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KOMATSU 730E DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30620, A30622 & UP) KOMATSU 730E – PDF DOWNLOAD
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- KOMATSU 730E DUMP TRUCK OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:A30620, A30622 & UP
- PUBLICATION NUMBER:CEAM025901
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Description
KOMATSU 730E DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30620, A30622 & UP) KOMATSU 730E
KOMATSU 730E DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30620, A30622 & UP) KOMATSU 730E – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 730E DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30620, A30622 & UP) KOMATSU 730E
- 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.
TABLE OF CONTENTS:
KOMATSU 730E DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30620, A30622 & UP) KOMATSU 730E
1 INTRODUCTION.................................................................. 16 FOREWORD.................................................................... 16 ABOUT THIS MANUAL........................................................... 17 ALERTS...................................................................... 18 TRUCK MODEL ILLUSTRATION.................................................... 19 NON-OEM PARTS IN CRITICAL SYSTEMS........................................... 20 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................................................ 37 Fire Extinguishers And First Aid Kits................................... 37 Precautions For High Temperature Fluids................................. 37 Asbestos Dust Hazard Prevention......................................... 37 Fire Prevention......................................................... 37 Rops Precautions........................................................ 38 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.............................................................. 40 Emergency Egress Ladders................................................ 40 OPERATING THE MACHINE....................................................... 41 General Information..................................................... 41 Starting The Engine..................................................... 41 Traveling In The Machine................................................ 41 Traveling In Reverse.................................................... 42 Traveling On Slopes..................................................... 42 Traveling On Snow....................................................... 42 Traveling Near High Voltage Cables...................................... 42 Traveling On Loose Ground............................................... 42 Ensuring Good Visibility................................................ 43 Avoid Damage To The Dump Body........................................... 43 Safe Parking Of The Machine............................................. 43 Loading The Machine..................................................... 43 Dumping The Machine..................................................... 43 Towing The Machine...................................................... 43 EXTERIOR LIGHTING....................................................... 44 Fog Lights.......................................................... 44 Headlights.......................................................... 44 Brake Light......................................................... 44 Retard Light........................................................ 45 Clearance/Turn Signal Lights........................................ 45 Backup Lights....................................................... 45 Retard Lights....................................................... 45 Brake Lights........................................................ 45 Backup Alarm........................................................ 46 PRECAUTIONS FOR MAINTENANCE................................................. 47 BEFORE PERFORMING MAINTENANCE........................................... 47 Securing The Dump Body.............................................. 47 DURING MAINTENANCE...................................................... 48 Warning Tag......................................................... 48 Proper Tools........................................................ 48 Attachments......................................................... 48 Working Under The Machine........................................... 48 Keeping The Machine Clean........................................... 48 Adding Fuel Or Oil To The Machine................................... 49 Radiator Coolant Level.............................................. 49 Use Of Lighting..................................................... 49 Handling High Pressure Hoses........................................ 49 Precautions With High Pressure Oil.................................. 49 Maintenance Near High Temperatures and High Pressures............... 49 Rotating Fan And Belts.............................................. 50 Waste Materials..................................................... 50 Use of Tie-Off Anchor During Maintenance............................ 50 Handling Tires...................................................... 50 Tire Maintenance.................................................... 51 Storing Tires After Removal......................................... 51 Battery Hazard Prevention........................................... 51 Jump Starting With Booster Cables............................... 52 Jump Starting With Receptacles.................................. 52 WHEN REPAIRS ARE NECESSARY.................................................. 54 Observe The Following Precautions....................................... 54 SPECIAL PRECAUTIONS......................................................... 55 Preliminary Procedures Before Welding or Performing Maintenance......... 55 Engine Shutdown Procedure Before Welding or Performing Maintenan........ 55 4 WARNING AND CAUTIONS.......................................................... 58 GENERAL INFORMATION......................................................... 58 PIN PLATE................................................................... 58 GRADE SPEED CHART........................................................... 59 MACHINE SAFETY.............................................................. 59 KEY SWITCH.................................................................. 62 OIL FILL AND CHECK.......................................................... 63 HIGH PRESSURES.............................................................. 64 BATTERY AND ISOLATION BOX................................................... 66 HIGH VOLTAGE................................................................ 67 WELDING..................................................................... 68 LIFTING POINTS.............................................................. 68 AUTOMATIC LUBRICATION FILL.................................................. 69 ROPS/FOPS................................................................... 70 LUBRICATION CHART........................................................... 70 5 OPERATING INSTRUCTIONS........................................................ 72 PREPARING FOR OPERATION..................................................... 72 Safety Is Thinking Ahead................................................ 72 Walk Around Inspection.................................................. 72 TRUCK OPERATION............................................................. 77 ENGINE START-UP SAFETY.................................................. 77 After Engine Has Started............................................ 77 MACHINE OPERATION SAFETY PRECAUTIONS.................................... 78 Machine Operation On The Haul Road.................................. 79 Starting On A Grade With A Loaded Truck............................. 79 Retarding On A Grade................................................ 79 Passing............................................................. 80 Loading............................................................. 80 Dumping............................................................. 81 Lowering The Dump Body (When Dumping On Flat Ground)................ 82 Lowering The Dump Body (When Dumping Over A Berm Or Into A Crush.... 82 SUDDEN LOSS OF ENGINE POWER............................................. 82 EMERGENCY STEERING SYSTEM............................................... 83 Operation........................................................... 83 Pre-Operation Testing............................................... 83 Additional Guidelines............................................... 84 SAFE PARKING PROCEDURES................................................. 84 NORMAL ENGINE SHUTDOWN PROCEDURE........................................ 84 DISABLED TRUCK CONNECTORS................................................... 86 GENERAL INFORMATION..................................................... 86 STEERING AND BRAKE SYSTEM............................................... 86 Components Required................................................. 86 Hookup.............................................................. 86 HOIST SYSTEM............................................................ 87 Hookup.............................................................. 87 Dumping Procedure................................................... 88 TOWING...................................................................... 89 Towing Procedure........................................................ 89 PAYLOAD METER III SYSTEM.................................................... 90 GENERAL INFORMATION..................................................... 90 Data Summary........................................................ 90 Data Gathering...................................................... 90 COMPONENT DESCRIPTION................................................... 90 Operator Display.................................................... 90 Operator Switch..................................................... 90 Brake Lock Switch................................................... 91 Payload Meter Module................................................ 91 Communications Ports................................................ 91 Load Lights......................................................... 91 OPERATORS DISPLAY AND SWITCH............................................ 91 Reading the Load Display............................................ 91 Setting the Operator ID............................................. 92 Load and Ton Counter................................................ 92 Viewing Live Sensor Data............................................ 92 Other Display Messages.............................................. 93 HAUL CYCLE WARNING FLAGS................................................ 93 Haul Cycle Data..................................................... 93 Haul Cycle Warning Flags............................................ 95 PC SOFTWARE OVERVIEW.................................................... 96 SYSTEM CONFIGURATION.................................................... 97 Connecting to the Payload Meter..................................... 97 Displayed Payload Units............................................. 97 Connection Menu..................................................... 97 Configure the Payload Meter......................................... 98 Setting the Date and Time........................................... 98 Setting the Truck Type and Serial Number............................ 99 Setting the Gauge Display Units..................................... 99 Setting the Carryback Alarm Threshold............................... 99 Setting the Truck Number............................................100 Setting the Komatsu Distributor.....................................100 Setting the Komatsu Customer........................................100 Clean Truck Tare Calibration........................................100 Inclinometer Calibration............................................101 DOWNLOADING PAYLOAD DATA................................................101 UPLOADING DATA..........................................................102 DATA ANALYSIS...........................................................103 Creating a Query....................................................103 Payload Detail Screen...............................................104 Creating Reports....................................................104 Creating Graphs.....................................................104 Exporting Data......................................................105 Importing Data......................................................106 Deleting Haul Cycle Records.........................................106 Viewing Alarms......................................................106 Deleting Alarm Records..............................................106 Patent Acknowledment................................................106 AUTOMATIC LUBRICATION SYSTEM................................................107 GENERAL INFORMATION.....................................................107 COMPONENT DESCRIPTION...................................................107 Filter..............................................................108 Vent Valve..........................................................109 Flow Control Valve..................................................109 Grease Reservoir....................................................109 Pressure Reducing Valve.............................................109 Hydraulic Motor and Pump............................................109 Solenoid Valve......................................................109 Pressure Cut Off Switch.............................................109 Injectors...........................................................110 Grease Pressure Failure Switch......................................111 Relief Valve (unloader valve).......................................111 Lubrication Cycle Timer.............................................111 SYSTEM OPERATION........................................................111 Filling The Reservoir...............................................111 Priming The Automatic Lubrication System............................112 PREVENTIVE MAINTENANCE PROCEDURES.......................................113 Daily Lubrication System Inspection.................................113 250 Hour Inspection.................................................113 1000 Hour Inspection................................................114 SYSTEM CHECKOUT.........................................................114 General Checks......................................................114 Lubrication Controller Components...................................114 RESERVE ENGINE OIL SYSTEM (Optional)........................................116 Operation...............................................................116 Changing Oil............................................................116 6 OPERATOR CAB AND CONTROLS.....................................................120 CAB INTERIOR................................................................120 STEERING WHEEL AND CONTROLS.................................................121 Horn Button.............................................................121 Tilt / Telescope Lever..................................................121 Multi-Function Turn Signal Switch.......................................121 Turn Signal Operation...................................................121 High Beam Headlight Operation...........................................121 Windshield Wiper Operation..............................................122 PEDALS......................................................................123 SERVICE BRAKE PEDAL.....................................................123 DYNAMIC RETARD PEDAL....................................................123 Dynamic Retarding.......................................................123 ACCELERATOR PEDAL.......................................................123 OVERHEAD PANEL AND DISPLAYS.................................................125 RADIO SPEAKERS..........................................................125 WARNING ALARM BUZZER....................................................125 CAB RADIO...............................................................125 WARNING LIGHT DIMMER CONTROL............................................125 STATUS/WARNING INDICATOR LIGHT PANEL....................................125 AIR CLEANER VACUUM GAUGES...............................................125 WINDSHIELD WIPERS.......................................................125 CENTER CONSOLE..............................................................126 FNR CONTROL LEVER.......................................................126 Lowering The Dump Body..................................................127 WINDOW CONTROL SWITCHES.................................................127 ENGINE STOP SWITCH......................................................127 OVERRIDE/FAULT RESET SWITCH.............................................127 RETARD SPEED CONTROL (RSC) SWITCH.......................................127 RETARD SPEED CONTROL (RSC) ADJUST DIAL..................................127 DATA STORE BUTTON.......................................................128 DIAGNOSTIC PORTS............................................................129 ENGINE (CENTRY).........................................................129 ENGINE (CENSE)..........................................................129 STATEX III..............................................................129 KOMTRAX Plus AND PAYLOAD METER..........................................129 INTERFACE MODULE .......................................................130 OPERATOR’S SEAT (Standard)..................................................131 SEAT BELTS..............................................................131 ADJUSTMENT..............................................................131 HEATER / AIR CONDITIONER CONTROLS...........................................133 Fan Speed Control Knob..................................................133 Temperature Control Knob................................................133 Air Flow Directional Knob...............................................133 Heater/Air Conditioner Vents............................................133 INSTRUMENT PANEL ...........................................................134 CONTROL SYMBOLS.........................................................134 Key Switch..............................................................135 Engine Shutdown Switch..................................................136 Fog Light Swich.........................................................136 Ladder Light Switch.....................................................136 Backup Light Switch.....................................................136 Panel Illumination Lights...............................................136 Cab Air Conditioner/Heater Vents........................................136 Engine Cold Weather Starting Aid Switch.................................136 Rotating Beacon Light Switch (Optional).................................136 Heated Mirror Switch (Optional).........................................136 Leakage Test Switch (Trolley Only)......................................137 Wheel Brake Lock Control Switch.........................................137 Parking Brake Switch....................................................137 Tachometer..............................................................137 Right Turn Signal Indicator.............................................137 High Beam Indicator.....................................................138 Left Turn Signal Indicator..............................................138 Speedometer/Payload Meter Display.......................................138 Voltmeter Gauge.........................................................138 Engine Oil Pressure Gauge...............................................138 Water Temperature Gauge.................................................138 Fuel Level Gauge........................................................138 Hourmeter...............................................................138 Headlight Switch........................................................139 Panel Light Dimmer......................................................139 Payload Meter Switch....................................................139 OVERHEAD STATUS/WARNING INDICATOR...........................................140 STATUS / WARNING INDICATOR LIGHT SYMBOLS................................141 High Hydraulic Oil Temperature......................................141 Low Steering Pressure...............................................141 Low Accumulator Precharge Pressure..................................142 No Power............................................................143 Low Brake Pressure..................................................143 Low Hydraulic Tank Level............................................143 Automatic Lubrication System Pressure...............................143 Circuit Breaker Tripped.............................................143 Hydraulic Oil Filter Monitor........................................143 Low Fuel............................................................144 Parking Brake.......................................................144 Service Brake.......................................................144 Body Up.............................................................144 Dynamic Retarding...................................................144 Stop Engine.........................................................144 Manual Backup Lights................................................145 Engine Shutdown Timer...............................................145 Retard Speed Control (RSC) Indicator................................145 Check Engine........................................................145 Service Engine Indicator (AEM)......................................145 Propulsion System Temperature.......................................145 Blower Fault........................................................146 Service Engine Indicator (CENSE)....................................146 Hazard Light Switch.................................................146 Lamp Test Switch....................................................146 KOMTRAX Plus................................................................147 KOMTRAX Plus OPERATION..................................................147 Basic Precautions...................................................147 Interface Module....................................................149 DOWNLOADING KOMTRAX Plus DATA...........................................149 GENERAL INFORMATION.................................................149 KOMTRAX Plus DOWNLOADING PROCEDURE..................................149 Location of Downloaded Files........................................150 UPLOADING KOMTRAX Plus DATA.............................................151 ORBCOMM.................................................................152 CENTRYTM FUEL SYSTEM DIAGNOSTICS............................................154 GENERAL OPERATION.......................................................154 DETERMINING FAULT CODES.................................................154 EXITING THE DIAGNOSTICS MODE............................................155 7 LUBRICATION AND SERVICE.......................................................158 GENERAL INFORMATION.........................................................158 HYDRAULIC SYSTEM SERVICE................................................158 Hydraulic Tank......................................................158 Hydraulic Filters...................................................159 Hydraulic Pump Drive Shaft..........................................159 WHEEL MOTOR SERVICE.....................................................159 COOLANT LEVEL SERVICE...................................................159 Radiator Filling Procedure..........................................159 Coolant Specifications..............................................160 Unacceptable Practices..............................................160 RESERVE ENGINE OIL SERVICE (If Equipped)................................160 Reserve Oil Tank Filling Procedure (Remote Fill)....................160 CAB AIR FILTER SERVICE..................................................161 FUEL SYSTEM SERVICE.....................................................161 Fuel Tank Cleaning..................................................161 Fuel Filter Service.................................................162 INTAKE AIR CLEANER SERVICE..............................................162 FRONT WHEEL SERVICE.....................................................164 Oil Sampling........................................................164 FRONT ENGINE MOUNT TRUNION SERVICE......................................164 QUICK FILL SERVICE CENTER...............................................164 LUBRICATION CHART...........................................................166 EVERY 10 HOUR (DAILY) MAINTENANCE...........................................167 INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION......................169 INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION.....................170 EVERY 250 HOUR LUBRICATION AND MAINTENANCE..................................171 EVERY 500 HOUR LUBRICATION AND MAINTENANCE..................................173 EVERY 1000 HOURS LUBRICATION AND MAINTENANCE................................175 EVERY 2500 HOUR MAINTENANCE.................................................176 EVERY 5000 HOUR MAINTENANCE.................................................177 EVERY 10,000 HOUR MAINTENANCE...............................................178 8 SPECIFICATIONS................................................................180 MAJOR COMPONENT DESCRIPTION.................................................180 Truck And Engine........................................................180 Alternator (GTA-22).....................................................180 Wheel Motors (GE 788)...................................................180 Blower..................................................................180 Suspension..............................................................180 Operator's Cab..........................................................180 Power Steering..........................................................180 Dynamic Retarding Gird..................................................180 Brake System............................................................180 SPECIFICATIONS..............................................................181 Engine..................................................................181 Electric Drive System...................................................181 Dynamic Retarding.......................................................181 Battery Electric System.................................................181 Service Capacities......................................................181 Hydraulic Systems.......................................................181 Service Brakes..........................................................181 Steering................................................................181 Standard Dump Body Capacities And Dimensions............................182 Tires...................................................................182 Weight Distribution.....................................................182 Overall Truck Dimensions................................................182 9 RADIO.........................................................................186 RADIO OPERATION.............................................................186 GENERAL RADIO RECEIVER FUNCTIONS........................................186 Turning On the Power....................................................186 One-Hour Timer..........................................................187 Finding a Station.......................................................187 Setting the Presets.....................................................187 Adjusting the Receiver Audio Settings...................................188 Display.................................................................188 Adjusting the Receiver Menu Settings....................................188 Front Auxiliary Mode....................................................189 Rear Auxiliary Mode.....................................................189 CLOCK.......................................................................190 Clock/Alarm Button......................................................190 Setting the Clock.......................................................190 Setting the Alarm.......................................................190 Turning the Alarm Off...................................................191 Activating Snooze.......................................................191 CD PLAYER...................................................................192 Playing A Compact Disc..................................................192 Playing an MP3 DISC.....................................................192 CD Mode Displays........................................................192 Button Functions........................................................192 MP3 PLAYER..................................................................194 Playing MP3 Files.......................................................194 MP3 Mode Displays.......................................................194 Button Functions........................................................195 iPod®.......................................................................196 Playing an iPod®........................................................196 iPod® Mode Displays.....................................................196 Button Functions........................................................196 WEATHERBAND (USA Only)......................................................198 TROUBLESHOOTING.............................................................199 Tips About The Audio System.............................................199 Understanding Radio Reception...........................................199 Care of The Compact Discs...............................................199
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1 review for KOMATSU 730E DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30620, A30622 & UP) KOMATSU 730E – PDF DOWNLOAD
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Zayd Abram –
Very timely response with my order!!!