2009-10-20.PDF; KOMTRAX Troubleshoot Guide_68411

1 of 35 Guide Version KTS02-00

Troubleshoot information

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

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Table of Contents Table of Contents  Terminology ............................................................................................................................ 3  General information regarding ................................................................................ 4  Terminal Configuration Process .............................................................................. 6  KOMTRAX Device Types .................................................................................................... 7  KOMTRAX Power Modes .................................................................................................. 8  Most Common Issues .......................................................................................................... 9  Common Troubleshooting Solution ....................................................................... 10  Machine Never Communicated- TC301, TC310 terminal ........................ 11  Machine Never Communicated- MH800/ 801machine (with TH300/301 modem) ....................................................................................................... 12  TC310 Removal of Shipping Mode ........................................................................ 14  MH800/ 801 Removal of Shipping Mode .......................................................... 15  Machine Stopped Communicating~ TC301 and TC310 ............................. 17  Machine Stopped Communicating- MH800/801(with TH300/301 Modem) .................................................................................................................................. 19  Deactivating KOMTRAX: TC301/TC310 ............................................................... 21  Deactivating KOMTRAX: MH800 / MH801 monitor panel ......................... 21  Replacing a TC301/TC310 KOMTRAX Terminal ............................................. 22  Replacing a TH300 modem (MH800/801 Machine) ......................................... 22  Replacing a MH800/801 Monitor Panel............................................................. 22  APPENDIX ............................................................................................................................... 23  Forms ........................................................................................................................................ 24  Replacement Form ........................................................................................................ 24  Request for De-Activating KOMTRAX System .............................................. 25  Installation and Check Processes ........................................................................ 26  Install Check Procedure for KOMTRAX TC300/TC301/TC310 terminal .............................................................................................................................. 26  Codes to Troubleshoot TC300/TC301Installation check procedure .......................................................................................................................... 29  TC300/TC301 LED information............................................................................ 30  MH800/801: Modem Assignment and On Board Inspection ................. 31  Troubleshoot codes for MH800 on-board inspection results ......... 33  Obtaining Monitor and Modem Serial Numbers (MH800 Monitor) ... 34 

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Terminology Configuration Command Function level

Function level 1

GPS Installation check or On-Board Inspection (For MH800 equipped machines) KBA KOMTRAX KOMTRAX 2.5 LED MH800/ MH801 Modem Movement Trigger On-board inspection

Operation map Orbcomm Service Menu SMR TC310 Terminal TH300/ TH301

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. The level of information and abilities KOMTRAX could report for a specified machine. Function level is determined by a combination of the machine’s computer/capability (Komatsu equipment only), the KOMTRAX terminal, and machine specific wiring harness. GPS, SMR, Operation map, engine lock, alerts This is the information you will obtain when installing KOMTRAX on any nonKomatsu equipment or on Komatsu equipment without a machine specific wiring harness. Global Positioning System 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. KOMTRAX Business Application- this is the global website currently used to view your KOMTRAX information. Komatsu’s wireless monitoring system. 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. Light-emitting diode. Found on the TC100/TC300/TC301/TC310. Helps to troubleshoot problems with KOMTRAX installation based on which LED’s are on, off, or flashing. Machine monitor panel that features a flat screen colored monitor panel and integrated KOMTRAX reporting logic 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. 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. 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. Bar graph reflecting the times of day a machine’s engine was on or off. The satellite company KOMTRAX utilizes to transmit its data and communicate with the machine. Accessed through MH800 monitor panel by holding #4 and typing #1, #2, and #3 in sequence. Service Meter Reading or Machine’s engine hours KOMTRAX terminal typically found on most Utility machines. Draws slightly less power than the standard TC301. Used to describe the KOMTRAX unit/hardware whether it be a TC100, TC300, TC301, or TC310. 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.

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General information regarding KOMTRAX reporting schedule Level 3 Location X SMR (Service meter reading) X Operation Map X Fuel Gauge (Residual value) X High Water Temp Gauge X Caution Summary X Abnormality Summary * X Actual Working Hours X Fuel Consumption X Avg Hourly Fuel Consumed 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 Level Level Level Level Level Level Level Monthly Data: 1st day of the month: 6am 1 1+ 22 2+ 2.5 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 X X X

Level 1+ X X X X

Level 2X X X X X X X

Level 2 X X X X X X X

Level 2+ X X X X X X X

Level 2.5 X X X X X X X X X X

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As they occur reports Maintenance Reminder 30 hrs prior to set interval and at 0 hours * Maintenance Item Reset Notice * Engine Start attempt during engine lock out period Abnormalities ** Movement triggered location report***

Level 1

Level 1+

Level 2-

Level 2

Level 2+

Level 2.5

Level 3

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X X

X 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.

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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 terminal’s 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.

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KOMTRAX Power Modes 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

14 days

key switch on

2 min on; 58 minutes off

2 min on; 8 min off

See chart 2 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

KOMTRAX type

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

MH800, 801 with 7 day until power save mode Chart 1

Monitor

Monitor P/N

PC128/138USLC-8 PC128UU-8 PC120/130-8 PC88MR-8

Air conditioning

7835-31-3003 and up

Air conditioning

7835-31-3300 and up

PC78US-8 PC160LC-8 PC108MR

MH800, 801 with Long term transportation mode Chart 2

Monitor

Monitor P/N

Air conditioning

7835-31-1005 and up

Heater

7835-31-1105 and up

No Heater

7835-31-1205 and up

Air conditioning

7835-31-3003 and up

PC108MR

Air conditioning

7835-31-3300 and up

Air conditioning

7835-31-5003 and up

PC300-8 PC400-8

Heater

7835-31-5103 and up

No Heater

7835-31-5203 and up

Air conditioning

7831-69-1101and up

Heater

7831-69-1121and up

PC200-8

PC128/138US-8 PC128UU-8 PC120/130-8 PC88MR-8 PC78US-8 PC160LC-8

D155AX-6

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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.

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Machine Never Communicated- TC301, TC310 terminal

1st, if it is a utility machine and has the TC310 terminal, be sure the process to take it out of shipping   mode has been performed. See that information in the section labeled TC310 Removal of  Shipping Mode within this document.  If it is a Utility machine and has the MH800/ 801monitor  panel (such as PC88MR‐8 or PC138USLC‐8), reference the section labeled MH800/ 801 Removal 

of Shipping Mode.   

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 [email protected] 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 ohm’s. If it is under 0.2 or over 0.9, you may need to replace the antenna cable.

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Machine Never Communicated- MH800/ 801machine (with TH300/301 modem)

Also see MH800/801 Removal of Shipping Mode information following  this section  1) 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.

Satellite in view

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

13 of 35 vii. Check resistance in the cable, end to end. It should ohm out around 0.5 ohm’s. 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= KOMTRAX Communication=

TH300 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. 4. 5. 6.

Turn machine on Connect test connectors Watch LED turn from ‘F’ to ‘C’ 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

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MH800/ 801 Removal of Shipping Mode 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

 

 

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

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”

Exit Shipping

4) Press F6 (√) to confirm your selection 5)

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Do you want to exit shipping mode?

Do you really want to change?

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

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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 IT’S 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 LED’s 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 [email protected] 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 ohm’s. 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.

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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

Positioning in Progress No Satellite in View Power Supply Abnormal

Meaning:

MH800 monitor cannot supply main power to the TH300 modem

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)

03200

b.

c.

d. e.

Double click F6 after selecting 03200 Battery Voltage. This reading should be between 24 and 28v

iii. If within normal range, proceed to 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 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 TH300 internal circuit abnormality i. The TH300 modem has a problem and will need to be replaced. If there is anything else displayed, contact [email protected]

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

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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 Step 1: Hold 4

Step 2: Press 1, then 2, then 3

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) KOMTRAX Terminal Select No KOMTRAX TH200 TH300

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 [email protected] 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 [email protected].

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Replacing a TC301/TC310 KOMTRAX Terminal 1.) 2.) 3.) 4.) 5.)

Disconnect the two antenna cables and the wiring harness from the old KOMTRAX terminal Remove the old KOMTRAX terminal and replace with the new one Reconnect wiring harness and antennas Record both the KOMTRAX p/n and s/n of both the defective and new terminals 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 [email protected]

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 [email protected]

Replacing a MH800/801 Monitor Panel 1.) Follow the proper instructions for replacing a monitor panel, including releasing all locks and 2.) 3.) 4.) 5.)

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 Reconnect wiring harness and gps antenna cable into the monitor panel Record the monitor panel part number and serial number Perform “Modem Assignment and On-Board Inspection” process as found in the appendix, to successful ends Fill out the Terminal replacement form in full and send to [email protected]

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APPENDIX

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Forms Replacement Form Date

Terminal Replacement Sheet Dealer send to:

[email protected]

KAC personnel send to: (After making online change)

[email protected]

Name

Machine information Model Type Serial Number

What was replaced? MH800 (Monitor panel)

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).

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

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.

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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 machine’s 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

TC301 or TH300 p/n Monitor info (on MH800 machine) Check box if complete

Serial

TC301 or TH300 s/n Monitor p/n Procedure 1

Orbcomm s/n Monitor s/n

Procedure 2

Resell Move outside Country Other ______________

Reason

Subsidiary Date of Receipt Department Phone Check box for task KLTD Date request was received

Contact Date

Company Manager Procedure 1

Procedure 2 Date procedure was completed

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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.)

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

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

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.

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.

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. 3rd character depends on the network status of the machine. Ex)CAN-->3 Normal finish Note: It takes at least 90 seconds to reach this state. 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.

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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. 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)

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Codes to Troubleshoot TC300/TC301Installation check procedure

(be sure pins on wiring harness have not been pushed out) While LED changes from d → ??? → ─ ??? =

d

Description

Solution #

Solution

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

F

E

??

N/A

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

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

b

3

GPS is not detected (other signals are detected)

7

4

Orbcomm satellite is not detected (other signals are detected)

2. Start the engine Make sure there is no obstacle around the GPS antenna Check the connectivity of the TC301 GPS cable connector 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 0

#1 + #3 + #4 (Only alternator R-signal is detected fine) #2 + #3 + #4 (Only ACC signal of starting key switch is detected fine) The on-board inspection has not been performed

See above See above Perform and complete the on-board inspection

While LED changes from d → * → ??? 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

???

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TC300/TC301 LED information

1

2

3

4

5

6

7

3

2

1

CAN detected No Fuel Sensor

Communication with S‐NET C signal off

Engine signal on

ACC on Alternator R on

No CAN No Fuel Sensor

No Comm. With S‐NET C signal off

Engine Signal off

ACC off Alternator R off

8

1 2 3 4 5 6 7 8

TC301 Controller

Universal install, this will not be lit.   Machine specific install, the light will be lit. Fuel sensor will not be connected on machines with CAN connection

Not used for troubleshooting

Notes When machine is on, light should be on Check pins on wiring harness and connection to ACC and Alternator.  Check ACC supply is between 20 and 30v. Check Alternator R is between 20 and 30v

Nameplate

ACC signal and Alternator R signal status Engine control signal status S‐NET connection and C signal status CAN connection status Download Writing (not used) Download Writing (not used) 7 segment LED (terminal status, messages to send, connection with main satellite) GPS satellite conenction

LED Flashing Slow ACC off Alternator R on

No CAN Fuel Sensor detected

If install check is not completed, a ‐‐ will appear If install check is done, and the terminal is not configured, a 'C' will  appear. If install check done and terminal configured, a number (0 to 9) will  appear

Not used for troubleshooting

If Flashing, satellite cannot be  detected. 

Make sure plug from GPS antenna cable is secured into controller.  Ensure the cable is not cut and the antenna is not obstructed (Antenna  appears as a small, round or square, black disk. slow flash = 2 sec on/ 2 sec off

When off or flashing, gpg satellite is  not found‐ check gps antenna, cable,  and cable connection

C signal on

ACC on Alternator R off

Any check of the lights must be done with the machine key to On or the engine running LED ON LED OFF LED Flashing fast

4

5 & 6 off is normal

6

5

Either 5 or 6 lit = Download  writing mode

If no display, check  power to controller

When lit, GPS satellite  detected

When lit, antenna can see  communication satellite 7

8

Quick flash = .5 sec on/ .5 sec off

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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

Not Yet Open

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.

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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: If any of these appear different, see troubleshoot info for MH800

i)

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

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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.

Orbcomm

Inspection Status 0

Description On-board inspection for MH 800 is not performed correctly

3

MH800 cannot detect Orbcomm satellite or GPS

7

MH800 cannot detect GPS

B

MH800 cannot detect Orbcomm Satellite

F

On-board inspection for MH800 is completed

Solution Perform On-board inspection 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 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 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 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.

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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 Step 1: Hold 4

Step 2: Press 1, then 2, then 3

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(√)

20402

Monitoring 20402 Monitor Serial No

004121

35 of 35 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 Inspection. d. Move down to “Modem S/N” and press F6 (√) Monitoring 20402 Monitor Serial No

004121

Monitoring Hold

e. Record Orbcomm Modem Serial. TH300 S/N: DQ0000054023

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.