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KOMATSU 730E DUMP TRUCK Operation & Maintenance Manual (SN:A30597 – A30602 & A30604 – A30609) KOMATSU 730E – PDF DOWNLOAD
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- KOMATSU 730E DUMP TRUCK Operation & Maintenance Manual
- SERIAL NUMBER:A30597 – A30602 & A30604 – A30609
- PUBLICATION NUMBER:CEAM022201
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Description
KOMATSU 730E DUMP TRUCK Operation & Maintenance Manual (SN:A30597 – A30602 & A30604 – A30609) KOMATSU 730E
KOMATSU 730E DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30597 – A30602 & A30604 – A30609) KOMATSU 730E – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 730E DUMP TRUCK Operation & Maintenance Manual (SN:A30597 – A30602 & A30604 – A30609) KOMATSU 730E
- This manual is written for use by the operator and/or the service technician. It is designed to help these persons to 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 must be understood and followed when operating or repairing 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. 930E).
The three numbers represent the basic truck model.
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 Gross Vehicle Weight (GVW). GVW is total weight: the empty vehicle weight + the fuel and lubricants + the payload.
TABLE OF CONTENTS:
KOMATSU 730E DUMP TRUCK Operation & Maintenance Manual (SN:A30597 – A30602 & A30604 – A30609) KOMATSU 730E
COVER............................................................................ 0 INTRODUCTION..................................................................... 5 FOREWORD..................................................................... 5 TRUCK MODEL ILLUSTRATION..................................................... 6 ABOUT THIS MANUAL............................................................ 7 ALERTS PAGE.................................................................. 8 TABLE OF CONTENTS................................................................ 9 STANDARD CHARTS AND TABLES....................................................... 19 EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values......... 19 STANDARD ASSEMBLY TORQUES For 12-Point, Grade 9 Cap screws (SAE)............. 20 STANDARD ASSEMBLY TORQUES For Class 10.9 Cap screws & Class 10 Nuts.......... 20 GENERAL SAFETY................................................................... 25 PERSONAL SAFETY.............................................................. 25 Safety Rules............................................................. 25 Truck Safety Features.................................................... 25 Clothing And Personal Items.............................................. 25 Unauthorized Modification................................................ 25 Leaving The Operator’s Seat.............................................. 25 Mounting And Dismounting................................................. 25 Fire Extinguishers And First Aid Kits.................................... 26 Precautions For High Temperature Fluids.................................. 26 Asbestos Dust Hazard Prevention.......................................... 26 Fire Prevention For Fuel And Oil......................................... 26 ROPS Precautions......................................................... 27 Preventing Injury From Work Equipment.................................... 27 Precautions For Optional Attachments..................................... 27 Precautions When Starting The Machine.................................... 27 PRECAUTIONS FOR TRUCK OPERATION.............................................. 28 Safety Is Thinking Ahead................................................. 28 Safety At The Work Site.................................................. 28 Fire Prevention.......................................................... 28 Preparing For Operation.................................................. 28 Ventilation For Enclosed Areas........................................... 28 Mirrors, Windows, And Lights............................................. 28 In The Operator’s Cab - Before Starting The Engine....................... 29 Seat Belts............................................................... 29 OPERATING THE MACHINE........................................................ 29 Starting The Engine...................................................... 29 Truck Operation - General................................................ 29 Traveling In The Truck................................................... 30 Precautions When Traveling In Reverse.................................... 30 Traveling On Slopes...................................................... 30 Ensuring Good Visibility................................................. 31 Operating On Snow........................................................ 31 Avoid Damage To The Dump Body............................................ 31 Driving Near High-Voltage Cables......................................... 31 When Loading The Truck................................................... 31 When Dumping............................................................. 31 Working On Loose Ground.................................................. 31 Parking The Machine...................................................... 32 TOWING....................................................................... 32 WORKING NEAR BATTERIES....................................................... 32 Battery Hazard Prevention................................................ 32 Jump-Starting With Booster Cables........................................ 33 Jump Starting With Receptacles........................................... 33 PRECAUTIONS FOR MAINTENANCE.................................................. 34 BEFORE PERFORMING MAINTENANCE............................................ 34 Stopping The Engine Before Service................................... 34 Warning Tag.......................................................... 34 Proper Tools......................................................... 34 Securing The Dump Body............................................... 34 DURING MAINTENANCE....................................................... 35 Personnel............................................................ 35 Attachments.......................................................... 35 Working Under The Machine............................................ 35 Keeping The Machine Clean............................................ 35 Rules To Follow When Adding Fuel Or Oil.............................. 35 Radiator Coolant Level............................................... 35 Use Of Lighting...................................................... 35 Precautions With The Battery......................................... 36 Handling High-Pressure Hoses......................................... 36 Precautions With High-Pressure Oil................................... 36 Maintenance Near High Temperatures And High Pressures................ 36 Rotating Fan And Belts............................................... 36 Waste Materials...................................................... 36 TIRES.................................................................... 37 Handling Tires....................................................... 37 Tire Maintenance..................................................... 38 Storing Tires After Removal.......................................... 38 ADDITIONAL JOB SITE RULES.................................................... 39 WHEN REPAIRS ARE NECESSARY................................................... 40 WARNINGS AND CAUTIONS............................................................ 43 OPERATING INSTRUCTIONS........................................................... 51 PREPARING FOR OPERATION...................................................... 51 SAFETY IS THINKING AHEAD..................................................... 51 WALK AROUND INSPECTION....................................................... 51 ENGINE START-UP.............................................................. 56 AFTER ENGINE HAS STARTED..................................................... 57 EMERGENCY STEERING SYSTEM.................................................... 58 Operation................................................................ 58 Pre-Operation Testing.................................................... 58 Additional Guidelines.................................................... 59 MACHINE OPERATION SAFETY PRECAUTIONS......................................... 59 LOADING...................................................................... 60 HAULING...................................................................... 60 PASSING...................................................................... 61 DUMPING...................................................................... 61 To Raise The Dump Body:.................................................. 61 To Lower The Dump Body: (When dumping over a berm or into a crusher):.... 62 To Lower The Dump Body (When dumping on flat ground):.................... 62 SAFE PARKING PROCEDURES...................................................... 63 ENGINE SHUTDOWN PROCEDURE.................................................... 63 DELAYED ENGINE SHUTDOWN PROCEDURE............................................ 64 SUDDEN LOSS OF POWER......................................................... 64 DISABLED TRUCK DUMPING PROCEDURE............................................. 65 Hookup................................................................... 65 Raising the Body......................................................... 65 Lowering the Body........................................................ 65 TOWING....................................................................... 66 OPERATOR CAB AND CONTROLS........................................................ 67 STEERING WHEEL AND CONTROLS.................................................. 68 STEERING WHEEL........................................................... 68 HORN BUTTON.............................................................. 68 TILT/TELESCOPE LEVER..................................................... 68 MULTI-FUNCTION TURN SIGNAL SWITCH........................................ 68 Turn Signal Operation................................................ 68 High Beam Headlight Operation........................................ 68 Windshield Wiper Operation........................................... 68 PEDALS....................................................................... 69 SERVICE BRAKE PEDAL...................................................... 69 DYNAMIC RETARDER PEDAL................................................... 69 THROTTLE PEDAL........................................................... 69 OVERHEAD PANEL CONTROLS AND COMPONENTS....................................... 70 GRADE/SPEED WARNING CHART................................................ 70 RADIO SPEAKERS........................................................... 70 WARNING ALARM BUZZER..................................................... 70 CAB RADIO................................................................ 70 WARNING LIGHTS DIMMER CONTROL............................................ 70 WARNING/STATUS INDICATOR LIGHT PANEL..................................... 70 AIR CLEANER VACUUM GAUGES................................................ 70 WINDSHIELD WIPERS........................................................ 70 TRUCK CONTROLS........................................................... 71 F-N-R Selector Switch................................................ 71 Hoist Control Lever.................................................. 71 CONSOLE SWITCHES AND CONTROLS............................................ 72 Cigarette Lighter.................................................... 72 Left-Hand Window Control Switch...................................... 72 Right-Hand Window Control Switch..................................... 72 Engine Shutdown Switch............................................... 72 Override Switch...................................................... 72 Retard Speed Control (RSC) Switch.................................... 73 Retard Speed Control (RSC) Dial...................................... 73 Statex III Download Port............................................. 74 Engine Diagnostic Port (CENSE)....................................... 74 Engine Diagnostic Connectors......................................... 74 Passenger Seat....................................................... 74 PAYLOAD METER............................................................ 74 Payload Meter Download Connector..................................... 74 CAB CLIMATE CONTROL.......................................................... 75 HEATER / AIR CONDITIONER CONTROLS........................................ 75 Fan Speed Control Knob............................................... 75 Temperature Control Knob............................................. 75 Air Flow Directional Knob............................................ 75 Heater/Air Conditioner Vents......................................... 75 OPERATOR SEAT................................................................ 76 Seat Belts............................................................... 76 ADJUSTMENT............................................................... 76 INSTRUMENT PANEL............................................................. 77 GENERAL INFORMATION...................................................... 78 CONTROL SYMBOLS.......................................................... 78 Key Switch........................................................... 79 Engine Shutdown Switch With Timer Delay.............................. 79 Fog Light Switch..................................................... 79 Ladder Light Switch.................................................. 79 Backup Light Switch.................................................. 79 Panel Illumination Lights............................................ 79 Cab Air Conditioner/Heater Vents..................................... 80 Engine Cold Weather Starting Aid Switch.............................. 80 Rotating Beacon Light Switch......................................... 80 Heated Mirror Switch................................................. 80 Wheel Brake Lock Switch.............................................. 80 Parking Brake Switch................................................. 80 Digital Tachometer................................................... 81 Right Turn Signal Indicator Light.................................... 81 High Beam Headlight Indicator Light.................................. 81 Left Turn Signal Indicator Light..................................... 81 Digital Speedometer/Payload Meter Display............................ 81 Voltmeter Gauge...................................................... 81 Engine Oil Pressure Gauge............................................ 81 Engine Water Temperature Gauge....................................... 81 Fuel Gauge........................................................... 81 Engine Hourmeter..................................................... 81 Headlight Switch..................................................... 82 Panel Illumination Lights Dimmer Rheostat............................ 82 Payload Meter Switch................................................. 82 OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL................................ 83 DESCRIPTION OF INDICATOR SYMBOLS......................................... 83 INDICATOR LIGHT FUNCTIONS................................................ 84 A1. High Hydraulic Oil Temperature................................... 84 B1. Low Steering Pressure............................................ 84 C1. Low Accumulator Precharge Pressure............................... 85 D1. Electric System Fault............................................ 85 E1. Low Brake Pressure............................................... 85 A2. Low Hydraulic Tank Level......................................... 85 B2. Automatic Lubrication System Pressure............................ 85 C2. Circuit Breaker Tripped.......................................... 85 D2. Hydraulic Oil Filter Monitor..................................... 86 E2. Low Fuel......................................................... 86 A3. Parking Brake.................................................... 86 B3. Service Brake.................................................... 86 C3. Body Up.......................................................... 86 D3. Dynamic Retarding................................................ 86 E3. Stop Engine...................................................... 86 A4. Not Used......................................................... 87 B4. Manual Backup Lights............................................. 87 C4. Engine Shutdown Timer............................................ 87 D4. Retard Speed Control (RSC)....................................... 87 E4. Check Engine..................................................... 87 A5. Service Engine Indicator (AEM)................................... 87 B5. High Wheel Motor Temperature..................................... 87 C5. Blower Fault..................................................... 87 D5, E5, A6, B6, and C6. Not Used..................................... 87 D6. Service Engine (CENSE)........................................... 87 E6. Not Used......................................................... 87 Komatsu Engines w/Centry™ Fuel Control............................... 88 Hazard Warning Light Switch.......................................... 88 Lamp Test Switch/Centry™ Diagnostic Test Switch...................... 88 VEHICLE HEALTH MONITORING SYSTEM (VHMS)...................................... 88 BASIC PRECAUTIONS........................................................ 88 OPERATION................................................................ 88 INTERFACE MODULE......................................................... 90 CENTRY™ FUEL SYSTEM DIAGNOSTICS.............................................. 91 GENERAL OPERATION........................................................ 91 DETERMINING FAULT CODES.................................................. 91 EXITING THE DIAGNOSTICS MODE............................................. 92 LUBRICATION AND SERVICE.......................................................... 93 GENERAL INFORMATION.......................................................... 93 HYDRAULIC TANK SERVICE....................................................... 93 Adding Oil............................................................... 93 COOLING SYSTEM SERVICE....................................................... 94 Radiator Filling Procedure............................................... 94 RESERVE ENGINE OIL SYSTEM - (IF EQUIPPED).................................... 94 Reserve Oil Tank Filling Procedure (Remote Fill)......................... 94 LEFT-HAND FUEL RECEIVER - OPTIONAL (WIGGINS QUICK FILL)...................... 95 LUBRICATION CHART............................................................ 96 10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS.................................. 97 50 HOUR LUBRICATION AND MAINTENANCE CHECKS................................... 99 100 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................. 99 250 HOUR LUBRICATION AND MAINTENANCE CHECKS..................................100 500 HOUR LUBRICATION AND MAINTENANCE CHECKS..................................102 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................104 1500 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................105 2500 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................105 5000 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................106 10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................107 AUTOMATIC LUBRICATION SYSTEM.....................................................109 GENERAL DESCRIPTION..........................................................109 SYSTEM COMPONENTS............................................................110 Filter Assembly..........................................................110 Hydraulic Motor and Grease Pump..........................................110 Reservoir................................................................110 Fixed Pressure Reducing Valve............................................110 Flow Control Valve.......................................................110 Solenoid Valve...........................................................112 Vent Valve...............................................................112 Time Delay Module........................................................112 Pump Cutoff Pressure Switch..............................................112 Unloader Valve...........................................................112 Pressure Switch..........................................................112 Pressure Gauge...........................................................112 Manual Override Button...................................................112 Injectors................................................................112 SYSTEM OPERATION.............................................................114 Normal Operation.........................................................114 Pressure Failure Detection Circuits......................................115 GENERAL INSTRUCTIONS.........................................................116 LUBRICANT REQUIRED FOR SYSTEM............................................116 SYSTEM PRIMING...........................................................116 LUBRICANT PUMP...........................................................116 Pump Housing Oil Level...............................................116 Pump Pressure Control................................................116 FILTER AND RESERVOIR.................................................117 Filter Assembly Element..............................................117 INJECTORS (SL-1 Series H)................................................118 Injector Specifications..............................................118 Injector Adjustment..................................................118 INJECTOR OPERATION.......................................................119 SYSTEM CHECKOUT..........................................................120 Lubrication Cycle Timer Check........................................120 Lubrication Cycle Timer Adjustment...................................121 PREVENTIVE MAINTENANCE INSPECTION........................................121 10 Hour Lubrication System Inspection................................121 250 Hour Inspection..................................................121 1000 Hour Inspection.................................................122 SYSTEM TROUBLESHOOTING CHART.............................................123 730E MAJOR COMPONENTS............................................................126 MAJOR COMPONENT DESCRIPTION......................................................125 SPECIFICATIONS...............................................................127 PAYLOAD METER III™...............................................................129 INDEX........................................................................129 Introduction.................................................................131 Data Summary.............................................................131 Data Gathering...........................................................131 COMPONENT DESCRIPTION........................................................132 System Diagram...........................................................132 Suspension Pressure Sensors..............................................132 Inclinometer.............................................................132 Operator Display.........................................................132 Operator Switch..........................................................133 Speed Input..............................................................133 Body-Up Switch...........................................................133 Brake Lock Switch........................................................133 Payload Meter............................................................133 Communications Ports.....................................................133 Key Switch Input.........................................................134 Payload Meter Power......................................................134 Load Lights..............................................................134 Wiring and Termination...................................................135 TCI Outputs..............................................................135 OPERATOR’S DISPLAY AND SWITCH................................................136 Reading the Speedometer..................................................136 Reading the Load Display.................................................136 Using the Operator ID....................................................136 Using the Load and Ton Counter...........................................136 Total Ton Counter........................................................136 Total Load Counter.......................................................137 Clearing the Counters....................................................137 Viewing Live Sensor Data.................................................137 Other Display Messages...................................................137 PAYLOAD OPERATION & CALCULATION..............................................138 Haul Cycle States........................................................138 Haul Cycle Description...................................................138 Load Calculation.........................................................139 Carry Back...............................................................139 Measurement Accuracy.....................................................139 SOURCES FOR PAYLOAD ERROR....................................................139 Payload Error............................................................139 Loading Conditions.......................................................140 Pressure Sensors.........................................................140 Swingloads...............................................................140 Speed and Distance.......................................................140 HAUL CYCLE DATA..............................................................140 Haul Cycle Data..........................................................141 Haul Cycle Warning Flags.................................................142 Frame Torque Data........................................................143 Sprung Weight Data.......................................................143 Maximum Speed Data.......................................................143 Alarm Records............................................................143 Fault Code Data..........................................................144 PC SOFTWARE OVERVIEW.........................................................145 PC Overview..............................................................145 System Configuration.....................................................145 Installing the PLMIII Software...........................................145 DOWNLOADING DATA.............................................................146 PLM III SYSTEM CONFIGURATION.................................................147 Starting Communications..................................................147 Displayed Payload Units..................................................147 Time Units...............................................................147 Connection Menu..........................................................147 Connecting to the Payload Meter..........................................148 Configure the Payload Meter..............................................148 Setting the Date and Time................................................148 Setting the Truck Type...................................................149 Setting the Gauge Display Units..........................................149 Setting the Frame Serial Number..........................................149 Setting the Truck Number.................................................149 Setting the Komatsu Distributor..........................................149 Setting the Komatsu Customer.............................................149 Clean Truck Tare.........................................................150 Inclinometer Calibration.................................................150 DATA ANALYSIS................................................................151 Creating a Query.........................................................151 Sorting on Truck Unit Number.............................................151 Sorting on Truck Type....................................................151 Sorting on Date Range....................................................152 Sorting on Time Range....................................................152 Payload Detail Screen....................................................153 Creating Reports.........................................................153 Summary - one page report................................................154 Detailed - multi-page report.............................................154 Creating Graphs..........................................................155 Exporting Data...........................................................155 CSV Export...............................................................155 Compressed...............................................................156 Importing Data...........................................................157 Deleting Haul Cycle Records..............................................157 Viewing Alarms...........................................................158 Deleting Alarm Records...................................................158 AM/FM RADIO / CD / MP3 / USB / iPOD™ / AUX PLAYER................................161 OPERATING INSTRUCTIONS.......................................................161 GENERAL RADIO RECEIVER FUNCTIONS.........................................161 Turning On the Power.................................................161 One-Hour Timer.......................................................161 Adjusting the Volume.................................................162 Display..............................................................162 Radio Mode Displays..................................................162 CD Mode Displays.....................................................162 MP3/USB/iPod Mode Displays...........................................162 AUX Input Displays...................................................163 CLOCK/ALARM Button...................................................163 Front Auxiliary Mode.................................................163 Rear Auxiliary Mode..................................................163 Adjusting the Receiver Audio Settings................................163 Adjusting the Receiver Menu Settings.................................164 USING THE RADIO..........................................................165 Finding a Station....................................................165 Setting the Presets..................................................165 USING THE CLOCK..........................................................166 Setting the Clock....................................................166 USING THE ALARM..........................................................166 Setting the Alarm....................................................166 Turning the Alarm Off................................................167 Activating Snooze....................................................167 USING THE WEATHERBAND (USA Only).........................................167 USING THE COMPACT DISC PLAYER/USB........................................168 Playing A Compact Disc...............................................168 Button Functions.....................................................168 PLAYING AN MP3 DISC/USB..................................................169 Root Directory.......................................................169 Empty Directory or Folder............................................169 No Folder............................................................169 File Name Display....................................................169 PLAYING MP3 FILES........................................................169 Button Functions.....................................................169 USING AN iPOD®...........................................................170 Playing an iPod......................................................170 Button Functions.....................................................170 OPERATING TIPS...........................................................171 Tips About The Audio System..........................................171 Understanding Radio Reception........................................171 Care of The Compact Discs............................................171 TROUBLESHOOTING..........................................................172
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