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Table of Contents

Summary
KOMTRAX System
KOMTRAX Component
KOMTRAX -TH Modem
MH Monitor
Work Flow from Machine reigstration to Operation
ORBCOMM communication
Power Saving Mode

Guidance
Step1-Key Person-Office: Confirmation of machine operation in KOMTRAX Screen (KBA)
Step2-DBKeyperson: Contact user to ask macine status (Office)
Step3-SubsidiaryAdmin: Confirm machine status based on the info from Key Person
(Office)
Step4-(DB) Service - Troubleshooting(local)
Step5-TH Modem Replacement
Step6-MH Monitor Replacement
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KOMTRAX Management (System Summary)

KOMTRAX is a system to monitor machine location and working status remotely.
KOMTRAX was developed to obtain machine information from the office without visiting machine to
imporove customer service and efficiency of work in Komatsu group.

Orbcomm LLC
GPS Satellite(rounds the earth)

Gateway Control Center:GCC

Line

Gateway Earth Station: GES

Internet
Machine with KOMTRAX installed

Terminal Main Function

Location mesurement(GPS satellite)
Obtaining Machine Information
Wireless Communication
Engine Lock
internet/intranet
KLTD

Komatsu/Subsidiary/
Sales Service Comany
KOMTRAX Server
Customer Transmitted data from the machine
is stored and managed. Then
provided to users
System Summary
Summary:
Controller (KOMTRAX Terminal) which is to be installed on construction machines have following four
functions.
1. Function to calculate machine location by using signal from GPS satellite.
2. Function to obtain machine information (information to be obtained differs depending on machine
function)
3. Wireless communication function to communicate externally (Orbcomm satellite communication)
4. Engine lock function

On the other hand, those info is handled in server
Server for Communication (communication server)+stored/managed(Databse server)+provided (web
server) is set in Komatsu.

It means when KOMTRAX terminal detects new info from the machine, it communicates externally via
communication function and stores in server.
Users can view information on Web server/client system via internet.
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KOMTRAX Component(Summary)

MH800 Type Multi Monitor Machine Monitor. KOMTRAX software and circuit to process GSP is built
into it.
On-board inspection can be performed/communication status can be
monitored.
TH300 Type KOMTRAX ModemModem for ORBCOMM communication
GPS Antenna Antenna for GPS (installed on cab) Connect the connector to MH800.
Communication Antenna Antenna for ORBCOMM communication (mounted on backside of cab)
Connect the connector to TH300
MH-TH harness Harness to connect MH800 and TH300. Exclusive harness
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KOMTRAX TH300 Summary(1)

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KOMTRAX TH300 Summary (2)

Note: Please refer to appropreate Shop Manual for specific machine

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KOMTRAX MH 800 Summary (1)

To TH
modem
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KOMTRAX MH800 Summary (2)

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KOMTRAX MH800 Summary (3)

Note: Please refer to appropreate Shop Manual for specific machine

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KOMTRAX MH800+TH300 Summary

Note: Please refer to appropreate Shop Manual for specific machine

Global (Work flow for Factory install) 10/26

Task
Plant DB Subsidiary KLTD orbcomm
LLC
Inpector Person incharge of plant Keyperson Admin Support Center
Install TC301
or
MH800+TH300
On-board inspection performed in factory is only to check if terminal can
receive
an electric wave from a satellite.
Terminal will not communicate at this point.
On-board inspection
(perform outside)
TC301: Confirm LED
displays "C" Plant Machine Registration
TC301
MH800 ->Model/Type/Serial TC301
Below needs to be done
on the monitor panel MH800
1)select TH300 ->Model/Type/SerialMH800
2)on-board inspection TH300
Machine Delivery

Machine
Registration

Activation Request
Select a country
e-mail
Click Apply button cc cc To

Check if Start button is Activation Request Activation Request

available.

Process activation

e-mail

Activation Setting
Register mail address/GCC
Start button setting

Confirm the machine

is located outside of
a building. In this process, the server sends a
Move the machine command for the first time (requesting
to outside information of on-board inspection)

Start button Tereminal responds and sends the

(machineregistration) requested info (terminal sends the info
Server Trigger) for the first time)

1F command Server sends config info and terminal

(machine must be located outside of a building) responds to it (config info like time zone
is sent from server and terminal
Config responds to it.)
(machine must be located outside of a building)

Operation starts
(machine must be located outside of a building)
After configuration process is done
between server and terminal, a machine
starts communication.
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ORBCOMM Communication (Summary

As ORBCOMM Satellite communication covers the earth with multiple
complicated
Satellite orbits, the satellite schedule differes depending on the machine
location(latitude, location from GCC), or time.
In addition, the satellite schedule is affected by the number of terminals which
are waiting to communicate.
Therefore, communication could be even difficult with normal situation.
Please be aware when troubleshooting.
Communication via Orbcomm satellite is possible when
1. The satellite comes into view (the satellite comes above)
2. The satellite covers ORBCOMM GES In order to communicate
3. After waiting for its turn for communication successfully via Orbcomm, the
satellite needs to come into view.
ORBCOMM Satellite is not
geostationally satellite which
appear to be fixed one spot from
the earth, ORBCOMM operates
Low Earth Orbit sattellites which
rounds the earth for 90 minutes at
the hight of 740km-830km
(basically 825km)

Successful communication requires

Satellite not only the satellite needs to come
Satellite
Cover Area into view, but also the coverage of
the same satellite need to include
ORBCOMM GES and the root
machine-satelite-GES need to be
established.
In other words, the satellite needs
Machine to cover the machine and GES at
GES (Gateway Earth Station)
the same time.
Even though the route machine-satellite-GES is established, it does not mean
communication can be done right away. In the satellites covered area, many terminals
other than KOMTRAX terminal are waiting its turn to communicate.

Orbcomm satellites cannot process all the requests from each terminal at the same
time, so depending on traffic, each needs to wait 5 to 10min normally.

When Komtrax terminal is sending data, data is sent when it comes its turn, but when
the server request data to terminal, after request command is sent when its turn,
terminal has to wait its turn, then data is sent. If the communication route is not
established on time. the terminal has to wait for the next satellite to establish the
communication route, await its turn then send finally send data.
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Power Saving Mode (Summary

KOMTRAX can be working while key switch is OFF at the machine.

However, KOMTRAX works as below to prevent battery run out while key switch is OFF.
It means KOMTRAX communication is very difficult while key swich is OFF, so please
be aware of this when troubleshoot is performed.
(There is a case that communication is difficult under normal condition)

*0

*0
power saving mode:If key switch is never turn on for 14 days, it goes to power saving mode.
new power saving mode:If machine has not worked for two consecutive hours for 7 days,
it goes to power saving mode.

*1
If key switch is on for a short period of time while the machine is in new power saving mode,
(not enough time to charge battery)
the normal sleeping cycle (active for 2 min, de-active for 8 min) will be repeated for 6 hours
after key switch is off.
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KeypersonOffice confirm if the machine is ready for operation in KOMTRAX screen (KBA).
(If all the process is not complete for operation, the machine will not communicate successfully.
therefore this needs to be checked.)

Step1-1Did you confirm the machine is not communicating at all?

Yes -> Proceed to Step1-2
No -> Proceed toStep2 (in case the machine was communicating in the past and all the
process for operation is done, but it does not communicate any more)

Step1-2Have you registered the machine in KBA?

Yes -> Proceed to Step1-3
No -> Register the machine(refer to KBA-KeyPerson Manual) then proceed Step1-3
Step1-3Have you made activation request from KBA?
Yes -> Proceed to Step1-4
No -> Request activation (refer to KBA-KeyPerson Manual) then proceed to Step1-4
Step1-4Have you pressed start in KBA?
Yes -> Proceed to Step1-5
No -> Press start (refer to KBA-KeyPerson Manual) then proceed to Step1-5
Note
Config communication is started between machine and server.
Config communication startcommand is sent per hour for 1week. If a responce from the
machine shows on-board inspection has not been performed, the command will not send
automatically
Be sure that machine is located outside. (sky must be clear of view)
Environment of the machine affects communication. So be sure to check the status of the
machine when performing troubleshoot. If there is a problem with environment, fix it and start from
Step1-5.
If possible, while the machine is outside and key is on, configuration may be processed faster.
(start-complete)
Be aware of power saving mode.
Step1-5Does communication status in Attribut into shows "Complete"?
Machines Details-> Attribute Infomation->Communication Setting-> "Completed"
Completed = Operation starts (Config is complete)
Not Completed = Operation has not started
Yes -> (config communication complete) Operation starts normally.
No -> Proceed to Step1-5

Step1-6Does communication setting still shows "Not Completed" after a week start button is
pressed
(configuration is in process)
Yes -> proceed to Step2
No ->Operation starts normally.
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KeypersonOfficecontact user and inform Admin of the result

(Ask user about the machine status. Confirm if the machine is a good condition for
communication)

Step2-1: Confirm below item.

If there is no problem ->Proceed to Step2-2
If there is a problem ->Discuss with user and solve the problem. then proceed to Step2-2

Item to confirm
If battery has been removed from the machine or not
If any trouble(being repaired) is occuring to machine or not
If machine is located outside where clear view of the sky or not
If any modification has been done to machine (e.g ROPS) (check if antenna is covered or
not)
If antenna has been installed properly
If machine is in power saving mode or not (key switch has never been turned on during
14 days?)

Step2-2 if the machine has already started, perform data request and confirm
The machine responded Normal
No responce proceed to Step2-3

Step2-3 Inform Admin of the result of Step1/Step2-1,2

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AdminOfficeconfirm communication status in KOMTRAX screen (KMD)

(consider if the communication can be started when the machine operation is in the process,)

Step3-1: Is it before the operation or after the operation?

After->the machine is in operation. perform data request and monitor or request for
troubleshoot, proceed to Step4-1
Before->the machine is before the operation. Proceed to Step3-2

Step3-2Check with KLTD if threre is any failure with Orbcomm GES

Yes->Ask Key Person to await until the failure is solved.
No->proceed to Step3-3

Step3-3Check below item in KMD and provide appropreate solution (machine needs to be
communicating)

1. If inspection retry shows any number except "0", it is in process of config Ask
KeyPerson to wait ->Proceed to Step1-5

2. If inspection retry shows "0", config communication has been failed.

->Request troubleshooting->Proceed to Step4-1
->or send "Inspection retry" and monitor->Proceed to Step1-5

3. If inspection retry shows "168", and the inspection status shows "Uninspected", on-
board inspection signal has not been received.
->Request troubleshooting->Proceed to Step4-1
->Or send 1F and monitor->Proceed to Step1-5

4. If inspection retry shows "168" and inspection status shows "Uninspected (***), the
response for on-board inspection signal has failure.
->Request to complete on-board inspection->After it is done, Admin sends "1F"

Inform Key Person of MH monitor/TH modem info and ask to compare actual MH monitor
and TH modem info at the machine.
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Service PersonJobsiteTroubleshooting

Environment of the machine, check the status

Step4-1: check if there is following problem applies (if possible, please take pictures around
the machine)
Yes->
After following item has been corrected (before operation), proceed to Step1-5 or if it
is after operation, perform data request and confirm communication is possible (key on is
recommended)
The machine is not located outside
There is an electronical problem (check if no electronical problem engine can be
started without problem)
The machine has water damatgeif a controller does not have any problem due to
water damage
If any option has been installed on the top or machine
The antenna is installed incorrectly (has modification been made with antenna?)
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Check if on-board inspection has been completed or not

Step4-2: Check if on-board inspection is completed (Open) This can be confirmed on MH

monitor panel
If possible, take a picture of monitor panel

yesOpen->Proceed to Step4-3
noNotYetOpen->Perform on-board inspection->Proceed to Step1-5

Enter service mode 4+123 Select 11 KOMTRAX settings

Select 01 Terminal
Status

Openon-board inspection is complete NotYetOpenon-board inspection is not

complete
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Check if MH monitor info in the sever and MH monitor on machine are the same.

Step4-3Check MH Monitor/TH Modem on MH monitor panle and compare the info from
Admin
If possible, take pictures of monitor panel

ye->Proceed to Step4-4
no->(if the error was made by plant) Admin and KLTD need to discuss how to correct
the info and inform of what needs to be done

Enter Service Mode

4+123

Select 01Monitoring

20227 20402

2 0 2 2 7 Mo n ito r Ass'y P / N 7 8 3 5 - 3 1 - 5 0 0 0

2 0 4 0 2 Mo n ito r S e r ial 020202

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Check if TH modem info in the server and TH modem on the machine are the same.

Check MH Monitor/TH Modem on MH monitor panle and compare the info from Admin
If possible, take pictures of monitor panel

Yes->Proceed to Step4-4
No->(if the error was made by plant) Admin and KLTD need to discuss how to correct
the info and inform of what needs to be done

Enter Service mode4+123

Select 11 KOMTRAX
settings

TH300

Select 03 Modem S/N

000036920
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Check if any specific error is displayed or not

Step4-4is below message displayed on the MH monitor panelif possible, take a picture
of monitor panel
Yes->

Power cannot be detected:Power Supply Abnormal:MH->cable->TH

noStep4-5

Follow below instruction and remove the harness between MH-TH

1.The same error is still displayed when a harness is removed from MH.
->MH has a problem->replace MH
2. The error did not occur when 1 is tried. but harness is connected to MH and
removed from TH, the error occurs.->harness has a problem->Replace harness
3. The error is not displayed after trying 1 and 2
->TH has a problem->Replace TH
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check if any error message is displayed on the monitor panel.

Step4-4 is below message displayed on the monitor panelif possible, take pictures of
monitor panel
Yes->

No modem connection :Modem Connection Lost:cableTH

No->Proceed to Step4-5

Follow below instructions to check harness between MH-TH

1.Check connection of MH and TH->if they are not connected properly, make
correction.
2.Disconnect and reconnect the connector of MH and TH
3. After 1 and 2 are done, but the error is still displayed.->TH has a problem-
>Replace TH
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Check if signal from satellite can be received

Step4-5check if satellite comes into view for 5 min during 60 min time period.
if satellite comes into view, take pictures of monitor panel if possible.

No satellite in View does not mean there is a communication problem.

Yes->Proceed to Step4-6
No->Before operation, proceed to Step1-5
After opertaion, perform data request and confirm the machine is communicating.

NoSatellite in ViewCannot receive signal from satelliteSatellite in ViewReceiving signal

from satellite
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Check communication antenna

Step4-6Check if there is any problem below.

yes->after confirmation (Before Operation) Proceed to Step1-5
(After Operation) Perform data request and check if the machine is
communicating.
No->Proceed to Step4-7

Check if harness is disconnected or it

has any other problem. Check if the antenna is
mounted properly (not loose)
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Check if any error is displayed on the monitor panel.

Step4-7check if below message is displayed on the monitor panel

(take pictures of monitor panel if possible.)
Yes->

Configuration is in the process:Waiting for Response:

No ->Replace TH modem.

Waiting for Response

This message is displayed while configuration is in the middle.

But if configuration is not complete (Satellite in view is displayed on the monitor) after
a week since retry command is sent, and you cannot find any other problem, discuss
admin(KLTD) for TH modem replacement.
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TH modem Replacement

TH modem replacement requires setting in Komtrax system. Please follow the work flow.
communication will not start only modem is replaced at the machine)
Please refer to Shop Manual for instruction as to how to perform modem replacement at the
machine.
After TH modem is replaced, check monitor panel to see if TH modem information is updated
(refer to pg19)

000036920
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MH Monitor Replacement
MH monitor replacement requires setting in Komtrax system. Please follow the work flow.
(communication will not start only monitor is replaced at the machine)
Please refer to Shop Manual for instruction as to how to perform monitor replacement at the
machine.
On-board inspection needs to be performed after new monitor is replaced.
(refer to Service News AT07196)
Please be sure to take below action before replacing monitor.
Set Lock function off
Initialize the password