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Troubleshoot information

Information in this guide will be updated regularly. Check guide number for current version

Guide Version KTS02-00

2 of 35 Table of Contents

TableofContentsTerminology ............................................................................................................................ 3General information regarding ................................................................................ 4Terminal Configuration Process .............................................................................. 6KOMTRAX Device Types .................................................................................................... 7KOMTRAX Power Modes .................................................................................................. 8Most Common Issues .......................................................................................................... 9Common Troubleshooting Solution ....................................................................... 10

Machine Never Communicated- TC301, TC310 terminal ........................ 11Machine Never Communicated- MH800/ 801machine (with TH300/301 modem) ....................................................................................................... 12TC310 Removal of Shipping Mode ........................................................................ 14MH800/ 801 Removal of Shipping Mode .......................................................... 15Machine Stopped Communicating~ TC301 and TC310 ............................. 17Machine Stopped Communicating- MH800/801(with TH300/301 Modem) .................................................................................................................................. 19

Deactivating KOMTRAX: TC301/TC310 ............................................................... 21Deactivating KOMTRAX: MH800 / MH801 monitor panel ......................... 21Replacing a TC301/TC310 KOMTRAX Terminal ............................................. 22Replacing a TH300 modem (MH800/801 Machine) ......................................... 22Replacing a MH800/801 Monitor Panel ............................................................. 22APPENDIX ............................................................................................................................... 23Forms ........................................................................................................................................ 24

Replacement Form ........................................................................................................ 24Request for De-Activating KOMTRAX System .............................................. 25

Installation and Check Processes ........................................................................ 26Install Check Procedure for KOMTRAX TC300/TC301/TC310 terminal .............................................................................................................................. 26Codes to Troubleshoot TC300/TC301Installation check procedure .......................................................................................................................... 29TC300/TC301 LED information ............................................................................ 30MH800/801: Modem Assignment and On Board Inspection ................. 31Troubleshoot codes for MH800 on-board inspection results ......... 33Obtaining Monitor and Modem Serial Numbers (MH800 Monitor) ... 34

3 of 35

Terminology Configuration Command

The messages sent to the KOMTRAX terminal or monitor panel that program it with information such as what to report, when, what time zone it should recognize, and the movement trigger.

Function level The level of information and abilities KOMTRAX could report for a specified machine. Function level is determined by a combination of the machines computer/capability (Komatsu equipment only), the KOMTRAX terminal, and machine specific wiring harness.

Function level 1 GPS, SMR, Operation map, engine lock, alerts This is the information you will obtain when installing KOMTRAX on any non-Komatsu equipment or on Komatsu equipment without a machine specific wiring harness.

GPS Global Positioning System Installation check or On-Board Inspection (For MH800 equipped machines)

Final step of the KOMTRAX installation process. This is the physical procedure that must be followed through to the proper result (see section regarding this process within) in order to ensure proper installation and reporting of your KOMTRAX unit. Instructions for the procedure can be found in this manual.

KBA KOMTRAX Business Application- this is the global website currently used to view your KOMTRAX information.

KOMTRAX Komatsus wireless monitoring system. KOMTRAX 2.5 New KOMTRAX controller (starting at p/n 7826-20-7035) that can provide daily

values for fuel consumption and actual working hours on most all Tier III Komatsu equipment where it is not currently being reported.

LED Light-emitting diode. Found on the TC100/TC300/TC301/TC310. Helps to troubleshoot problems with KOMTRAX installation based on which LEDs are on, off, or flashing.

MH800/ MH801 Machine monitor panel that features a flat screen colored monitor panel and integrated KOMTRAX reporting logic

Modem Device used to send data from machine and receive data from KBA website. Only found on machines with the color display MH800/801 monitor panel. The Orbcomm modem is also labeled TH300 or TH301.

Movement Trigger A condition programmed into the terminal that causes a location report be sent when the machine moves a set amount of distance from its most recent reported position.

On-board inspection Similar to the installation check, this process is performed through the MH800 monitor panel and ensures all parts of the KOMTRAX reporting system on that machine are functioning properly. Instructions for the procedure can be found in this manual.

Operation map Bar graph reflecting the times of day a machines engine was on or off. Orbcomm The satellite company KOMTRAX utilizes to transmit its data and communicate

with the machine. Service Menu Accessed through MH800 monitor panel by holding #4 and typing #1, #2, and #3

in sequence. SMR Service Meter Reading or Machines engine hours TC310 KOMTRAX terminal typically found on most Utility machines. Draws slightly

less power than the standard TC301. Terminal Used to describe the KOMTRAX unit/hardware whether it be a TC100, TC300,

TC301, or TC310. TH300/ TH301 TH300 is an Orbcomm satellite communication modem, which plugs into the

MH800/ 801 monitor panel and transmits the data you see on the KBA website.

4 of 35 General information regarding KOMTRAX reporting schedule

Monthly Data: 1st day of the month: 6am Level 1 Level

1+ Level

2- Level

2 Level

2+ Level

2.5 Level

3 Work days of month X X X X X X X Movement days of month X X X X X X X Monthly SMR X X X X X X X Average SMR per day X X X X X X X Monthly Eco Lamp On/Off Hrs & Ratio X O X Load Map Time & Ratio X O X Actual Work Hours & Ratio X X X ATT lever hours & Ratio** X O X Dig Hours** X Hoist Hours** X Travel Hours X Breaker Hours** X Relief Hours** X Eco Lamp Hours X P Mode Hours** X E Mode Hours** X B Mode Hours** X L Mode Hours** X

--The 2.5 controller adds Daily Actual Working Hours and Daily Fuel Burn only. --O Varies by machine

Daily Data: 1am everyday Level 1 Level

1+ Level

2- Level

2 Level

2+ Level

2.5 Level

3 Location X X X X X X X SMR (Service meter reading) X X X X X X X Operation Map X X X X X X X Fuel Gauge (Residual value) X X X X X X High Water Temp Gauge X X X X X Caution Summary X X X X X Abnormality Summary * X X X X X Actual Working Hours X X Fuel Consumption X X Avg Hourly Fuel Consumed X X Digging Time** X Hoist Time** X Travel Time** X ATT Time** X Breaker Time** X Relief Time** X Eco Lamp Time** X P Mode Time** X E mode Time** X L Mode Time** X B mode Time** X * Abnormality codes are relayed from the machine immediately, the first time the specific code occurs each day ** Not available on Dozers

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As they occur reports Level 1 Level

1+ Level

2- Level

2 Level

2+ Level

2.5 Level

3 Maintenance Reminder 30 hrs prior to set interval and at 0 hours * X X X X X

Maintenance Item Reset Notice * X X X X X Engine Start attempt during engine lock out period X X X X X X X

Abnormalities ** X X X X X Movement triggered location report*** X X X X X X X

* Except Utility Equipment ** Abnormality codes are relayed from the machine immediately, the first time the specific code occurs during the day. *** Movement Triggers cause a position report to occur based on the following conditions: Wheeled machine and Non-Komatsu machines = Approximately every 15km from last reported position. This is 15km in a straight line, and not 15km on the odometer. Komatsu Crawler machines = The first location report will occur approximately 1km from last reported location. If the machine continues to move, then another location will occur after an additional 3km from most recently reported position; then after 5km more, then 7km more, etc., until it generates a location every 15km.

6 of 35

Terminal Configuration Process

In order for KOMTRAX to know what to report, when to report it, the time zone it should recognize, etc., the unit must be programmed using over-the-air commands. KAC will initiate a process to configure/program the terminal within 3 business days of it appearing on the website. There are a number of items that could affect the terminals ability to be programmed to report:

1) The location of the machine relative to its view of the sky and surrounding horizons (buildings, trees, mountains, etc.). This means that even though it may be able to see directly up, you would greatly improve the chances of it seeing the satellite holding its programming messages by also ensuring it can see 360o on the horizontal plane. The satellites rarely pass directly overhead.

2) The location of the communication antenna on the machine (highest point, no obstructions around it).

3) The satellite coverage during a specific time of day for a specific place 4) The mode of the KOMTRAX controller such as Operation, Normal, Power

Save, and Shipping. a. Great: Operation mode When the machine is running or the key

turned to On, the KOMTRAX unit is on continuously and looking for satellites

b. Good: Normal mode- When the machine is off, the KOMTRAX unit looks for satellites 2 minutes every 10 minutes.

c. Poor: Power save mode- When the machine has not been operated for a period of time (definition of a period of time varies by KOMTRAX p/n as well as machine model for MH800 machines), it reverts to a power save mode to avoid draining the battery. During this mode, the KOMTRAX unit looks for satellites 2 minutes every 60 minutes. See power save mode information in display 1.

d. Awful: Long Term Transport Mode- Machine is set so no power is transferred to the terminal when the machine is off. If the terminal has no power it will not only make it impossible to receive its programming but also prevent it from sending any daily, monthly, etc. reports in the event it is programmed. See information within the troubleshoot section regarding Cancellation of Shipping Mode for both MH800,801 machines and TC310 (Utility) machines.

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KOMTRAX Device Types Difference between TC and MH

TC301 and TC310 are the model numbers of the KOMTRAX device on approximately half of the equipment with KOMTRAX. This device contains both the KOMTRAX logic and the modem used to send the machine data. A version of the TC type device shown below.

MH800 or MH801 is the model number of the color monitor panel on much Komatsu equipment. The KOMTRAX programming logic resides within the monitor panel of the machine and an external modem is connected to send the machine data.

Obtaining information and troubleshooting these devices will vary based on whether you are dealing with a TC type KOMTRAX device or a machine with the MH800/801 color monitor panel as shown above.

8 of 35 KOMTRAX Power Modes

KOMTRAX type

Days inactive until it reverts to power save

mode

What takes it out of power

save

KOMTRAX on time in power

save

KOMTRAX on time in

Normal mode

Transport Mode

TC301 14 days key switch on 2 min on; 58 minutes off 2 min on; 8 min off N/A

TC301 (pn 7826-20-7034 and up) 7 days

key switch on for more than 2 hours

consecutively

2 min on; 58 minutes off 2 min on; 8 min off N/A

TC310 7 days key switch on for more than 2 hours

consecutively

2 min on; 58 minutes off 2 min on; 8 min off Varies

MH800, MH801 monitor panel 14 days key switch on

2 min on; 58 minutes off 2 min on; 8 min off

See chart 2 below

MH800, MH801 monitor panel with machine model and monitor pn as shown in chart 1 below

7 days key switch on for more than 2 hours

consecutively

2 min on; 58 minutes off 2 min on; 8 min off

See chart 2 below

MH800, 801 with 7 day until power save mode

Chart 1 Monitor Monitor P/N

PC128/138USLC-8

Air conditioning 7835-31-3003 and up

PC128UU-8

PC120/130-8

PC88MR-8

PC78US-8

PC160LC-8

PC108MR Air conditioning 7835-31-3300 and up

MH800, 801 with Long term transportation mode

Chart 2 Monitor Monitor P/N

PC200-8

Air conditioning 7835-31-1005 and up

Heater 7835-31-1105 and up

No Heater 7835-31-1205 and up

PC128/138US-8

Air conditioning 7835-31-3003 and up

PC128UU-8

PC120/130-8

PC88MR-8

PC78US-8

PC160LC-8

PC108MR Air conditioning 7835-31-3300 and up

PC300-8 PC400-8

Air conditioning 7835-31-5003 and up

Heater 7835-31-5103 and up

No Heater 7835-31-5203 and up

D155AX-6 Air conditioning 7831-69-1101and up

Heater 7831-69-1121and up

9 of 35 Most Common Issues

1. Antenna installed upside down- Especially on Larger machines such as WA500, HD325, D275.

a. Ensure the small (6-7 inch) communication antenna is pointing upright 2. KOMTRAX device in Power Save Mode

a. If a machine has NEVER communicated, the KOMTRAX device may be in power save mode.

i. Contact KAC KOMTRAX support requesting the configuration commands be resent.

ii. Key on or start the machine within one hour of making the request. 3. Dead battery- Especially on smaller machines

a. Replace or recharge battery. 4. Shipping mode on PC88MR-8, PC130-8, PC138USLC-8, PC160LC-8

a. Remove Shipping mode setting by accessing the monitor panel Service Menu, selecting KOMTRAX settings, and then choosing Exit Shipping Mode. See the section in this document for Removal of Shipping Mode for the MH800 machine or for the TC310 terminal.

5. Shipping mode on Utility equipment a. Remove terminal from shipping mode (F displayed in LED window with machine

on). See the section titled TC310 Removal of shipping mode. 6. Installation check process not completed by the plant. A will be displayed in the led

window of the KOMTRAX terminal (TC version) a. Perform installation check/on-board inspection as found in this document

7. Antenna; damaged antenna or antenna cable, or not grounded a. Check connectivity of antenna through cable, from end to end b. Check resistance in antenna cable- should be about 0.5 ohms c. Unscrew antenna from mount and sand off any residue from the threads and from

inside the mount, then reattach. d. Check the antenna ground. Sand off any rust from the mounting place of the base

of the antenna. 8. Incorrect KOMTRAX information registered by manufacturing plant or device installer,

especially in the event of a terminal, modem, or monitor panel replacement. a. Always record the KOMTRAX p/n and s/n when trying to troubleshoot a never

reported or non-reporting unit. On MH800/801 machines, always record the monitor panel p/n and s/n as well as the modem s/n. How to locate this information is explained in this document in the section titled Obtaining Monitor and Modem Serial Numbers (MH800 Monitor)

9. Antenna covered with wrapping or tape- Especially on Small Dozers a. Remove any plastic, cardboard, tape, or other wrap from the communication

antenna and antenna base

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Common Troubleshooting Solution

There are two common themes that would create the need to troubleshoot a machine or KOMTRAX terminal:

1) Machine Never Communicated 2) Machine Stopped Communicating

Additionally, on an MH800, 801 equipped machine (PC88, 138US, 160, 200, 220, 270, 300, 400LC, LL, or HD-8 and D155AX-6) when the TH300/ TH301 modem connected to the monitor panel is replaced, ONLY the following action is necessary:

1. Dismount and unplug defective modem from wiring harness and communication antenna

2. Mount and plug in new TH300 or TH301 modem to wiring harness and communication antenna

3. Send in replacement form containing defective and replaced modem information

DO NOT ACCESS THE KOMTRAX SETTINGS THROUGH THE SERVICE MENU AND DELETE TH300 THEN REASSIGN IT. THE SIMPLE PROCESS OF EXCHANGING THE MODEM AND INFORMING KAC KOMTRAX SUPPORT OF THE NEW AND OLD MODEM INFORMATION WILL CAUSE THE UNIT TO BEGIN REPORTING AGAIN WITHIN 48-72 HOURS, IF THE MODEM WAS THE ONLY PROBLEM

The following sections discuss the most common issues and the troubleshoot steps that will get your unit reporting

properly.

11 of 35 Machine Never Communicated- TC301, TC310 terminal 1st,ifitisautilitymachineandhastheTC310terminal,besuretheprocesstotakeitoutofshippingmodehasbeenperformed.SeethatinformationinthesectionlabeledTC310RemovalofShippingModewithinthisdocument.IfitisaUtilitymachineandhastheMH800/801monitorpanel(suchasPC88MR8orPC138USLC8),referencethesectionlabeledMH800/801RemovalofShippingMode.

1) Contact KAC KOMTRAX support and request the configuration commands be resent to the machine. If possible, have the machine started briefly to take it out of sleep mode for a few hours. If the machine does not check in within 48 hours, a machine visit is probably required. On occasion, the machine may have transmitted back a code indicating the problem (bad gps antenna, install check not finished, etc.) which is another reason to contact KAC KOMTRAX support before initiating a visit.

a. Be sure to get the KOMTRAX serial number from KAC. b. Before changing any parts or troubleshooting, verify the KOMTRAX s/n is the same as the

one KAC provided you c. If these match what KAC has in their database then the problem will be found at the machine.

2) Ensure battery power of machine is OK. 3) Check terminal for water damage and if damaged, you may need to replace (unlikely) 4) Check the LED display of terminal with key set to on or engine on.

a. If there is a displayed, then the installation check has not been completed. See instructions for completing the install check found in the APPENDIX. Follow the recommended checks for troubleshooting if you cannot get the install check to finish normally (found after the instructions for completing the install check).

b. If there is a C displayed, take notice whether the C flashes. i. If C flashes, follow antenna check information in #5 and #6 below. The flashing C

when key is on indicates the antenna cannot see the satellite. Flashing will occur on occasion, since the satellites are not constantly overhead, but it should be solid a majority of the time.

c. If the LED does not light up after key is on, check the Deutsch connector of the wiring harness.

i. If Connection is solid, check voltage from the wiring harness. Should be between 20 and 30V (on 24V machine) and 12V and 16V (on 12V machine)

ii. If power is OK, check the individual pins and test for connectivity, if necessary. d. If there is anything else displayed, contact KOMTRAX@KomatsuNA.com

5) Verify the antenna is on top of the machine (or in original install point) pointing upward with no obstructions above or besides. The Orbcomm communication antenna needs to be at least 1ft away from other Radio antennas ( GPS is OK ) In the case of some utility equipment, the KOMTRAX antenna is installed under a protective cover. This is OK, but you may want to consider moving the antenna above the machine while troubleshooting.

6) Check the connection of the communication antenna. a. Make sure it snaps into place at the terminal end b. Ensure it has a proper ground (no rust or paint on or under the base) c. Unscrew the antenna from its mount and sand off any residue from the threads and

inside the socket. Replace the antenna d. Visually inspect the communication antenna and cable for crimps or cuts e. Check resistance in the cable, end to end. It should ohm out around 0.5 ohms. If it is under

0.2 or over 0.9, you may need to replace the antenna cable.

12 of 35 Machine Never Communicated- MH800/ 801machine

(with TH300/301 modem) AlsoseeMH800/801RemovalofShippingModeinformationfollowingthissection1) Contact KAC KOMTRAX support and request the configuration commands be resent to the

machine. If the machine does not check in within 48 hours, a machine visit is probably required. On occasion, the machine may have transmitted back a code indicating the problem (bad gps antenna, install check not finished, etc.) which is another reason to contact KAC KOMTRAX support before initiating a visit.

a. Be sure to get the KOMTRAX related serial number from KAC. i. Before changing any parts or troubleshooting, verify the Monitor and Modem

serial numbers are the same as what KAC Support told you ii. If these match what KAC has in their database then the problem will be found

at the machine. (this IS NOT the same as the TH300/301 s/n) and Modem s/n. These numbers can be obtained through the service menu of the monitor panel.

2) Ensure battery power of machine is OK. a. From the Service Menu, select Monitoring, then page down to Battery Voltage and

select. Ensure it is between 23 and 28 v 3) Check the monitor display to make sure satellite in view

a. From the service menu>KOMTRAX settings, select GPS and Communication Status. a. If there is no option for KOMTRAX settings, communication has not been

opened. Move to Perform modem assignment and on-board inspection for MH800 equipped machines found in the appendix.

i. The menu below should appear. Take a picture of this screen if different.

b. If the screen alternates between No satellite in view and satellite in view frequently, check the following:

i. Verify the antenna is on top of the machine pointing upward with no obstructions above or besides.

ii. Check the connection of the communication antenna. iii. Make sure it locks into place at the terminal end iv. Move the machine to a different area and check the screen again v. Ensure it has a proper ground (no rust or paint on or under the base)

1. Unscrew the antenna from its mount and sand off any residue from the threads and inside the socket. Replace the antenna

vi. Visually inspect the communication antenna and cable for crimps or cuts

Satellite in view

13 of 35 vii. Check resistance in the cable, end to end. It should ohm out around 0.5 ohms.

If it is under 0.2 or over 0.9, you may need to replace the antenna cable.

If the message on the monitor has not changed, proceed below: c. Connect a new satellite cable and position a new antenna on top of the machine.

i. Check the screen again, if satellite in view stays on screen for a majority of the time replace the old antenna and cable

d. From the service menu, Key in [(8)] and [(9)] on the numeric keypad followed by F6; the [KOMTRAX Terminal Select] Screen will appear

Ensure the following is true: Terminal type= TH300 KOMTRAX Communication= Open

e. If Terminal type = No KOMTRAX, or terminal type = TH200, move to Perform

modem assignment and on-board inspection for MH800 equipped machines found in the appendix

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TC310 Removal of Shipping Mode 1. Locate the terminal (see shop manual if unsure) and the test

connectors which should be on the wiring harness connecting the KOMTRAX terminal to the machine.

2. If the inspection connectors are not connected, an F should appear in the led window as shown below, when the machine is on. Be sure connectors are not connected before moving to the next step.

3. Turn machine on 4. Connect test connectors 5. Watch LED turn from F to C 6. Turn machine off. KOMTRAX terminal will stay in Normal Mode

for 7 days. Be sure the battery has a full charge 7. Notify KAC KOMTRAX support to resend configuration

commands to the machine

=

15 of 35 MH800/ 801 Removal of Shipping Mode

1) Access the service menu by holding down the number 4 and pressing 1 then 2 then 3 2) Select KOMTRAX Settings from the service menu 3) Then select Exit Shipping mode 4) Press F6 () to confirm your selection 5)

If the shipping mode has already been removed, only the Komatsu logo will appear when the monitor is turned on

Exit Shipping

If your machine is set to shipping mode, there will be an icon of a boat, as shown below, when the monitor is turned on. Follow the steps below to change mode and ensure KOMTRAX is setup properly

16 of 35 6) The screen should then go back to the KOMTRAX settings menu shown below left. Select

Terminal Status and verify that the TH300 is assigned and the communication is set to Open

7) If TH300 is assigned and communication is open, backup to the KOMTRAX settings screen

and select GPS & Communication Status. Be sure the following is true: a. Location is given and reads under positioning OR positioning in progress b. Communication = connected OR satellite in view. If it reads No satellite in

view or Modem connection lost for extended periods of time, see troubleshoot info in the section titled MH800 stopped communicating

c. Number of messages not yet sent should be = 0, or rapidly declining

Do you really want to change? Do you want to exit shipping mode?

17 of 35 Machine Stopped Communicating~ TC301 and TC310

1) Review the machine Notice information on the website. You may find the terminal stopped reporting after a few Battery Voltage Low messages were received.

MOST FAILURES OCCUR DUE TO PROBLEMS WITH THE COMMUNICATION ANTENNA CABLE OR ANTENNA ITSELF 2) When visiting the machine, always have a spare antenna and antenna cable, as well as a

replacement controller or modem. If you can determine the cause of failure is one of these items, this will save an additional trip and time to get it communicating again.

3) Be sure to get the KOMTRAX serial number from KAC. a. Before changing any parts or troubleshooting, verify the KOMTRAX s/n is the same as the one

KAC provided you b. If these match what KAC has in their database then the problem will be found at the machine

WHEN THE MACHINE IS VISITED MAKE SURE ITS MOVED OUTSIDE WITH A CLEAR VIEW OF SKY AWAY FROM OTHER OBSTICLES WITHIN 100FT (I.E. BUILDINGS, LARGE MACHINES ETC) 4) Ensure battery power of machine is OK. 5) Check terminal for water damage and if damaged, you may need to replace. 6) Check the 7 segment led display of terminal with key set to on or engine on.

a. If there is a number displayed, take notice whether it flashes. A flashing number indicates the antenna cannot see the satellite. This will occur from time to time during the day, but should not constantly occur.

i. If it flashes when the key is on, follow antenna check information in #7 and #8 below. The flashing number when key is on indicates the antenna cannot see the satellite. The number represents the minimum number of messages the controller is holding, waiting to send.

b. If the 7 segment LED or other LEDs do not light up after key is on, check the Deutsch connector of the wiring harness.

i. If Connection is solid, check voltage from the wiring harness. Should be between 20 and 30vdc (on 24vdc machine), between 11-15vdc in a 12vdc machine

ii. If power is OK, check the individual pins and test for connectivity, if necessary.

c. If there is a C in the led window, then the terminal was probably replaced in the past and the initial configuration commands may need to be resent. Make sure the C is on without flashing for 5 minutes every ten/

d. If there is a displayed, the terminal has been replaced and the install check must be performed to proper completion.

e. If there is anything else displayed, contact KOMTRAX@KomatsuNA.com 7) Verify the antenna is on top of the machine, (or in original install point) pointing upward

with no obstructions above or besides. The Orbcomm communication antenna needs to be at least 1ft away from other Radio antennas ( GPS is OK ) In the case of some utility equipment, the KOMTRAX antenna is installed under a protective cover. This is OK, but you may want to consider moving the antenna above the machine while troubleshooting.

8) Check the connection of the communication antenna. a. Make sure it snaps into place at the terminal end b. Ensure it has a proper ground (no rust or paint on or under the base)

18 of 35 c. Unscrew the antenna from its mount and wipe off any liquid gasket from the threads

and inside the socket. Replace the antenna d. Visually inspect the communication antenna and cable for crimps or cuts e. Check resistance in the cable, end to end. It should ohm out around 0.5 ohms. If it

is under 0.3 or over 0.9, you may need to replace the antenna cable. f. Check connectivity in the antenna itself

9) If the number still flashes for more than 20 minutes consecutively, the terminal may need to be replaced. Once replaced, if the install check fails and the sequence of codes flashes in the following order, D 7 the problem is with the antenna and/or antenna cable and the old controller may still be OK. Try the install check again before reinstalling the old terminal.

19 of 35 Machine Stopped Communicating- MH800/801(with

TH300/301 Modem) 1) Review the machine Notice information on the website. You may find the terminal

stopped reporting after a few Battery Voltage Low messages were received. MOST FAILURES OCCUR DUE TO PROBLEMS WITH THE COMMUNICATION ANTENNA CABLE OR ANTENNA ITSELF 2) When visiting the machine, always have a spare antenna and antenna cable, as well as a

replacement modem. If you can determine the cause of failure is one of these items, this will save an additional trip and time to get it communicating again.

3) Always get the monitor s/n and Orbcomm modem s/n from KAC before visiting the machine so you can begin your troubleshooting by verifying this information is correct. See Obtain Monitor and Modem Serial Numbers in the Machine Stopped Communicating-MH800/801 section.

a. If these match what KAC has in their database then the problem will be found at the machine.

4) Ensure battery power of machine is OK. 5) Check terminal for water damage and if damaged, you may need to replace. 6) Check GPS and Communication Status screen via the service menu>KOMTRAX settings>

GPS and Communication Status. Number of messages not yet sent should be greater than 0 a. If 0, there may be a problem with the monitor panel or the KOMTRAX programming

may have been erased. Tell KAC support and ask for the config commands to be resent.

b. No Satellite in view on constant i. perform antenna and cable checks

ii. Plug in new modem to see if message changes to satellite in view. If so, replace modem and send in replacement form.

c. Modem connection lost message i. Check wiring harness connecting modem to monitor panel including pins to

see if they have been pushed out. ii. Connect another modem to the wiring harness. If the message goes away, the

original modem is the problem. Fill our and send replacement form. d. Power Supply abnormal message

Meaning: MH800 monitor cannot supply main power to the TH300 modem

Positioning in Progress

No Satellite in ViewPower Supply Abnormal

20 of 35 i. Check that the engine starts. If not, charge or change battery and try again

ii. If so, check the battery voltage via the monitor panel by going to service menu>Monitoring>Battery Voltage (03200)

iii. If within normal range, proceed to b. b. MH800 internal circuit abnormality

i. Disconnect TH300 cable from the MH800 monitor panel (CM03), then check monitor to see if it still shows Power supply abnormal

ii. If Power Supply Abnormal still appears, there is a problem with the MH800 monitor and it should be changed out. See instructions in this guide for Deactivating KOMTRAX for a machine with MH800 monitor.

iii. If new message appears; Modem connection lost, see cause # c c. Abnormality in harness between MH800 and TH300

i. Connect harness from Monitor to a different TH300 modem and check the monitor for the message on the GPS and Communication Status screen

ii. If Power supply abnormal still appears, there is a problem with the harness and it will need to be replaced

iii. If the message Power supply abnormal is gone, see #d d. TH300 internal circuit abnormality

i. The TH300 modem has a problem and will need to be replaced. e. If there is anything else displayed, contact KOMTRAX@KomatsuNA.com

2) Other Options could include the following:

a. Monitor panel was replaced i. When this occurs, the modem assignment and on-board inspection must be

carried out. Additionally, a replacement form must be sent in with the new monitor panel information so it can be programmed again.

b. Modem was replaced i. When this occurs, just plug in the new modem, reconnect the antenna cable,

and send in the replacement form so the new modem can get setup with the satellite company

c. Modem was replaced and TH300 was deleted in the monitor panel then reassigned i. When this occurs, 1) The on-board inspection must be performed again and 2)

the KOMTRAX configuration messages need to be resent to the machine. Be sure to inform KAC KOMTRAX support of this situation.

Notify KAC KOMTRAX support before replacing any hardware if you think this may be the case

03200

Double click F6 after selecting 03200 Battery Voltage. This reading

should be between 24 and 28v

21 of 35 Deactivating KOMTRAX: TC301/TC310

1. Go to the KOMTRAX website to check if there are any Engine Locks active on the

machine. If so, be sure to clear them before removing the antennas, unplugging the unit, and/or sending in the deactivation form.

2. Unplug the wiring harness from KOMTRAX 3. Remove and store both the gps and communication antenna. 4. Send in the Deactivation form found in this document.

Deactivating KOMTRAX: MH800 / MH801 monitor

panel

1.) Go to Service Menu by pressing and holding 4, then pressing 1, 2, 3 in sequence 2.) Key in [(8)] and [(9)] on the numeric keypad followed by F6; the [KOMTRAX

Terminal Select] Screen will appear. (you may need to reset monitor password to 000000 before being allowed to proceed)

3.) Move cursor to No KOMTRAX and press F6 (). Follow instructions to restart monitor 4.) Remove and store communication antenna. 5.) Fill out the deactivation form found within this guide (and on the extranet) and email

to KOMTRAX@komatsuna.com 6.) In a case where the MH800 monitor is to be replaced, and after deactivating KOMTRAX, be

sure to write down your current smr and monitor password before disconnecting the monitor panel.

7.) Fill out Deactivation form found on in the appendix of this guide and email to KOMTRAX@komatsuna.com.

Step 1: Hold 4

Step 2: Press 1, then 2, then 3

KOMTRAX Terminal Select No KOMTRAX TH200

TH300

22 of 35 Replacing a TC301/TC310 KOMTRAX Terminal

1.) Disconnect the two antenna cables and the wiring harness from the old KOMTRAX terminal 2.) Remove the old KOMTRAX terminal and replace with the new one 3.) Reconnect wiring harness and antennas 4.) Record both the KOMTRAX p/n and s/n of both the defective and new terminals 5.) Perform the installation check procedure to successful ends (For machines where KOMTRAX was

standard equipment, see shop manual for this process. Otherwise, check the Installation check process in the appendix of this document.

6.) Fill out the Terminal replacement form in full and send to KOMTRAX@KomatsuNA.com

Replacing a TH300 modem (MH800/801 Machine)

1.) Remove TH300 modem by unbolting the unit, unplugging the wiring harness, and disconnect the antenna cable.

2.) Install new TH300 modem and reconnect wiring harness and antenna cable 3.) From GPS and Communication Status screen, verify the satellite is in view or the status is

connected 4.) Fill out the Terminal replacement form in full and send to KOMTRAX@KomatsuNA.com

Replacing a MH800/801 Monitor Panel 1.) Follow the proper instructions for replacing a monitor panel, including releasing all locks and

recording the proper SMR. Be sure to set the old SMR value into the new monitor panel during setup or the monitor panel will need to be replaced again

2.) Reconnect wiring harness and gps antenna cable into the monitor panel 3.) Record the monitor panel part number and serial number 4.) Perform Modem Assignment and On-Board Inspection process as found in the appendix, to

successful ends 5.) Fill out the Terminal replacement form in full and send to KOMTRAX@KomatsuNA.com

23 of 35

APPENDIX

24 of 35

Forms Replacement Form

Terminal Replacement Sheet Date Dealer send to: KOMTRAX@KomatsuNA.com Name

KAC personnel send to: (After making online change) Register_gkom@komatsu.co.jp

Machine information Model

Type

Serial Number

What was replaced?

MH800 (Monitor panel)

TH300 (modem on machine with MH800 monitor panel)

TC300/TC301 (K2 Terminal)

Faulty Terminal/Monitor Part number

Serial number

New Terminal/Monitor Part number

Serial number

Reason for replacement

Date of replacement

Country to use

Dealership

When uninstalling a TH300 unit from a MH800 machine or replacing the MH800 monitor panel, be sure to first reset the password (if set) back to 000000 (six zeroes). If replacing the TH300 only, you WILL NOT need to set the monitor panel to No KOMTRAX, or perform the install check. Simply replace the hardware and send us the new and old TH300 part number and serial number information.

25 of 35

Request for De-Activating KOMTRAX System IMPORTANT NOTE: Although your are canceling the communication contract with the satellite company by filling out and sending this form, the modem on the machine still transmits data. The modem/KOMTRAX device must be unplugged from the wiring harness and antenna removed in order to ensure 1) compliance with any local or international data transportation laws, bandwidth rights/use, and modem type approvals in the area the machine is located or moving through, AND 2) to ensure your machines data is not transmitted without your consent. Steps to follow:

Procedure 1) Be sure all engine locks have been cleared through the Global KOMTRAX website

Procedure 2) Disable the KOMTRAX settings/unit- these actions will prevent the KOMTRAX unit from continuing to draw battery power:

1. On MH800 machine, access the service menu via the monitor panel and set KOMTRAX setting = No KOMTRAX

2. On Non-MH800 machine (TC301 terminal), unplug the wiring harness from the KOMTRAX unit

Additionally, you should remove the Communication antenna and store.

Dealer Date of request Dealer

Keyperson Machine Owner

Model Type Serial

TC301 or TH300 p/n TC301 or TH300 s/n Orbcomm s/n

Monitor info (on MH800 machine) Monitor p/n Monitor s/n

Check box if complete Procedure 1 Procedure 2 Reason

Resell Move outside Country Other ______________

Subsidiary

Date of Receipt Company Contact Date

Department Manager Phone Check box for task Procedure 1 Procedure 2

KLTD Date request was received Date procedure was completed

26 of 35

Installation and Check Processes Install Check Procedure for KOMTRAX

TC300/TC301/TC310 terminal

NOTE: This procedure only supports universal KOMTRAX installations. Machine specific KOMTRAX retrofit install check procedures can be found in the shop manual for that respective model. Method of inspection-machine outside with clear view of sky Turn off the starting switch and wait for at least 5 seconds. Visually check that inspection connectors are connected Turn the starting switch to ACC position and wait for about 5 seconds. Check that the 7-segment lamp becomes as shown below. (A bar is displayed.)

1.) Disconnect inspection connector #1and wait for about 5 seconds.

If the lamp does not change from the state shown at left, retry steps (1) to (5).

KOMTRAX terminal

Perform steps (3) to (5) in 60 seconds. If not, start from (1) again.

By default a dash is displayed. The dash states that on board inspection has NOT yet been completed.

The dot flashes fast 2 to 3 times when it detects disconnection or connection of a connector.

27 of 35 2.) Re-connect inspection connector. Wait for about 5 seconds and check the flashing of the dot.

A) Check that that the 7-segment lamp changes as shown below.

If the lamp does not change as shown above, retry process from beginning, disconnecting the other test connector.

3.) Turn the key to the START position from the ACC position. There MUST BE constant voltage going to the KOMTRAX terminal during this process so it is important to ensure the key is never turned to OFF. A) Hold the starting switch at the START position for more than 3 seconds and check that

the engine does not start. Return top ACC position. Do not return the starting switch to the OFF position. If you have returned to the OFF position, retry from step 1).

B) If the engine starts, repeat from step 1). If the engine starts again, notify the KOMTRAX team of the codes on the 7-segment lamp.

4.) Turn the starting switch again from the ACC position to the START position and check that

the engine starts. A) Ensure that the inspection has finished normally by the 7-segment lamp. B) (Caution) The last letter, shown as 1 below, varies according to the machine network

types.

C) If the 7-segment lamp does not change as shown above, reference the Codes to Troubleshoot TC300/TC301/TC310 installation check procedure as shown after this section

5.) Turn the starting switch to the OFF position. If the 7-segment lamp displays C after several seconds, the inspection is finished normally.

The 7-segment lamp changes as shown above repeatedly. * [-] shown above is not displayed any more after 30 seconds. [0] may

change within 30 seconds.

Normal finish Note: It takes at least 90

seconds to reach this state.

3rd character depends on the network status of the machine. Ex)CAN-->3

28 of 35 6.) The machine must be parked in an open-air place, since the KOMTRAX terminal

communicates with the ORBCOMM satellite frequently during the inspection or configuration. If the machine is parked in an indoor place where the radio waves from the satellite are obstructed, the inspection will not finish.

7.) IF INSPECTION DOES NOT FINISH NORMALLY, whereas the code sequence is d 1 -- d 3 -- d 5 -- d 7 -- d b -- Leave the machine ON for up to 1 hour. The final install check will continue retrying and when the appropriate satellites come into view, the code should eventually change and result in a C being displayed.

When the starting key switch is turned on, and the TC301 install check is not completed, a "-" is displayed on the 7-segment LED. After the installation check is completed and the terminal is waiting for the configuration setting from the server, "C" is displayed. After the configuration is completed, a number, 0-9 may be displayed and indicates the number of non-transmitted messages from the terminal. (After the terminal starts communicating normally, 7-segment LED will display a number. If the number flashes with the Key in the on position, it is unable to send any data via satellite and the antenna and antenna cable should be checked)

If the lamp displays this, the inspection is not finished normally. In this case, repeat from step (1).

If the inspection is finished normally, do not perform inspection again.

29 of 35 Codes to Troubleshoot TC300/TC301Installation

check procedure (be sure pins on wiring harness have not been pushed out)

??? = Solution # Description Solution

F On-board inspection is completed (all the signals are detected normally)

N/A

E 1 The ACC signal of starting key switch is not detected (other signals are detected)

Check the connectivity of the harness to the ACC signal of the machine starting key switch

d 2 The alternator R-signal (Electricity being generated) is not detected (other signals are detected)

1. Check the connectivity of the harness to the machine alternator

2. Start the engine

b 3 GPS is not detected (other signals are detected)

Make sure there is no obstacle around the GPS antenna Check the connectivity of the TC301 GPS cable connector

7 4 Orbcomm satellite is not detected (other signals are detected)

Make sure there is no obstacle around the Orbcomm antenna Check the connectivity of the TC301 Orbcomm cable connector Make sure Antenna is grounded and the base is free from rust Set communication antenna further away from radio antenna

C #1 and #2 from above See above

A #1 and #3 See above

9 #2 and #3 See above

6 #1 and #4 See above

5 #2 and #4 See above

3 #3 and #4 See above

8 #1 + #2 + #3 (Only Orbcomm satellite signal is detected fine)

See above

4 #1 + #2 + #4 (Only GPS signal is detected fine) See above

2 #1 + #3 + #4 (Only alternator R-signal is detected fine)

See above

1 #2 + #3 + #4 (Only ACC signal of starting key switch is detected fine)

See above

0 The on-board inspection has not been performed Perform and complete the on-board inspection

??? Description Solution

- TC301: Machine Network is being detected Please wait a few minutes

E TC301: Detected network and the wire-harness type does not match

Order proper wiring harness, if available

While LED changes from d * ???

??While LED changes from d ???

30 of 35 TC300/TC301 LED information

1

ACCsignalandA

lternatorRsignalstatus2

Enginecontrolsignalstatus3

SNETconnectionandCsignalstatus

4CA

Nconnectionstatus

5Dow

nloadWriting(notused)

6Dow

nloadWriting(notused)

77segm

entLED(term

inalstatus,messagestosend,connectionw

ithmainsatellite)

8GPSsatelliteconenction

Anycheckofthelightsm

ustbedonewiththem

achinekeytoOnortheenginerunning

LEDFlashingSlow

1ACCoff

AlternatorRon

234NoCA

NFuelSensordetected

5678

slowflash=2secon/2secoff

Universalinstall,thisw

illnotbelit.Machinespecificinstall,thelightw

illbelit.Fuelsensorw

illnotbeconnectedonmachinesw

ithCAN

connection

Makesureplugfrom

GPSantennacableissecuredintocontroller.

Ensurethecableisnotcutandtheantennaisnotobstructed(Antenna

appearsasasmall,roundorsquare,blackdisk.

Either5or6lit=Dow

nloadwritingm

ode5&

6offisnormal

Notusedfortroubleshooting

Whenlit,antennacansee

communicationsatellite

Ifnodisplay,checkpow

ertocontroller

Ifinstallcheckisnotcompleted,aw

illappearIfinstallcheckisdone,andtheterm

inalisnotconfigured,a'C'will

appear.Ifinstallcheckdoneandterm

inalconfigured,anumber(0to9)w

illappear

Notes

LEDOFF

LEDFlashingfast

ACCon

AlternatorRon

ACCoff

AlternatorRoff

Whenm

achineison,lightshouldbeonCheckpinsonw

iringharnessandconnectiontoACCandA

lternator.CheckA

CCsupplyisbetween20and30v.

CheckAlternatorRisbetw

een20and30v

LEDON

ACCon

AlternatorRoff

Notusedfortroubleshooting

Quickflash=.5secon/.5secoff

EnginesignalonEngineSignaloff

Whenofforflashing,gpgsatelliteis

notfoundcheckgpsantenna,cable,andcableconnection

Whenlit,G

PSsatellitedetected

IfFlashing,satellitecannotbedetected.

CsignalonCom

municationw

ithSNET

CsignaloffNoCom

m.W

ithSNET

Csignaloff

CAN

detectedNoFuelSensor

NoCA

NNoFuelSensor

12

34

56

78

TC301Controller

Nam

eplate

31 of 35

MH800/801: Modem Assignment and On Board Inspection

Modem assignment- assign TH300 modem to MH800 monitor Be sure to check the KOMTRAX website first. If the machine has reported a current location and smr, DO NOT perform this step of assigning modem to the machine. 1.) From the service menu, if there is an option for KOMTRAX setting, select it and go to the

Terminal status screen. A) If there is not an option for KOMTRAX setting, get there by Keying in [ (8)] and

[ (9)] on the numeric keypad followed by F6; the [KOMTRAX Terminal Select] Screen will appear

2.) Ensure the following is true: A) Terminal type= TH300 B) KOMTRAX Communication= Open

i) If Terminal type = No KOMTRAX, select TH300 by pressing F6, then follow prompts to restart monitor.

ii) If Terminal type = TH200, go back to the main service menu and type [8] then [9] and push F6. From here, select No KOMTRAX by pressing F6, then follows the prompts to restart monitor. a. Follow this action by returning to Terminal Select screen and selecting TH300.

Follow the prompts until monitor restarts again. iii) If Terminal type = TH300 AND KOMTRAX Communication is set to Open, proceed

to directions for obtaining monitor and modem serial numbers, unless you are here troubleshooting. a. When troubleshooting, and terminal type = TH300, select No KOMTRAX by

pressing F6, then follow the prompts to restart monitor. (1) To perform this step after the modem begins communicating normally will

cause a severe delay in re-configuring the modem to report properly again. b. Next, go to step (2.B.iii) below.

When this step is successfully completed, the Terminal Status screen should appear as below On-Board Inspection 3.) Once TH300 is selected and KOMTRAX communication is set to Not Yet Open, take

action to change this setting to Open by performing an inspection of terminal installation. A) From the service menu>KOMTRAX settings, select GPS and Communication Status.

The menu below should appear. Take a picture of this screen if different.

Not Yet Open

32 of 35

B) From GPS and Communication Status screen, hold down 4, and press 1 then 2 then 3. This will bring you to the KOMTRAX Communication screen.

C) Press F6 to indicate you are Sure to Open. This will begin the inspection and the following screen should eventually appear: i) If any of these appear different, see troubleshoot info for MH800

Opening KOMTRAX Communication Orbcomm OK

GPS OK

Transmission OK Inspection Status 7F

D) Record what you see here and take a picture. 4.) When the inspection is complete, press F6 to get back to the terminal status screen, which

should now appear as below (GMT time will vary):

KOMTRAX Communication

KOMTRAX Communication Opened

33 of 35

Troubleshoot codes for MH800 on-board inspection results

When inspection is not completed normally, be sure to take a picture of the monitor for the two screens shown below. This will

be required to help determine the best course of action.

Inspection Status Description Solution

0 On-board inspection for MH 800 is not performed correctly Perform On-board inspection

3 MH800 cannot detect Orbcomm satellite or GPS

Make sure there are no obstacles around machine/on cab Make sure GPS cable is connected properly to MH800 monitor. Be sure antenna is outside machine. Make sure Communication cable is securely fastened to antenna and to the TH300 modem. Be sure antenna is outside the machine and upright Harness between MH800 and TH300 is connected securely

7 MH800 cannot detect GPS Make sure there are no obstacles around machine/on cab Make sure GPS cable is connected properly to MH800 monitor. Be sure antenna is outside machine.

B MH800 cannot detect Orbcomm Satellite

Make sure there are no obstacles around machine/on cab Make sure Communication cable is securely fastened to antenna and to the TH300 modem. Be sure antenna is outside the machine and upright Harness between MH800 and TH300 is connected securely Perform Modem assignment and on-board inspection. If this continues, a modem replacement may be necessary

F On-board inspection for MH800 is completed N/A

Note: When on-board inspection is completed, you may not see an "F" right away. Instead, you might see "3","7" or "B". This is normal, as long as "F" is displayed after it.

OrbcommOrbcomm

34 of 35 Obtaining Monitor and Modem Serial Numbers (MH800

Monitor) 1) Collecting the monitor serial

a. Go to Service Menu by pressing and holding 4, then pressing 1, 2, 3 in sequence

b. The Service Menu should appear. Find and select Monitoring by pressing F6 ()

c. The following screen will appear. Key in 20402 using the keypad and double click F6()

Step 1: Hold 4

Step 2: Press 1, then 2, then 3

20402

Monitoring 20402 Monitor Serial No 004121

35 of 35

nspection.

2) Collecting the Modem Serial a. From the menu above, press F5 ( ) twice to return to the main service menu. b. From here, select option 11- KOMTRAX Settings and press F6 () c. If you do not have an option for KOMTRAX settings see process for

completing Modem Assignment and On-board Id. Move down to Modem S/N and press F6 ()

e. Record Orbcomm Modem Serial. Inform KAC the monitor serial and Orbcomm serial. If these match what KAC has in their database then the problem will be found at the machine.

TH300 S/N: DQ0000054023

Monitoring 20402 Monitor Serial No 004121

Monitoring Hold

TerminologyGeneral information regardingTerminal Configuration ProcessKOMTRAX Device TypesKOMTRAX Power ModesMost Common IssuesCommon Troubleshooting SolutionMachine Never Communicated- TC301, TC310 terminalMachine Never Communicated- MH800/ 801machine (with TH300/301 modem)TC310 Removal of Shipping ModeMH800/ 801 Removal of Shipping ModeMachine Stopped Communicating~ TC301 and TC310Machine Stopped Communicating- MH800/801(with TH300/301 Modem)

Deactivating KOMTRAX: TC301/TC310 Deactivating KOMTRAX: MH800 / MH801 monitor panelReplacing a TC301/TC310 KOMTRAX TerminalReplacing a TH300 modem (MH800/801 Machine)Replacing a MH800/801 Monitor PanelAPPENDIXFormsReplacement FormRequest for De-Activating KOMTRAX System

Installation and Check ProcessesInstall Check Procedure for KOMTRAX TC300/TC301/TC310 terminalCodes to Troubleshoot TC300/TC301Installation check procedureTC300/TC301 LED informationMH800/801: Modem Assignment and On Board Inspection Troubleshoot codes for MH800 on-board inspection resultsObtaining Monitor and Modem Serial Numbers (MH800 Monitor)

Word BookmarksTC310removal_of_shippingTH800removal_of_shippingRANGE!A1:Q33OLE_LINK1Text1Text2Text5Text6Text7Check1Check2Check3Text3Text4Text8Text9Text10Text11Text12Text13Check4Check5Text15Text14Text16Text17Text18Check6Check7Text19Text20get_serialnumbersOnboard_inspection_n_modem_assignment