombol MODE dan tahan hingga pada
Display Panel muncul “ Cd dP “
Display Panel muncul “ Cd dP “
2. Tekan lagi tombol MODE sesaat berulang-ulang
2. Tekan lagi tombol MODE sesaat berulang-ulang
hingga muncul display JAM / TANGGAL.
hingga muncul display “ SP:XX “.
3. Jika setting sudah selesai tekan MODE
3. Selesai setting tekan MODE

ž Angka yang dpt di-set adalah yang berkedip/aktif

LIGHT ž XX merupakan angka setting SPEED LIMIT
ž Setting menggunakan tombol INC
TOTAL ž Setting menggunakan tombol LIGHT
ž Pemindahan angka aktif gunakan tombol INC
SFT TOTAL
ž Pemindahan angka aktif gunakan tombol SFT

By. WIED_JULY-04
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Komatsu Pay Load Meter Card Type 16

DOWNLOAD
DOWNLOADDATA-1
DATA-1

Data yang tersimpan di Pay Load Meter (PLM)

controller sangat banyak dan lengkap. Dengan
DOWN LOAD DATA DENGAN CARD
demikian sangat penting artinya bagi
departemen produksi maupun maintenance. 1. Tekan tombol MODE dan tahan hingga pada
Agar data tsb bermanfaat maka harus diambil Display Panel muncul “ Cd dP “
(down load) dari controller agar dapat kita
baca, analisa dan simpulkan tentang berbagai Huruf dP berkedip.
TOTAL
hal. 2. Tekan lagi tombol SFT hingga diisplay
Cd:dP berkedip semua.
TOTAL
MODE 3. Tekan tombol SFT lagi. Kemudian lampu
indikator CARD ACCESS akan menyala.
Jika proses down load sudah selesai maka
display akan kembali ke normal operasi secara
otomatis.

NOTE ;
Saat DOWN DATA data ; unit parkir, engine stop, starting
TOTAL switch ON, hoist lever FLOAT, transmisi NETRAL
SFT

By. WIED_JULY-04
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Komatsu Pay Load Meter Card Type 17

DOWNLOAD
DOWNLOADDATA-2
DATA-2

DOWN LOAD DATA DENGAN PERSONAL COMPUTER

1. Gunakan Laptop atau Desktop Personal Computer 5. Selanjutnya akan muncul dialog box seperti
yang telah di-install software PLM Komatsu HD 785 gambar di bawah. Click pada “ PLM “
2. Syarat kondisi unit saat down load dengan PC
sama dengan saat down load dengan Card Dump
3. Hubungkan PC ke PLM melalui connector RS232C
(di sebelah kiri operator seat) menggunakan tool
PN. 581-86-55970.
4. Jalankan program PLM, misal dari START menu.

By. WIED_JULY-04
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Komatsu Pay Load Meter Card Type 18

DOWNLOAD
DOWNLOADDATA-3
DATA-3
6. Selanjutnya akan muncul dialog box seperti
gambar di bawah. Click pada “ DOWNLOAD “

7. Selanjutnya akan muncul dialog box seperti 9. File data hasil download dapat dilihat melalui WINDOWS
gambar di sebelah kanan. Click pada “ START “ EXPLORER di ;
C:\PLM 16\data\HD785\xxxxxx\20021221\PLM001
8. Setelah DOWNLOAD STATUS complete (100%)
Untuk kembali click pada “ BACK “. Selanjutnya
cari data hasil down load di folder PLM (windows
explorer)

By. WIED_JULY-04