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KOMATSU 730E-8 Dump Truck Operation & Maintenance Manual (SN:A40004 & Up) KOMATSU 730E-8 – PDF DOWNLOAD
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- KOMATSU 730E-8 Dump Truck Operation & Maintenance Manual
- SERIAL NUMBER:A40004 & Up
- PUBLICATION NUMBER:CEAM027700
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Description
KOMATSU 730E-8 Dump Truck Operation & Maintenance Manual (SN:A40004 & Up) KOMATSU 730E-8
KOMATSU 730E-8 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A40004 & UP) KOMATSU 730E-8 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 730E-8 Dump Truck Operation & Maintenance Manual (SN:A40004 & Up) KOMATSU 730E-8
- This manual is written for use by the operator and/or the service technician and is designed to help these persons become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel must read and understand the materials in this manual before operating the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings and cautions are to be understood and followed when operating or accomplishing repairs on the truck.
- The illustrations used in this manual are typical of the component shown and may not be an exact reproduction of what is found on the truck. A product identification plate is located on the frame in front of the right side front wheel and designates the truck model number, product identification number (vehicle serial number), and maximum GVW (Gross Vehicle Weight) rating. The KOMATSU truck model designation consists of three numbers and one letter (i.e. 830E). The three numbers represent the basic truck model.
- The letter “M”, when present, designates a Mechanical drive system; The letter “E”, when present, designates an Electrical wheel motor drive system. The product identification number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration. The GVW is what determines the load on the drive train, frame, tires, and other components.
- The vehicle design and application guidelines are sensitive to the total maximum GVW. GVW is TOTAL WEIGHT: the Empty Vehicle Weight + the fuel & lubricants + the payload. To determine allowable payload: Service all lubricants for proper level and fill fuel tank of empty truck (which includes all accessories, body liners, tailgates, etc.) and then weigh truck. Record this value and subtract from the GVW rating. The result is the allowable payload.
TABLE OF CONTENTS:
KOMATSU 730E-8 Dump Truck Operation & Maintenance Manual (SN:A40004 & Up) KOMATSU 730E-8
1 INTRODUCTION.................................................................. 14 FOREWORD.................................................................... 14 ABOUT THIS MANUAL........................................................... 15 ALERTS...................................................................... 16 TRUCK MODEL ILLUSTRATION.................................................... 17 WARNINGS.................................................................... 18 CALIFORNIA PROPOSITION 65 WARNINGS...................................... 18 NON-OEM PARTS IN CRITICAL SYSTEMS........................................... 19 2 STANDARD CHARTS AND TABLES.................................................... 22 GENERAL INFORMATION......................................................... 22 EFFECT OF SPECIAL LUBRICANTS............................................ 22 SUGGESTED SOURCES FOR RUST PREVENTIVE GREASE............................ 22 STANDARD TIGHTENING TORQUES................................................. 23 CLASS 10.9 CAP SCREWS & CLASS 10 NUTS................................... 23 SAE GRADE 5 AND GRADE 8 CAP SCREWS...................................... 24 SAE GRADE 9 CAP SCREWS.................................................. 25 T-BOLT CLAMPS........................................................... 25 SPLIT FLANGE CLAMPS..................................................... 26 FLARED TUBE AND HOSE FITTINGS........................................... 26 JIC 37° SWIVEL NUTS..................................................... 27 PIPE THREAD FITTINGS.................................................... 28 O-RING BOSS FITTINGS.................................................... 29 O-RING FACE SEAL FITTINGS............................................... 30 CONVERSION MULTIPLIERS...................................................... 31 METRIC TO ENGLISH....................................................... 31 ENGLISH TO METRIC....................................................... 32 TEMPERATURE CONVERSIONS................................................. 33 3 GENERAL SAFETY................................................................ 36 GENERAL SAFETY.............................................................. 36 Safety Rules............................................................ 36 Truck Safety Features................................................... 36 Clothing And Personal Items............................................. 36 Unauthorized Modification............................................... 36 Leaving The Operator’s Seat............................................. 36 Mounting And Dismounting................................................ 36 Fire Extinguishers And First Aid Kits................................... 37 Precautions For High Temperature Fluids................................. 37 Asbestos Dust Hazard Prevention......................................... 37 Fire Prevention......................................................... 37 ROPS Precautions........................................................ 37 Preventing Injury From Work Equipment................................... 38 Precautions For Optional Attachments.................................... 38 Precautions When Starting The Machine................................... 38 PRECAUTIONS FOR TRUCK OPERATION............................................. 39 Safety Is Thinking Ahead................................................ 39 Safety At The Worksite.................................................. 39 Preparing For Operation................................................. 39 Ventilation For Enclosed Areas.......................................... 39 Mirrors, Windows, And Lights............................................ 39 Before Starting The Engine.............................................. 39 Seat Belts.............................................................. 39 Emergency Egress Ladders................................................ 40 OPERATING THE MACHINE....................................................... 41 General Information..................................................... 41 Starting The Engine..................................................... 41 Traveling In Reverse.................................................... 41 Traveling On Slopes..................................................... 42 Traveling On Snow....................................................... 42 Traveling Near High Voltage Cables...................................... 42 Traveling On Loose Ground............................................... 42 Ensuring Good Visibility................................................ 42 Avoid Damage To The Dump Body........................................... 42 Safe Parking Of The Machine............................................. 42 Loading The Machine..................................................... 43 Dumping The Machine..................................................... 43 Towing The Machine...................................................... 43 EXTERIOR LIGHTING....................................................... 43 Fog Lights.......................................................... 44 Headlights.......................................................... 44 Brake Light......................................................... 44 Retard Light........................................................ 44 Clearance/Turn Signal Lights........................................ 44 Brake Lights........................................................ 44 Retard Lights....................................................... 44 Backup Lights....................................................... 44 Backup Alarm........................................................ 44 PRECAUTIONS FOR MAINTENANCE................................................. 45 BEFORE PERFORMING MAINTENANCE........................................... 45 Electrical System Isolation......................................... 45 Securing The Dump Body.............................................. 46 DURING MAINTENANCE...................................................... 46 Warning Tag......................................................... 46 Proper Tools........................................................ 47 Attachments......................................................... 47 Working Under The Machine........................................... 47 Keeping The Machine Clean........................................... 47 Adding Fuel Or Oil To The Machine................................... 47 Radiator Coolant Level.............................................. 47 Use of Lighting..................................................... 47 Handling High Pressure Hoses........................................ 48 Precautions With High Pressure Oil.................................. 48 Maintenance Near High Temperatures and High Pressures............... 48 Rotating Fan and Belts.............................................. 48 Waste Materials..................................................... 48 Use of Tie-Off Anchor During Maintenance............................ 48 Handling Tires...................................................... 48 Tire Maintenance.................................................... 49 Storing Tires After Removal......................................... 49 BATTERY HAZARD PREVENTION........................................... 49 Jump Starting With Booster Cables............................... 50 Jump Starting With Receptacles.................................. 51 WHEN REPAIRS ARE NECESSARY.................................................. 52 Observe The Following Precautions....................................... 52 SPECIAL PRECAUTIONS......................................................... 53 Preliminary Procedures Before Welding or Performing Maintenance......... 53 Engine Shutdown Procedure Before Welding or Performing Maintenan........ 53 Before welding on the machine, obey the following guidelines:........... 53 Discharging Control Cabinet Capacitors.................................. 54 4 WARNING AND CAUTIONS.......................................................... 56 GENERAL INFORMATION......................................................... 56 PIN PLATE................................................................... 56 GRADE SPEED CHART........................................................... 57 MACHINE SAFETY.............................................................. 57 KEY SWITCH.................................................................. 60 OIL FILL AND CHECK.......................................................... 61 HIGH PRESSURES.............................................................. 62 BATTERY AND ISOLATION BOX................................................... 64 HIGH VOLTAGE................................................................ 67 WELDING..................................................................... 69 LIFTING POINTS.............................................................. 70 EMERGENCY DUMPING........................................................... 70 AUTOMATIC LUBRICATION FILL.................................................. 71 ROPS/FOPS................................................................... 71 TOWING...................................................................... 71 LUBRICATION CHART........................................................... 71 5 OPERATING INSTRUCTIONS........................................................ 74 PREPARING FOR OPERATION..................................................... 74 Safety Is Thinking Ahead................................................ 74 Walk Around Inspection.................................................. 74 RETRACTABLE LADDER SYSTEM (If Equipped)..................................... 79 GENERAL INFORMATION..................................................... 79 LADDER SYSTEM DESCRIPTION............................................... 79 LADDER SYSTEM OPERATION................................................. 79 Retractable Ladder Switch............................................... 79 Ground Level Ladder Down Switch......................................... 80 Emergency Down Valve.................................................... 80 PRE-SHIFT BRAKE TEST........................................................ 81 OPERATION............................................................... 81 Service Brake Test...................................................... 82 Parking Brake Test...................................................... 82 Retard System Test...................................................... 83 Brake Test Exit Criteria................................................ 83 TRUCK OPERATION............................................................. 84 ENGINE START-UP SAFETY.................................................. 84 After Engine Has Started............................................ 84 MACHINE OPERATION SAFETY PRECAUTIONS.................................... 85 Machine Operation on the Haul Road.................................. 86 Starting on a Grade With a Loaded Truck............................. 86 Retarding on a Grade................................................ 86 Passing............................................................. 87 Loading............................................................. 87 Overload Speed Limit Function....................................... 87 Dumping............................................................. 88 Lowering the Dump Body (When Dumping on Flat Ground)................ 88 Lowering the Dump Body (When Dumping Over a Berm Or Into a Crush.... 89 SUDDEN LOSS OF ENGINE POWER............................................. 89 EMERGENCY STEERING SYSTEM............................................... 90 Operation........................................................... 90 Pre-Operation Testing............................................... 90 Additional Guidelines............................................... 91 SAFE PARKING PROCEDURES................................................. 91 NORMAL ENGINE SHUTDOWN PROCEDURE........................................ 91 DISABLED TRUCK CONNECTORS................................................... 93 GENERAL INFORMATION..................................................... 93 STEERING AND BRAKE SYSTEM............................................... 93 Hookup.............................................................. 93 HOIST SYSTEM............................................................ 93 Hookup.............................................................. 94 Dumping Procedure................................................... 94 TOWING...................................................................... 95 SPECIAL WIRING HARNESS.................................................. 95 PAYLOAD METER III SYSTEM.................................................... 98 GENERAL INFORMATION..................................................... 98 Data Summary........................................................ 98 Data Gathering...................................................... 98 COMPONENT DESCRIPTION................................................... 98 Operator Display.................................................... 98 Operator Switch..................................................... 98 Brake Lock Switch................................................... 98 Payload Meter Module................................................ 98 Communications Ports................................................ 99 Load Lights......................................................... 99 OPERATOR’S DISPLAY AND SWITCH........................................... 99 Reading the Load Display............................................ 99 Setting the Operator ID............................................. 99 Load and Ton Counter................................................ 99 Viewing Live Sensor Data............................................100 Other Display Messages..............................................100 HAUL CYCLE WARNING FLAGS................................................100 Haul Cycle Data.....................................................100 Haul Cycle Warning Flags............................................102 PC SOFTWARE OVERVIEW....................................................103 SYSTEM CONFIGURATION....................................................104 Connecting to the Payload Meter.....................................104 Displayed Payload Units.............................................104 Connection Menu.....................................................105 Configure the Payload Meter.........................................105 Setting the Date and Time...........................................105 Setting the Truck Type and Serial Number............................106 Setting the Gauge Display Units.....................................106 Setting the Carryback Alarm Threshold...............................106 Setting the Truck Number............................................106 Setting the Komatsu Distributor.....................................107 Setting the Komatsu Customer........................................107 Clean Truck Tare Calibration........................................107 Inclinometer Calibration............................................108 DOWNLOADING PAYLOAD DATA................................................108 UPLOADING DATA..........................................................109 DATA ANALYSIS...........................................................110 Creating a Query....................................................110 Payload Detail Screen...............................................110 Creating Reports....................................................111 Creating Graphs.....................................................111 Exporting Data......................................................112 Importing Data......................................................112 Deleting Haul Cycle Records.........................................112 Viewing Alarms......................................................113 Deleting Alarm Records..............................................113 Patent Acknowledgment...............................................113 AUTOMATIC LUBRICATION SYSTEM................................................114 GENERAL INFORMATION.....................................................114 COMPONENT DESCRIPTION...................................................114 Filter..............................................................115 Hydraulic Motor and Pump............................................115 Grease Reservoir....................................................115 Pressure Reducing Valve.............................................115 Flow Control Valve..................................................115 Solenoid Valve......................................................116 Vent Valve..........................................................116 Lubrication Cycle Timer.............................................116 Pressure Cut Off Switch.............................................116 Injectors...........................................................116 Grease Pressure Failure Switch......................................117 Relief Valve (unloader valve).......................................117 SYSTEM OPERATION........................................................117 Filling The Reservoir...............................................117 Priming The Automatic Lubrication System............................118 PREVENTIVE MAINTENANCE PROCEDURES.......................................118 Daily Lubrication System Inspection.................................118 250 Hour Inspection.................................................119 1000 Hour Inspection................................................119 SYSTEM CHECKOUT.........................................................119 General Checks......................................................119 Lubrication Cycle Operation.........................................120 6 OPERATOR CAB AND CONTROLS.....................................................122 CAB INTERIOR................................................................122 STEERING WHEEL AND CONTROLS.................................................123 Horn Button.............................................................123 Tilt / Telescope Lever..................................................123 Multi-Function Turn Signal Switch.......................................123 Speed Control Lever.....................................................123 Turn Signal Operation...................................................123 High Beam Headlight Operation...........................................124 Windshield Wiper Operation..............................................124 PEDALS......................................................................125 SERVICE BRAKE PEDAL.....................................................125 DYNAMIC RETARD PEDAL....................................................125 Dynamic Retarding.......................................................125 ACCELERATOR PEDAL.......................................................125 OVERHEAD PANEL AND DISPLAYS.................................................126 RADIO SPEAKERS..........................................................126 WARNING ALARM BUZZER....................................................126 CAB RADIO...............................................................126 AIR CLEANER VACUUM GAUGES...............................................126 CENTER CONSOLE..............................................................127 DIRECTIONAL CONTROL LEVER...............................................127 ENGINE STOP SWITCH......................................................127 OVERRIDE/FAULT RESET SWITCH.............................................127 HOIST CONTROL LEVER.....................................................127 Raising The Dump Body...................................................128 Lowering The Dump Body..................................................128 WINDOW CONTROL SWITCHES.................................................128 DATA STORE BUTTON.......................................................128 FIRE SUPPRESSION CONTROL OUTLET.........................................128 COMMUNICATION RADIO OUTLET..............................................128 12V AUXILIARY POWER OUTLETS.............................................128 DIAGNOSTIC PORTS............................................................129 ENGINE..................................................................129 DRIVE SYSTEM............................................................129 PAYLOAD METER...........................................................129 KOMTRAX Plus ...........................................................129 INTERFACE MODULE (IM)...................................................129 ALTERNATE DRIVE SYSTEM (USB)............................................129 ALTERNATE DRIVE SYSTEM (ETHERNET).......................................129 OPERATOR SEAT (Standard)....................................................130 SEAT BELTS..............................................................130 ADJUSTMENT..............................................................130 PASSENGER SEAT (Standard)...................................................132 SEAT BELTS..............................................................132 ADJUSTMENT..............................................................132 OPERATOR SEAT (Optional)....................................................133 SEAT BELTS..............................................................133 ADJUSTMENT..............................................................133 PASSENGER SEAT (Optional)...................................................134 SEAT BELTS..............................................................134 ADJUSTMENT..............................................................134 HEATER / AIR CONDITIONER CONTROLS...........................................135 Fan Speed Control Knob..................................................135 Temperature Control Knob................................................135 Air Flow Directional Knob...............................................135 Heater/Air Conditioner Vents............................................135 INSTRUMENT PANEL ...........................................................136 CONTROL SYMBOLS.........................................................136 Cab/Air Conditioner Vents...............................................137 Status Indicator Light Panel............................................137 Hydraulic Oil Temperature Gauge.........................................137 Coolant Temperature Gauge...............................................137 Speedometer/Digital Display.............................................137 Fuel Level Gauge........................................................137 Drive System Temperature Gauge..........................................137 Hazard Warning Light Switch.............................................138 Pre-Shift Brake Test Switch.............................................138 Wheel Brake Lock Control Switch.........................................138 Rest Switch.............................................................138 Engine Warm Up..........................................................139 Key Switch..............................................................139 Warning Light...........................................................139 Digital Display Contrast Buttons........................................139 Turn Signal Indicators..................................................139 Panel Light Dimmer......................................................139 Mode Switches...........................................................139 Fog Light Swich.........................................................140 Backup Light Switch.....................................................140 Ladder Light Switch.....................................................140 Headlight/Panel Illumination Light Switch...............................140 STATUS INDICATOR LIGHT PANEL................................................141 STATUS INDICATOR LIGHT SYMBOLS..........................................141 Body Up.............................................................141 Parking Brake.......................................................141 Propel System Not Ready.............................................141 No Propel...........................................................141 Engine Warm Up......................................................142 Engine Shutdown Delay...............................................142 Retarding Grid Drier................................................142 Wheel Brake Lock....................................................142 Traction Control....................................................142 Repair Monitor......................................................142 Retractable Ladder Down.............................................142 Snapshot In Progress................................................142 Pantograph Energized................................................142 Pantograph Up.......................................................142 Service Brake.......................................................142 Dynamic Retarding...................................................142 No DC Link Voltage..................................................142 DIGITAL DISPLAY OPERATION...................................................143 Toggling Through Main Level Screens.....................................143 Toggling Through Warning Screens........................................144 Entering Payload Meter Data.............................................145 KOMTRAX Plus................................................................146 KOMTRAX Plus OPERATION..................................................146 Basic Precautions...................................................146 Interface Module....................................................147 DOWNLOADING KOMTRAX Plus DATA...........................................148 GENERAL INFORMATION.................................................148 KOMTRAX Plus DOWNLOADING PROCEDURE..................................148 Location of Downloaded Files........................................148 UPLOADING KOMTRAX Plus DATA.............................................149 ORBCOMM.................................................................150 KOMATSU WIRELESS BRIDGE (Optional)......................................151 General Information.................................................151 Communication Setup.................................................151 Switching to the KWB_SETUP Network..................................151 Setting the Computer Subnet Mask and IP Address.....................152 Setting Up the KWB..................................................152 Adding Encryption...................................................153 Final Computer Settings.............................................153 Downloading Data....................................................153 Resetting the KWB...................................................154 FUSES AND CIRCUIT BREAKERS..................................................155 FUSE BLOCK #1...........................................................155 FUSE BLOCK #2...........................................................156 FUSE BLOCK #3...........................................................157 FUSE BLOCK #4...........................................................157 CIRCUIT BREAKERS........................................................157 7 LUBRICATION AND SERVICE.......................................................160 GENERAL INFORMATION.........................................................160 HYDRAULIC SYSTEM SERVICE................................................160 Hydraulic Tank......................................................160 Hydraulic Filters...................................................161 Hydraulic Pump Drive Shaft..........................................161 WHEEL MOTOR SERVICE.....................................................161 COOLANT LEVEL SERVICE...................................................161 Radiator Filling Procedure..........................................162 Coolant Specifications..............................................162 Unacceptable Practices..............................................162 CAB AIR FILTER SERVICE..................................................162 FUEL SYSTEM SERVICE.....................................................163 Fuel Tank Cleaning..................................................163 Fuel Filter Service.................................................163 INTAKE AIR CLEANER SERVICE..............................................164 FRONT WHEEL SERVICE.....................................................165 Oil Sampling........................................................165 FRONT ENGINE MOUNT TRUNNION SERVICE.....................................165 QUICK FILL SERVICE CENTER...............................................165 TIE ROD INSPECTION AND TORQUE PROCEDURE.................................166 LUBRICATION CHART...........................................................168 EVERY 10 HOUR (DAILY) MAINTENANCE...........................................169 INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION......................171 INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION.....................172 EVERY 250 HOUR LUBRICATION AND MAINTENANCE..................................173 EVERY 500 HOUR LUBRICATION AND MAINTENANCE..................................175 EVERY 1000 HOURS LUBRICATION AND MAINTENANCE................................177 EVERY 2500 HOUR MAINTENANCE.................................................178 EVERY 5000 HOUR MAINTENANCE.................................................179 8 SPECIFICATIONS................................................................182 MAJOR COMPONENT DESCRIPTION.................................................182 Truck And Engine........................................................182 Alternator..............................................................182 AC Induction Traction Motorized Wheels..................................182 Suspension..............................................................182 Operator's Cab..........................................................182 Power Steering..........................................................182 Dynamic Retarding Grid..................................................182 Brake System............................................................182 SPECIFICATIONS..............................................................183 Engine..................................................................183 AC Electric Drive System................................................183 Dynamic Retarding.......................................................183 Battery Electric System.................................................183 Service Capacities......................................................183 Hydraulic Systems.......................................................183 Service Brakes..........................................................184 Parking Brake...........................................................184 Steering................................................................184 Standard Dump Body Capacities And Dimensions............................184 Tires...................................................................184 Weight Distribution.....................................................184 Overall Truck Dimensions................................................185 9 RADIO.........................................................................188 RADIO OPERATION.............................................................188 GENERAL RADIO RECEIVER FUNCTIONS........................................188 Turning On the Power....................................................188 One-Hour Timer..........................................................188 Finding a Station.......................................................188 Setting the Presets.....................................................189 Adjusting the Receiver Audio Settings...................................189 Display.................................................................190 Adjusting the Receiver Menu Settings....................................190 Front Auxiliary Mode....................................................190 Rear Auxiliary Mode.....................................................190 CLOCK.......................................................................191 Clock/Alarm Button......................................................191 Setting the Clock.......................................................191 Setting the Alarm.......................................................191 Turning the Alarm Off...................................................192 Activating Snooze.......................................................192 CD PLAYER...................................................................193 Playing a Compact Disc..................................................193 Playing an MP3 DISC.....................................................193 CD Mode Displays........................................................193 Button Functions........................................................193 MP3 PLAYER..................................................................195 Playing MP3 Files.......................................................195 MP3 Mode Displays.......................................................195 Button Functions........................................................195 iPod®.......................................................................197 Playing an iPod®........................................................197 iPod® Mode Displays.....................................................197 Button Functions........................................................197 WEATHERBAND (USA Only)......................................................199 TROUBLESHOOTING.............................................................200 Tips About the Audio System.............................................200 Understanding Radio Reception...........................................200 Care of the Compact Discs...............................................200
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⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]
