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KOMATSU 730E TROLLEY DUMP TRUCK Operation & Maintenance Manual (CEAM020701) KOMATSU 730E – PDF DOWNLOAD
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- KOMATSU 730E TROLLEY DUMP TRUCK Operation & Maintenance Manual
- PUBLICATION NUMBER:CEAM020701
- SERIAL NUMBERS: A30431, A30432, A30460, A30461, A30463, A30464, & A30467 – A30469
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Description
KOMATSU 730E TROLLEY DUMP TRUCK Operation & Maintenance Manual (CEAM020701) KOMATSU 730E
KOMATSU 730E TROLLEY DUMP TRUCK OPERATION & MAINTENANCE MANUAL (CEAM020701) KOMATSU 730E – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 730E TROLLEY DUMP TRUCK Operation & Maintenance Manual (CEAM020701) 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 TROLLEY DUMP TRUCK Operation & Maintenance Manual (CEAM020701) KOMATSU 730E
COVER............................................................................ 1 INTRODUCTION..................................................................... 5 FOREWORD..................................................................... 5 TRUCK MODEL.................................................................. 6 ABOUT THIS MANUAL............................................................ 7 ALERTS PAGE.................................................................. 8 TABLE OF CONTENTS................................................................ 9 TORQUE TABLES AND CONVERSION CHARTS.............................................. 19 EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values......... 20 STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts........ 20 STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws........... 21 STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws....................... 22 GENERAL SAFETY................................................................... 29 PERSONAL SAFETY.............................................................. 29 Safety Rules............................................................. 29 Truck Safety Features.................................................... 29 Clothing And Personal Items.............................................. 29 Unauthorized Modification................................................ 29 Leaving The Operator’s Seat.............................................. 29 Mounting And Dismounting................................................. 29 Fire Extinguishers And First Aid Kits.................................... 30 Precautions For High Temperature Fluids.................................. 30 Asbestos Dust Hazard Prevention.......................................... 30 Fire Prevention For Fuel And Oil......................................... 30 ROPS Precautions......................................................... 31 Preventing Injury From Work Equipment.................................... 31 Precautions For Optional Attachments..................................... 31 Precautions When Starting The Machine.................................... 31 PRECAUTIONS FOR TRUCK OPERATION.............................................. 32 Safety Is Thinking Ahead................................................. 32 Safety At The Work Site.................................................. 32 Fire Prevention.......................................................... 32 Preparing For Operation.................................................. 32 Ventilation For Enclosed Areas........................................... 32 Mirrors, Windows, And Lights............................................. 32 In The Operator’s Cab - Before Starting The Engine....................... 33 Seat Belts............................................................... 33 OPERATING THE MACHINE........................................................ 33 Starting The Engine...................................................... 33 Truck Operation - General................................................ 33 Traveling In The Truck................................................... 34 Precautions When Traveling In Reverse.................................... 34 Traveling On Slopes...................................................... 34 Ensuring Good Visibility................................................. 35 Operating On Snow........................................................ 35 Avoid Damage To The Dump Body............................................ 35 Driving Near High-Voltage Cables......................................... 35 When Loading The Truck................................................... 35 When Dumping............................................................. 35 Working On Loose Ground.................................................. 35 Parking The Machine...................................................... 36 TOWING....................................................................... 36 WORKING NEAR BATTERIES....................................................... 36 Battery Hazard Prevention................................................ 36 Jump-Starting With Booster Cables........................................ 37 Jump Starting With Receptacles........................................... 37 PRECAUTIONS FOR MAINTENANCE.................................................. 38 BEFORE PERFORMING MAINTENANCE............................................ 38 Stopping The Engine Before Service................................... 38 Warning Tag.......................................................... 38 Proper Tools......................................................... 38 Securing The Dump Body............................................... 38 DURING MAINTENANCE....................................................... 39 Personnel............................................................ 39 Attachments.......................................................... 39 Working Under The Machine............................................ 39 Keeping The Machine Clean............................................ 39 Rules To Follow When Adding Fuel Or Oil.............................. 39 Radiator Coolant Level............................................... 39 Use Of Lighting...................................................... 39 Precautions With The Battery......................................... 40 Handling High-Pressure Hoses......................................... 40 Precautions With High-Pressure Oil................................... 40 Maintenance Near High Temperatures And High Pressures................ 40 Rotating Fan And Belts............................................... 40 Waste Materials...................................................... 40 Use of Safety Tie-Off Anchor During Maintenance and Repair........... 40 TIRES.................................................................... 41 Handling Tires....................................................... 41 Tire Maintenance..................................................... 42 Storing Tires After Removal.......................................... 42 ADDITIONAL JOB SITE RULES.................................................... 43 WHEN REPAIRS ARE NECESSARY................................................... 44 WARNINGS AND CAUTIONS............................................................ 47 OPERATING INSTRUCTIONS........................................................... 55 PREPARING FOR OPERATION...................................................... 55 SAFETY IS THINKING talkAHEAD................................................. 55 WALK AROUND INSPECTION....................................................... 55 ENGINE START-UP.............................................................. 59 AFTER ENGINE HAS STARTED..................................................... 60 EMERGENCY STEERING SYSTEM.................................................... 61 Operation................................................................ 61 Pre-Operation Testing.................................................... 61 Additional Guidelines.................................................... 62 MACHINE OPERATION SAFETY PRECAUTIONS......................................... 62 LOADING...................................................................... 63 HAULING...................................................................... 63 PASSING...................................................................... 64 DUMPING...................................................................... 64 To Raise The Dump Body:.................................................. 64 To Lower The Dump Body: (When dumping over a berm or into a crusher):.... 65 To Lower The Dump Body (When dumping on flat ground):.................... 65 SAFE PARKING PROCEDURES...................................................... 66 ENGINE SHUTDOWN PROCEDURE.................................................... 66 DELAYED ENGINE SHUTDOWN PROCEDURE............................................ 67 SUDDEN LOSS OF POWER......................................................... 67 DISABLED TRUCK OPERATION..................................................... 68 GENERAL...................................................................... 68 STEERING AND BRAKE SYSTEM.................................................... 68 Components Required...................................................... 68 Hookup................................................................... 69 DISABLED TRUCK DUMPING PROCEDURE............................................. 70 Hookup................................................................... 70 Raising the Body......................................................... 70 Lowering the Body........................................................ 70 TOWING....................................................................... 71 TROLLEY OPERATING INSTRUCTIONS............................................... 71 AFTER THE ENGINE HAS STARTED............................................. 71 OPERATING IN DIESEL MODE................................................. 72 OPERATING IN TROLLEY LINE MODE........................................... 72 GETTING ON LINE.......................................................... 73 Operating On Trolley................................................. 74 GETTING OFF LINE......................................................... 76 LINE STATUS SIGNALS...................................................... 76 LINE STATUS SIGNAL MARKINGS.............................................. 77 TRAFFIC CONSIDERATION FOR TROLLEY LINE OPERATION......................... 77 APPROACHING SLOW MOVING VEHICLES IN A TROLLEY ASSISTED TRUCK............. 77 OPERATING SLOW MOVING VEHICLES ON TROLLEY ASSIST RAMPS................... 78 TRUCK FAILURE WHILE ON TROLLEY........................................... 78 OPERATOR CONTROLS................................................................ 79 STEERING WHEEL AND CONTROLS.................................................. 80 STEERING WHEEL............................................................... 80 HORN BUTTON.................................................................. 80 TILT/TELESCOPE LEVER......................................................... 80 MULTI-FUNCTION TURN SIGNAL SWITCH............................................ 80 Turn Signal Operation.................................................... 80 High Beam Headlight Operation............................................ 80 Windshield Wiper Operation............................................... 80 PEDALS....................................................................... 81 SERVICE BRAKE PEDAL.......................................................... 81 DYNAMIC RETARDER PEDAL....................................................... 81 THROTTLE PEDAL............................................................... 81 OVERHEAD PANEL CONTROLS AND COMPONENTS....................................... 82 GRADE/SPEED WARNING CHART.................................................... 82 RADIO SPEAKERS............................................................... 82 WINDSHIELD WIPERS............................................................ 82 WARNING ALARM BUZZER......................................................... 82 CAB RADIO.................................................................... 82 WARNING LIGHTS DIMMER CONTROL................................................ 82 AIR CLEANER VACUUM GAUGES.................................................... 82 CENTER CONSOLE............................................................... 83 TRUCK CONTROLS............................................................... 84 F-N-R Selector Switch.................................................... 84 Hoist Control Lever...................................................... 84 Trolley Master Control Lever............................................. 84 CONSOLE SWITCHES AND CONTROLS................................................ 84 Cigarette Lighter........................................................ 84 Window Control Switches.................................................. 84 Engine Shutdown Switch................................................... 84 Override Switch.......................................................... 85 Retard Speed Control (RSC) Switch........................................ 85 Retard Speed Control (RSC) Dial.......................................... 85 Statex III Download Port................................................. 86 Engine Diagnostic Port (CENSE)........................................... 86 Engine Diagnostic Connectors............................................. 86 Data Storage Button...................................................... 86 Passenger Seat........................................................... 86 PAYLOAD METER................................................................ 86 Payload Meter Download Connector......................................... 86 CAB CLIMATE CONTROL.......................................................... 87 HEATER/AIR CONDITIONER VENTS................................................. 87 HEATER/AIR CONDITIONER CONTROLS AND VENTS.................................... 87 Defroster Vent Control Switch............................................ 87 Heat Control Switch...................................................... 87 Temperature Control Knob................................................. 87 Fan Control Knob......................................................... 87 Heater/Air Conditioner Vents............................................. 87 OPERATOR SEAT................................................................ 88 ADJUSTMENT................................................................... 88 INSTRUMENT PANELS............................................................ 89 GENERAL INFORMATION.......................................................... 90 CONTROL SYMBOLS.............................................................. 90 Key Switch............................................................... 91 Engine Shutdown Switch With Timer Delay.................................. 91 Fog Light Switch......................................................... 91 Ladder Light Switch...................................................... 91 Backup Light Switch...................................................... 91 Panel Illumination Lights................................................ 91 Cab Air Conditioner/Heater Vents......................................... 92 Engine Cold Weather Starting Aid Switch.................................. 92 Rotating Beacon Light Switch............................................. 92 Heated Mirror Switch..................................................... 92 Wheel Brake Lock Switch.................................................. 92 Parking Brake Switch..................................................... 92 Digital Tachometer....................................................... 93 Right Turn Signal Indicator Light........................................ 93 High Beam Headlight Indicator Light...................................... 93 Left Turn Signal Indicator Light......................................... 93 Digital Speedometer/Payload Meter Display................................ 93 Voltmeter Gauge.......................................................... 93 Engine Oil Pressure Gauge................................................ 93 Engine Water Temperature Gauge........................................... 93 Fuel Gauge............................................................... 94 Engine Hourmeter......................................................... 94 Headlight Switch......................................................... 94 Panel Illumination Lights Dimmer Rheostat................................ 94 Payload Meter Switch..................................................... 94 OVERHEAD STATUS / WARNING INDICATOR LIGHT PANEL.............................. 95 INDICATOR LIGHT FUNCTIONS.................................................... 96 High Hydraulic Oil Temperature........................................... 96 Low Steering Pressure.................................................... 96 Low Accumulator Precharge Pressure Warning............................... 96 Electric System Fault Warning............................................ 97 Low Brake Pressure Indicator............................................. 97 Low Hydraulic Tank Level................................................. 97 Low Automatic Lubrication System Pressure................................ 97 Circuit Breaker Tripped.................................................. 97 Hydraulic Oil Filter..................................................... 97 Low Fuel Indicator....................................................... 98 Parking Brake Indicator.................................................. 98 Service Brake Indicator.................................................. 98 Body Up Indicator........................................................ 98 Dynamic Retarding Indicator.............................................. 98 Stop Engine Warning...................................................... 98 Backup Indicator......................................................... 98 Engine Shutdown Timer Switch............................................. 98 Retard Speed Control..................................................... 98 Check Engine............................................................. 99 Service Engine Indicator (AEM)........................................... 99 High Wheel Motor Temperature Indicator................................... 99 Blower Fault Warning..................................................... 99 Service Engine Indicator (CENSE)......................................... 99 Komatsu Engines w/Centry™ Fuel Control................................... 99 Hazard Warning Light Switch.............................................. 99 Lamp Test Switch/Centry™ Diagnostic Test Switch..........................100 REAR AXLE LIGHT BAR..........................................................103 Backup Lights............................................................103 Retard Lights............................................................103 Brake Light..............................................................103 Backup Alarm.............................................................103 CENTRY™ FUEL SYSTEM DIAGNOSTICS..............................................104 GENERAL OPERATION............................................................104 DETERMINING FAULT CODES......................................................104 EXITING THE DIAGNOSTICS MODE.................................................105 LUBRICATION AND SERVICE..........................................................107 GENERAL INFORMATION..........................................................107 HYDRAULIC TANK SERVICE.......................................................107 Adding Oil...............................................................107 COOLING SYSTEM SERVICE.......................................................108 Radiator Filling Procedure...............................................108 Coolant Specifications...................................................108 Unacceptable Practices...................................................108 WHEEL MOTOR SERVICE..........................................................108 RESERVE ENGINE OIL SYSTEM (IF EQUIPPED)......................................109 Reserve Oil Tank Filling Procedure (Remote fill).........................109 Inline Screen............................................................109 QUICK FILL SERVICE CENTER....................................................110 LEFT-HAND FUEL RECEIVER - OPTIONAL (WIGGINS QUICK FILL)......................111 LUBRICATION CHART............................................................112 10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS..................................113 10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS (Continued)......................114 50 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................115 100 HOUR LUBRICATION AND MAINTENANCE CHECKS..................................115 250 HOUR LUBRICATION AND MAINTENANCE CHECKS..................................116 250 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)......................117 500 HOUR LUBRICATION AND MAINTENANCE CHECKS..................................118 500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)......................119 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................120 1500 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................121 2500 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................121 5000 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................122 10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................123 AUTOMATIC LUBRICATION SYSTEM.....................................................125 GENERAL DESCRIPTION..........................................................125 SYSTEM COMPONENTS............................................................126 Filter Assembly..........................................................126 Hydraulic Motor and Grease Pump..........................................126 Reservoir................................................................126 Fixed Pressure Reducing Valve............................................126 Flow Control Valve.......................................................126 Solenoid Valve...........................................................128 Vent Valve...............................................................128 Time Delay Module........................................................128 Pump Cutoff Pressure Switch..............................................128 Unloader Valve...........................................................128 Pressure Switch..........................................................128 Pressure Gauge...........................................................128 Manual Override Button...................................................128 Injectors................................................................128 SYSTEM OPERATION.............................................................130 Normal Operation.........................................................130 Pressure Failure Detection Circuits......................................131 GENERAL INSTRUCTIONS.........................................................132 LUBRICANT REQUIRED FOR SYSTEM............................................132 SYSTEM PRIMING...........................................................132 LUBRICANT PUMP...........................................................132 Pump Housing Oil Level...............................................132 Pump Pressure Control................................................132 Filter And Reservoir.................................................133 Filter Assembly Element..............................................133 INJECTORS (SL-1 Series H)................................................134 Injector Specifications..............................................134 Injector Adjustment..................................................134 INJECTOR OPERATION.......................................................135 SYSTEM CHECKOUT..........................................................136 Lubrication Cycle Timer Check........................................136 Lubrication Cycle Timer Adjustment...................................137 PREVENTIVE MAINTENANCE INSPECTION........................................137 10 Hour Lubrication System Inspection................................137 250 Hour Inspection..................................................137 1000 Hour Inspection.................................................138 SYSTEM TROUBLESHOOTING CHART.............................................139 MAJOR COMPONENT DESCRIPTION......................................................141 SPECIFICATIONS...............................................................143 PAYLOAD METER III................................................................145 PAYLOAD METER III............................................................149 Introduction.............................................................149 Data Summary.........................................................149 Data Gathering.......................................................149 COMPONENT DESCRIPTION....................................................150 System Diagram.......................................................150 Suspension Pressure Sensors..........................................150 Inclinometer.........................................................150 Operator Display.....................................................150 Payload Operator Switch..............................................151 Speed Input..........................................................151 Body-Up Switch.......................................................151 Brake Lock Switch....................................................151 Payload Meter........................................................151 Communications Ports.................................................151 Key Switch Input.....................................................152 Payload Meter Power..................................................152 Load Lights..........................................................152 Wiring and Termination...............................................153 TCI Outputs..........................................................153 OPERATOR’S DISPLAY AND SWITCH............................................154 Reading the Speedometer..............................................154 Reading the Load Display.............................................154 Using the Operator ID................................................154 Using the Load and Ton Counter.......................................154 Total Ton Counter....................................................154 Total Load Counter...................................................155 Clearing the Counters................................................155 Viewing Live Sensor Data.............................................155 Other Display Messages...............................................155 PAYLOAD OPERATION AND CALCULATION........................................156 Description of Haul Cycle States.....................................156 Haul Cycle Description...............................................156 Load Calculation.....................................................157 Carry Back...........................................................157 Measurement Accuracy.................................................157 SOURCES FOR PAYLOAD ERROR................................................157 Payload Error........................................................157 Loading Conditions...................................................158 Pressure Sensors.....................................................158 Swingloads...........................................................158 Speed and Distance...................................................158 HAUL CYCLE DATA..........................................................158 Haul Cycle Data......................................................159 Haul Cycle Warning Flags.............................................160 M: Haul Cycle Too Long...............................................161 N: Sensor Input Error................................................161 Frame Torque Data....................................................161 Sprung Weight Data...................................................161 Maximum Speed Data...................................................161 Alarm Records........................................................161 Fault Code Data......................................................162 PC SOFTWARE OVERVIEW.....................................................163 PC Overview..........................................................163 System Configuration.................................................163 Installing the PLM III Software......................................163 DOWNLOADING DATA.........................................................164 PLM III SYSTEM CONFIGURATION.............................................165 Starting Communications..............................................165 Displayed Payload Units..............................................165 Time Units...........................................................165 Connection Menu......................................................165 Connecting to the Payload Meter......................................166 Configure the Payload Meter..........................................166 Setting the Date and Time............................................166 Setting the Truck Type...............................................167 Setting the Gauge Display Units......................................167 Setting the Frame Serial Number......................................167 Setting the Truck Number.............................................167 Setting the Komatsu Distributor......................................167 Setting the Komatsu Customer.........................................167 Clean Truck Tare.....................................................168 Inclinometer Calibration.............................................168 DATA ANALYSIS............................................................169 Creating a Query.....................................................169 Sorting on Truck Unit Number.........................................169 Sorting on Truck Type................................................169 Sorting on Date Range................................................170 Sorting on Time Range................................................170 Payload Detail Screen................................................171 Creating Reports.....................................................171 Summary - One Page Report............................................172 Detailed - Multi-Page Report.........................................172 Creating Graphs......................................................173 Exporting Data.......................................................173 CSV Export...........................................................173 Compressed...........................................................175 Importing Data.......................................................175 Deleting Haul Cycle Records..........................................175 Viewing Alarms.......................................................176 Deleting Alarm Records...............................................176 AM/FM RADIO / CD PLAYER..........................................................177 GENERAL RADIO RECEIVER FUNCTIONS.............................................177 Turning On the Power.....................................................177 One-Hour Timer...........................................................177 Display..................................................................178 Setting a Default Display................................................178 Adjusting the Brightness of the Display..................................178 Auxiliary Mode...........................................................178 Adjusting the Receiver Settings..........................................178 USING THE CLOCK..............................................................179 Setting the Clock........................................................179 USING THE ALARM..............................................................179 Setting the Alarm........................................................179 Turning the Alarm Off....................................................179 Activating Snooze........................................................179 Setting Alarm Volume.....................................................179 USING THE RADIO..............................................................180 Finding a Station........................................................180 Setting the Presets......................................................180 USING THE WEATHERBAND........................................................181 USING THE COMPACT DISC PLAYER................................................181 Playing a Compact Disc...................................................181 Button Functions.........................................................181 PLAYING AN MP3 DISC..........................................................182 MP3 Format Compatibility.................................................182 Root Directory...........................................................182 Empty Directory or Folder................................................182 No Folder................................................................182 File Name Display........................................................182 Pre-Programmed Playlists.................................................183 Playing MP3 Files........................................................183 Button Functions.........................................................183 TROUBLESHOOTING..............................................................184
PLEASE NOTE:
⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ 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]
