COMPONENT CODE D8

PARTS & SERVICE REF NO. AT06310

DATE December 4, 2006
NEWS (C) Page 1 of 17

SUBJECT: SETTING PROCEDURES OF SERVICE METER AND TRAVEL DIS-

TANCE ODOMETER WHEN THE MACHINE MONITOR IS REPLACED
PURPOSE: To inform field personnel.
APPLICATION: HD325-7 Dump Truck Serial Number 7001 to 7999
HD405-7 Dump Truck Serial Number 3001 to 3999
HD465-7E Dump Truck Serial Number 10001 to 19999
HD605-7E Dump Truck Serial Number 8001 to 8999
HD785-7 Dump Truck Serial Number 7001 to 7999
HM300-2 Dump Truck Serial Number 2001 to 2999
HM350-2 Dump Truck Serial Number 2001 to 2999
HM400-2 Dump Truck Serial Number 2001 to 2999
WA600-6 Wheel Loader Serial Number 60001 to 69999

FAILURE CODE: D800Z9

DESCRIPTION:

1. Introduction
It is necessary to set the service meter and the travel distance odometer when the machine monitor
is replaced.
When setting them, refer to the setting procedures detailed in this Service News.

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1. Purpose
Though it is necessary to set the "Service Meter", "Travel Distance Integrated Value", and
"Reverse Travel Distance Integrated Value (dump track only)" which are displayed on the
machine monitor when the machine monitor is replaced, the setting procedures of these
important information are not detailed in the Shop Manual so that they are not set
incorrectly, and this Service News introduces the setting procedures.

Since the execution items at the replacement of the machine monitor are detailed in Part:
Inspection and Adjustment in the Shop Manual be sure to refer to the Shop Manual.
This Service News describes about "Service Meter", "Travel Distance Integrated Value",
and "Reverse Travel Distance Integrated Value (dump track only)" out of the execution
items when the machine monitor is replaced.

Caution (1): When VHMS and KOMTRAX are installed, their data cannot be obtained
correctly unless the service meter is set.
Caution (2): It is impossible to set smaller values than the present values for "Service
Meter", "Travel Distance Integrated Value", and "Reverse Travel Distance
Integrated Value (dump track only)".

2. Setting procedure (For dump truck)

Set them in accordance with the following procedures:

2.1 Before replacing the machine monitor, record the "Service Meter", "Travel Distance
Integrated Value", and "Reverse Travel Distance Integrated Value (dump track only)"
on the machine monitor.

For the checking method of "Service Meter", "Travel Distance Integrated Value", and
"Reverse Travel Distance Integrated Value", refer to "Explanation of Each Device,
Machine Monitor in Part: Operation in the Operation and Maintenance Manual" of the
machine.

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(Note) When the machine monitor is out of order and these values cannot be checked,
check the Service Meter by the VHMS and KOMTRAX data.
Since "Travel Distance Integrated Value" and "Reverse Travel Distance Integrated
Value" cannot be checked by data from the VHMS and KOMTRAX, record the value
that was checked by asking the machine controller.
When Service Meter cannot be checked because the VHMS and KOMTRAX are not
installed, record the value checked by asking the machine controller.
Checking method of Service Meter by data from the KOMTRAX
1) Login from the KOMTRAX Operation Screen.

2) Select the machine check list.

Top menu

3) Record the "Latest Service Meter (H)" of the relevant machine.

Machine search list
Optional machine search Machine report preparation
Machine mode Select 1 machine.
User name and type
Management No.
Monitoring report
User code Serial No. Current location List display Select 1 or more machines.
(Management) Machine All machines Monthly operation/
Not specified Inventory point Not specified fuel consumption report
charge point type

Applicable machine group Private machine

Sort Applicable machine group
Display Registration Layout editing
Machine model All machines

User (Management) Inventory The latest The latest

Machine Management Communication The latest
Select Machine type User name Maker model Type Serial No. service meter state
code No. charge point point location receipt date
(H)

Dump KOMATSU Unclassified Unclassified Normal

For anything unclear about the KOMTRAX Operation Screen, contact

KOMTRAX Service Hot Line
Toll-free Number: 81-120-649-300 or mail address: [email protected].

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Checking method of Service Meter by data from the VHMS

1) Login from the WebCARE Screen.

2) Select the desired model and data receiving status on the machine monitoring
screen.
Machine
Home Fleet monitoring monitoring Tool used

Selection conditions
Place of operation Machine model and Serial No. Administration No.

Maker

Product group

Class

Machine model

Serial No.

Unit

Reset

Machine operation
Data receiving status Air code history Trend analysis
information
Bulletin-board site
Map analysis Component history Payload meter
management
Select

3) Record the values of the service meter on the Service Meter Progress screen.
Service meter progress
Machine information
User name: Field name: Maker:

Product group: Machine model: Serial No.:

For the WebCARE screen, contact Komatsu Construction Equipment Headquarters,

Product Support Headquarters, R & M Division, Engineering Support Team
(telephone: 81-3-5561-2765 or mail address: [email protected]).
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4) If you cannot check the latest data of the service meter on the WebCARE
screen, use the VHMS initialization tool to record the service meter value
recognized by VHMS.

To use the VHMS initialization tool, refer to the "Initialization of VHMS

Controller" in the "Inspection, Adjustment and Troubleshooting" section of the
Shop Manual.

4-1) Set up the VHMS setting tool and select [Setup].

4-2) Record the service meter value displayed on the SMR.

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2.2 Replacement of Machine Monitor

1) Pull out the screws (56B-54-15932) and washers (01245-00616) fixing the dashboard
cover (01643-70623), and remove the dashboard cover.

Screw

2) To enable the user to access connectors connected to the machine monitor, remove
the air conditioner duct on the rear of the machine monitor once, and disconnect all the
connectors of the machine monitor.

3) Replace the machine monitor fixed to the bracket (56B-54-15560) by bolts with a new
one.

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4) Fix the machine monitor to the bracket, and return all the removed connectors to where
they were.
5) Find a 1-pole connector (0P7) on the rear of the machine monitor, and check that it is
connected.

Machine monitor

6) The air conditioner duct and dashboard should be remain removed as the setting of
"Service Meter", "Travel Distance Integrated Value", and "Reverse Travel Distance
Integrated Value (dump track only)"is to be executed at above conditions.

2.3 Execute the setting items at replacement of the machine monitor in accordance with the
Shop Manual.

2.4 Setting "Service Meter", "Travel Distance Integrated Value", and "Reverse Travel
Distance Integrated Value (dump track only)"
1) Set the starting switch to the ON position.
When any trouble occurred, refer to Part: Troubleshooting in the Shop Manual to
correct the trouble.

2) Make sure that "Service Meter" and "Travel Distance Integrated Value" are displayed
on the character display of the machine monitor.

Character display

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3) Keep pressing the machine monitor mode selector switches ( ) and (<) for over 5
sec. at the same time and release them.

4) When the ID Input Screen appears, input ID=6491 as per the following procedures:

Cursor Most significant Least significant digit

digit
ID Inputting Method
<1> Press the (>) or (<) switch, and the value at the cursor position will increase or
decrease. Adjust the value to the specified value and press the switch.
<2> Adjust the 4-digit value as explained in <1>, and the Electric System Trouble
History Screen will appear.
<3> If you input incorrect values by mistake, move the cursor back to the most
significant digit by pressing the switch and input correct values again starting
from the most significant digit.

5) Make sure that the Electric System Trouble History Screen is displayed on the
character display.

E L E C T R I C F A U L T < >
* *

6) Disconnect the connector (0P7) on the rear of the machine monitor once, and
reconnect it.
The following screen (the service meter setting menu) will appear automatically.

< >

1 2 3 4 5 . 0 h

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7) Press the machine monitor mode selector switch ( ).

The screen below (Service Meter Setting Screen) will appear. Set the service meter
value recorded before the replacement in accordance with the following procedures:

< >

0 2 3 6 7 . 0 h

Most significant digit Cursor Least significant digit

Setting method
<1> Input the values 0 - 9 at the cursor position.
<2> When the cursor is at the most significant digit at first, the value will increase of
decrease and the displays at 0 - 9 change each time the (>) or (<) switch is pressed
once. Since the most significant digit of the service meter is at the 10,000 place, 0
is displayed at the most significant digit if the current service meter value is 2367.0
for example.
<3> When a target value is input, press the switch to set the value.
<4> The cursor moves to a digit below. Input values down to the least significant digit
same way as in <2> and <3>.
<5> Input values down to the tenth's place and press the switch. (The confirmation
screen will appear.)
<6> When the set value is outside the range (smaller than the current value), it will not
be accepted.
<7> If you input an incorrect value when the cursor is at any place other than the most
significant digit, the cursor moves to the most significant digit by pressing the
switch and you can input a correct value.
At the time, the input value remains as it is.

8) The Service Meter Setting Confirmation Screen will appear. Bring the cursor to YES by
pressing the (>) switch and press the switch to determine it.

Y E S < > N O E N T E R

9) The following screen (the service meter setting menu) will appear again.

< >

1 2 3 4 5 . 0 h

10) Press the (>) switch, and the Travel Distance Integration Setting Screen will appear.

O D O < >

1 2 3 4 5 . 6 k m

11) Set the travel distance integrated value as per the same setting procedures as the
service meter.

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12) When the travel distance integrated value is determined, the following screen will
appear again.

O D O < >

1 2 3 4 5 . 6 k m

13) Press the (>) switch, and the Reverse Travel Distance Integration Setting Screen will
appear.

B A C K W A R D O D O < >

1 2 3 4 5 . 7 k m

14) Set the reverse travel distance integrated value as per the same setting procedures as
the service meter.

15) After having set the reverse travel distance integrated value, set the starting switch to
the OFF position.

2.5 Return the air conditioning duct and dashboard to where they were, and exit "Service
Meter", "Travel Distance Integrated Value", and "Reverse Travel Distance Integrated
Value (dump track only)" settings.

3. Setting procedure (For wheel loader WA600-6)

Set them in accordance with the following procedures:

3.1 Before replacing the machine monitor, record the "Service Meter Reading" and the
"Travel Distance Integrated Value" on the machine monitor.
For the checking method of "Service Meter Reading" and "Travel Distance Integrated
Value," refer to "Explanation of Each Device, Machine Monitor in Part: Operation in the
Operation and Maintenance Manual" of the machine.

(Note) When the machine monitor is out of order and these values cannot be checked,
check the Service Meter Reading by the VHMS and KOMTRAX data.
Since "Travel Distance Integrated Value" and "Reverse Travel Distance
Integrated Value" cannot be checked by data from the VHMS, record the value
that was checked by asking the machine controller.

When Service Meter Reading cannot be checked because the VHMS is not
installed, record the value checked by asking the machine controller.
Checking method of Service Meter Reading by data from the VHMS
See the case for the dump truck.

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3.2 Replacement of Machine Monitor

After replacing the monitor panel in <7>, return all connectors for connecting the
machine monitor, proceed to Setting of Monitor Panel in 3.3 and on and install them
again after finishing the setting work.
Removal; Remove the machine monitor <6> Remove the front cover.
in the order of <1> - <7>. Screw tightening torque at reassembly:
Reinstallation; Reinstall a machine 3.44 - 4.41 Nm {0.35 - 0.45 kgm}
monitor in the order of <7> - <1>. For the screw positions and
configuration, see page 11.
Front cover

<7> Replace the machine

monitor fixed to the bracket.

<2> Remove the screws.

Screw tightening torque:
3.44 - 4.41 Nm {0.35 - 0.45 kgm}
Bolt tightening torque:
8.8 - 14.7 Nm {0.9 - 1.5 kgm}
<1> Remove the floor mat.

<5> Remove the connector from each switch.

(Note)
Raise the front cover a bit, unlock the
connector and pull out the connector from the
switch. (Pulling out the connector without
unlocking will break the switch. So, be sure to
unlock the connector in advance.)
For the harness assembly, see page 12.

Remove the parking

brake switch and two
machine monitor
mode switches from
the front cover, and
connect them to the
connectors.

<3> Remove the air conditioner duct hoses.

<4> Remove the connector from the sunlight Clamp tightening torque at reassembly:
sensor of the air conditioner. 6.31 - 7.29 Nm {0.64 - 0.74 kgm}

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Details of screw positions and configuration

Rubber washer

Spacer

8 places marked
with

AJSS
specifications
only

Large-diameter
washer
4 places marked with # 4 places marked with

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Harness assembly procedure (The figure below shows the rear view of the front cover.)

Front
Parking brake switch

Machine
monitor
mode switch

Machine
monitor
mode switch

Load meter switch (Option) Light switch Hazard switch

Dimmer switch
Load meter switch (Option) Front wiper switch

AJSS specifications only

Sunlight sensor of air conditioner

CN A03

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3.3 Execute the setting items at replacement of the machine monitor in accordance with the
Shop Manual.

3.4 Setting "Service Meter" and "Travel Distance Integrated Value."

1) Insert the T-adaptor for Connector 070 into the connector (CN C04) of the machine
monitor, ground the 6 pins of the Connector C04 to the body and tack them temporarily.

2) Set the starting switch to the ON position.

When any trouble occurred, refer to Part: Troubleshooting in the Shop Manual to
correct the trouble.

3) Make sure that "Service Meter" is displayed on the character display of the machine
monitor.

Character display

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3) Keep pressing the machine monitor mode selector switches ( ) and (<) for over 5
sec. at the same time and release them.

4) When the ID Input Screen appears, input ID=6491 as per the following procedures:

Cursor Most significant Least significant digit

digit

ID Inputting Method
<1> Press the (>) or (<) switch, and the value at the cursor position will increase or
decrease. Adjust the value to the specified value and press the switch.
<2> Adjust the 4-digit value as explained in <1>, and the Electric System Trouble
History Screen will appear.
<3> If you input incorrect values by mistake, move the cursor back to the most
significant digit by pressing the switch and input correct values again starting
from the most significant digit.

5) Make sure that the Electric System Trouble History Screen is displayed on the
character display.

E L E C T R I C F A U L T < >
* *

6) Release the 6 pins of the connector C04, which were grounded to the body and were
tacked temporarily in 1), to the open state and then ground them to the body again and
tack them temporarily.
The following screen (the service meter setting menu) will appear automatically.
< >

1 2 3 4 5 . 0 h

Caution: Note that, if the 6 pins of the connector C04 are released from grounding and 3
sec. elapses, the setting screen will disappear.

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7) Press the machine monitor mode selector switch ( ).

The screen below (Service Meter Setting Screen) will appear. Set the service meter
reading recorded before the replacement in accordance with the following procedures:

< >

0 2 3 6 7 . 0 h

Most significant digit Cursor Least significant digit

Setting method
<1> Input the values 0 - 9 at the cursor position.
<2> When the cursor is at the most significant digit at first, the value will increase of
decrease and the displays at 0 - 9 change each time the (>) or (<) switch is
pressed once. Since the most significant digit of the service meter is at the
10,000 place, 0 is displayed at the most significant digit if the current service
meter value is 2367.0 for example.
<3> When a target value is input, press the switch to set the value.
<4> The cursor moves to a digit below. Input values down to the least significant digit
same way as in <2> and <3>.
<5> Input values down to the tenth's place and press the switch. (The
confirmation screen will appear.)
<6> When the set value is outside the range (smaller than the current value), it will not
be accepted.
<7> If you input an incorrect value when the cursor is at any place other than the most
significant digit, the cursor moves to the most significant digit by pressing the
switch and you can input a correct value.
At the time, the input value remains as it is.

8) The Service Meter Setting Confirmation Screen will appear. Bring the cursor to YES by
pressing the (>) switch and press the switch to determine it.

Y E S < > N O E N T E R

9) The following screen (the service meter setting menu) will appear again.

< >

1 2 3 4 5 . 0 h

10) Press the (>) switch, and the Travel Distance Integration Setting Screen will appear.

O D O < >

1 2 3 4 5 . 6 k m

11) Set the travel distance integrated value as per the same setting procedures as the
service meter.
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12) When the travel distance integrated value is determined, the following screen will
appear again.

O D O < >

1 2 3 4 5 . 6 k m

13) After having set the travel distance integrated value, set the starting switch to the OFF
position.

14) Disconnect the T-adaptor for the connector 070 inserted in the machine monitor
connector (CN C04) and return the machine monitor connector to where it was.

3.5 Carry out the Reinstallation Procedures <1> - <6> in Paragraph 3.2 in the order of <6>
to <1> to finish the setting of "Service Meter" and "Travel Distance Integrated Value."

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