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KOMATSU 730E TROLLEY DUMP TRUCK OPERATION MAINTENANCE MANUAL (SN:A30600 – A30616) KOMATSU 730E – PDF DOWNLOAD
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- KOMATSU 730E TROLLEY DUMP TRUCK OPERATION MAINTENANCE MANUAL
- SERIAL NUMBER:A30600 – A30616
- PUBLICATION NUMBER:CEAM024000
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Description
KOMATSU 730E TROLLEY DUMP TRUCK OPERATION MAINTENANCE MANUAL (SN:A30600 – A30616) KOMATSU 730E
KOMATSU 730E TROLLEY DUMP TRUCK OPERATION MAINTENANCE MANUAL (SN:A30600 – A30616) KOMATSU 730E – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 730E TROLLEY DUMP TRUCK OPERATION MAINTENANCE MANUAL (SN:A30600 – A30616) 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 (SN:A30600 – A30616) KOMATSU 730E
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.............................................................. 55 AFTER ENGINE HAS STARTED..................................................... 56 EMERGENCY STEERING SYSTEM.................................................... 57 Operation................................................................ 57 Pre-Operation Testing.................................................... 57 Additional Guidelines.................................................... 58 MACHINE OPERATION SAFETY PRECAUTIONS......................................... 58 LOADING...................................................................... 59 HAULING...................................................................... 59 PASSING...................................................................... 60 DUMPING...................................................................... 60 To Raise The Dump Body:.................................................. 60 To Lower The Dump Body: (When dumping over a berm or into a crusher):.... 61 To Lower The Dump Body (When dumping on flat ground):.................... 61 SAFE PARKING PROCEDURES...................................................... 62 ENGINE SHUTDOWN PROCEDURE.................................................... 62 DELAYED ENGINE SHUTDOWN PROCEDURE............................................ 63 SUDDEN LOSS OF POWER......................................................... 63 DISABLED TRUCK DUMPING PROCEDURE............................................. 64 Hookup................................................................... 64 Raising the Body......................................................... 64 Lowering the Body........................................................ 64 TOWING....................................................................... 65 TROLLEY OPERATING INSTRUCTIONS............................................... 65 AFTER THE ENGINE HAS STARTED............................................. 65 OPERATING IN DIESEL MODE................................................. 66 OPERATING IN TROLLEY LINE MODE........................................... 66 GETTING ON LINE.......................................................... 67 Operating On Trolley................................................. 68 GETTING OFF LINE......................................................... 70 LINE STATUS SIGNALS...................................................... 70 LINE STATUS SIGNAL MARKINGS.............................................. 71 TRAFFIC CONSIDERATION FOR TROLLEY LINE OPERATION......................... 71 APPROACHING SLOW MOVING VEHICLES IN A TROLLEY ASSISTED TRUCK............. 71 OPERATING SLOW MOVING VEHICLES ON TROLLEY ASSIST RAMPS................... 72 TRUCK FAILURE WHILE ON TROLLEY........................................... 72 OPERATOR CAB AND CONTROLS........................................................ 73 STEERING WHEEL AND CONTROLS.................................................. 74 STEERING WHEEL........................................................... 74 HORN BUTTON.............................................................. 74 TILT/TELESCOPE LEVER..................................................... 74 MULTI-FUNCTION TURN SIGNAL SWITCH........................................ 74 Turn Signal Operation................................................ 74 High Beam Headlight Operation........................................ 74 Windshield Wiper Operation........................................... 74 PEDALS....................................................................... 75 SERVICE BRAKE PEDAL...................................................... 75 DYNAMIC RETARDER PEDAL................................................... 75 THROTTLE PEDAL........................................................... 75 OVERHEAD PANEL CONTROLS AND COMPONENTS....................................... 76 GRADE/SPEED WARNING CHART................................................ 76 RADIO SPEAKERS........................................................... 76 WARNING ALARM BUZZER..................................................... 76 CAB RADIO................................................................ 76 WARNING LIGHTS DIMMER CONTROL............................................ 76 WARNING/STATUS INDICATOR LIGHT PANEL..................................... 76 AIR CLEANER VACUUM GAUGES................................................ 76 WINDSHIELD WIPERS........................................................ 76 TRUCK CONTROLS........................................................... 77 F-N-R Selector Switch................................................ 77 Hoist Control Lever.................................................. 77 CONSOLE SWITCHES AND CONTROLS............................................ 78 Cigarette Lighter.................................................... 78 Left-Hand Window Control Switch...................................... 78 Right-Hand Window Control Switch..................................... 78 Engine Shutdown Switch............................................... 78 Override Switch...................................................... 78 Retard Speed Control (RSC) Switch.................................... 79 Retard Speed Control (RSC) Dial...................................... 79 Statex III Download Port............................................. 80 Engine Diagnostic Port (CENSE)....................................... 80 Engine Diagnostic Connectors......................................... 80 Passenger Seat....................................................... 80 PAYLOAD METER............................................................ 80 Payload Meter Download Connector..................................... 80 CAB CLIMATE CONTROL.......................................................... 81 HEATER / AIR CONDITIONER CONTROLS........................................ 81 Fan Speed Control Knob............................................... 81 Temperature Control Knob............................................. 81 Air Flow Directional Knob............................................ 81 Heater/Air Conditioner Vents......................................... 81 OPERATOR SEAT................................................................ 82 Seat Belts............................................................... 82 ADJUSTMENT............................................................... 82 INSTRUMENT PANEL............................................................. 83 GENERAL INFORMATION...................................................... 84 CONTROL SYMBOLS.......................................................... 84 Key Switch........................................................... 85 Engine Shutdown Switch With Timer Delay.............................. 85 Fog Light Switch..................................................... 85 Ladder Light Switch.................................................. 85 Backup Light Switch.................................................. 85 Panel Illumination Lights............................................ 85 Cab Air Conditioner/Heater Vents..................................... 86 Engine Cold Weather Starting Aid Switch.............................. 86 Rotating Beacon Light Switch......................................... 86 Heated Mirror Switch................................................. 86 Wheel Brake Lock Switch.............................................. 86 Parking Brake Switch................................................. 86 Digital Tachometer................................................... 87 Right Turn Signal Indicator Light.................................... 87 High Beam Headlight Indicator Light.................................. 87 Left Turn Signal Indicator Light..................................... 87 Digital Speedometer/Payload Meter Display............................ 87 Voltmeter Gauge...................................................... 87 Engine Oil Pressure Gauge............................................ 87 Engine Water Temperature Gauge....................................... 87 Fuel Gauge........................................................... 87 Engine Hourmeter..................................................... 87 Headlight Switch..................................................... 88 Panel Illumination Lights Dimmer Rheostat............................ 88 Payload Meter Switch................................................. 88 OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL................................ 89 INDICATOR LIGHT FUNCTIONS................................................ 90 A1. High Hydraulic Oil Temperature................................... 90 B1. Low Steering Pressure............................................ 90 C1. Low Accumulator Precharge Pressure............................... 91 D1. Electric System Fault............................................ 91 E1. Low Brake Pressure............................................... 91 A2. Low Hydraulic Tank Level......................................... 91 B2. Automatic Lubrication System Pressure............................ 91 C2. Circuit Breaker Tripped.......................................... 91 D2. Hydraulic Oil Filter Monitor..................................... 92 E2. Low Fuel......................................................... 92 A3. Parking Brake.................................................... 92 B3. Service Brake.................................................... 92 C3. Body Up.......................................................... 92 D3. Dynamic Retarding................................................ 92 E3. Stop Engine...................................................... 92 A4. Not Used......................................................... 93 B4. Manual Backup Lights............................................. 93 C4. Engine Shutdown Timer............................................ 93 D4. Retard Speed Control (RSC)....................................... 93 E4. Check Engine..................................................... 93 A5. Service Engine Indicator (AEM)................................... 93 B5. High Wheel Motor Temperature..................................... 93 C5. Blower Fault..................................................... 93 D5, E5, A6, B6, and C6. Not Used..................................... 93 D6. Service Engine (CENSE)........................................... 93 E6. Not Used......................................................... 93 Komatsu Engines w/Centry™ Fuel Control............................... 94 Hazard Warning Light Switch.......................................... 94 Lamp Test Switch/Centry™ Diagnostic Test Switch...................... 94 TROLLEY INDICATOR LIGHTS................................................. 94 Diesel Power Indicator............................................... 94 Ready For Trolley Indicator.......................................... 94 On Trolley Indicator................................................. 94 Trolley Fault Indicator.............................................. 95 Left Limit Indicator (Optional)...................................... 95 Max Speed Indicator.................................................. 95 High Speed Indicator................................................. 95 Med Speed Indicator.................................................. 96 Low Speed Indicator.................................................. 96 Right Limit Indicator (Optional)..................................... 96 CENTRY™ FUEL SYSTEM DIAGNOSTICS.............................................. 97 GENERAL OPERATION........................................................ 97 DETERMINING FAULT CODES.................................................. 97 EXITING THE DIAGNOSTICS MODE............................................. 98 LUBRICATION AND SERVICE.......................................................... 99 GENERAL INFORMATION.......................................................... 99 HYDRAULIC TANK SERVICE....................................................... 99 Adding Oil............................................................... 99 COOLING SYSTEM SERVICE.......................................................100 Radiator Filling Procedure...............................................100 RESERVE ENGINE OIL SYSTEM - (IF EQUIPPED)....................................100 Reserve Oil Tank Filling Procedure (Remote Fill).........................100 LEFT-HAND FUEL RECEIVER - OPTIONAL (WIGGINS QUICK FILL)......................101 LUBRICATION CHART............................................................102 10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS..................................103 50 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................105 100 HOUR LUBRICATION AND MAINTENANCE CHECKS..................................105 250 HOUR LUBRICATION AND MAINTENANCE CHECKS..................................106 500 HOUR LUBRICATION AND MAINTENANCE CHECKS..................................108 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................110 1500 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................111 2500 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................111 5000 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................112 10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................113 AUTOMATIC LUBRICATION SYSTEM.....................................................115 GENERAL DESCRIPTION..........................................................115 SYSTEM COMPONENTS............................................................116 Filter Assembly..........................................................116 Hydraulic Motor and Grease Pump..........................................116 Reservoir................................................................116 Fixed Pressure Reducing Valve............................................116 Flow Control Valve.......................................................116 Solenoid Valve...........................................................118 Vent Valve...............................................................118 Time Delay Module........................................................118 Pump Cutoff Pressure Switch..............................................118 Unloader Valve...........................................................118 Pressure Switch..........................................................118 Pressure Gauge...........................................................118 Manual Override Button...................................................118 Injectors................................................................118 SYSTEM OPERATION.............................................................120 Normal Operation.........................................................120 Pressure Failure Detection Circuits......................................121 GENERAL INSTRUCTIONS.........................................................122 LUBRICANT REQUIRED FOR SYSTEM............................................122 SYSTEM PRIMING...........................................................122 LUBRICANT PUMP...........................................................122 Pump Housing Oil Level...............................................122 Pump Pressure Control................................................122 FILTER AND RESERVOIR.................................................123 Filter Assembly Element..............................................123 INJECTORS (SL-1 Series H)................................................124 Injector Specifications..............................................124 Injector Adjustment..................................................124 INJECTOR OPERATION.......................................................125 SYSTEM CHECKOUT..........................................................126 Lubrication Cycle Timer Check........................................126 Lubrication Cycle Timer Adjustment...................................127 PREVENTIVE MAINTENANCE INSPECTION........................................127 10 Hour Lubrication System Inspection................................127 250 Hour Inspection..................................................127 1000 Hour Inspection.................................................128 SYSTEM TROUBLESHOOTING CHART.............................................129 MAJOR COMPONENT DESCRIPTION......................................................131 SPECIFICATIONS...............................................................133 PAYLOAD METER III™...............................................................135 INDEX........................................................................135 Introduction.................................................................137 Data Summary.............................................................137 Data Gathering...........................................................137 COMPONENT DESCRIPTION........................................................138 System Diagram...........................................................138 Suspension Pressure Sensors..............................................138 Inclinometer.............................................................138 Operator Display.........................................................138 Operator Switch..........................................................139 Speed Input..............................................................139 Body-Up Switch...........................................................139 Brake Lock Switch........................................................139 Payload Meter............................................................139 Communications Ports.....................................................139 Key Switch Input.........................................................140 Payload Meter Power......................................................140 Load Lights..............................................................140 Wiring and Termination...................................................141 TCI Outputs..............................................................141 OPERATOR’S DISPLAY AND SWITCH................................................142 Reading the Speedometer..................................................142 Reading the Load Display.................................................142 Using the Operator ID....................................................142 Using the Load and Ton Counter...........................................142 Total Ton Counter........................................................142 Total Load Counter.......................................................143 Clearing the Counters....................................................143 Viewing Live Sensor Data.................................................143 Other Display Messages...................................................143 PAYLOAD OPERATION & CALCULATION..............................................144 Haul Cycle States........................................................144 Haul Cycle Description...................................................144 Load Calculation.........................................................145 Carry Back...............................................................145 Measurement Accuracy.....................................................145 SOURCES FOR PAYLOAD ERROR....................................................145 Payload Error............................................................145 Loading Conditions.......................................................146 Pressure Sensors.........................................................146 Swingloads...............................................................146 Speed and Distance.......................................................146 HAUL CYCLE DATA..............................................................146 Haul Cycle Data..........................................................147 Haul Cycle Warning Flags.................................................148 Frame Torque Data........................................................149 Sprung Weight Data.......................................................149 Maximum Speed Data.......................................................149 Alarm Records............................................................149 Fault Code Data..........................................................150 PC SOFTWARE OVERVIEW.........................................................151 PC Overview..............................................................151 System Configuration.....................................................151 Installing the PLMIII Software...........................................151 DOWNLOADING DATA.............................................................152 PLM III SYSTEM CONFIGURATION.................................................153 Starting Communications..................................................153 Displayed Payload Units..................................................153 Time Units...............................................................153 Connection Menu..........................................................153 Connecting to the Payload Meter..........................................154 Configure the Payload Meter..............................................154 Setting the Date and Time................................................154 Setting the Truck Type...................................................155 Setting the Gauge Display Units..........................................155 Setting the Frame Serial Number..........................................155 Setting the Truck Number.................................................155 Setting the Komatsu Distributor..........................................155 Setting the Komatsu Customer.............................................155 Clean Truck Tare.........................................................156 Inclinometer Calibration.................................................156 DATA ANALYSIS................................................................157 Creating a Query.........................................................157 Sorting on Truck Unit Number.............................................157 Sorting on Truck Type....................................................157 Sorting on Date Range....................................................158 Sorting on Time Range....................................................158 Payload Detail Screen....................................................159 Creating Reports.........................................................159 Summary - one page report................................................160 Detailed - multi-page report.............................................160 Creating Graphs..........................................................161 Exporting Data...........................................................161 CSV Export...............................................................161 Compressed...............................................................162 Importing Data...........................................................163 Deleting Haul Cycle Records..............................................163 Viewing Alarms...........................................................164 Deleting Alarm Records...................................................164 AM/FM RADIO / CD / MP3 / USB / iPOD™ / AUX PLAYER................................167 OPERATING INSTRUCTIONS.......................................................167 GENERAL RADIO RECEIVER FUNCTIONS.........................................167 Turning On the Power.................................................167 One-Hour Timer.......................................................167 Adjusting the Volume.................................................168 Display..............................................................168 Radio Mode Displays..................................................168 CD Mode Displays.....................................................168 MP3/USB/iPod Mode Displays...........................................168 AUX Input Displays...................................................169 CLOCK/ALARM Button...................................................169 Front Auxiliary Mode.................................................169 Rear Auxiliary Mode..................................................169 Adjusting the Receiver Audio Settings................................169 Adjusting the Receiver Menu Settings.................................170 USING THE RADIO..........................................................171 Finding a Station....................................................171 Setting the Presets..................................................171 USING THE CLOCK..........................................................172 Setting the Clock....................................................172 USING THE ALARM..........................................................172 Setting the Alarm....................................................172 Turning the Alarm Off................................................173 Activating Snooze....................................................173 USING THE WEATHERBAND (USA Only).........................................173 USING THE COMPACT DISC PLAYER/USB........................................174 Playing A Compact Disc...............................................174 Button Functions.....................................................174 PLAYING AN MP3 DISC/USB..................................................175 Root Directory.......................................................175 Empty Directory or Folder............................................175 No Folder............................................................175 File Name Display....................................................175 PLAYING MP3 FILES........................................................175 Button Functions.....................................................175 USING AN iPOD®...........................................................176 Playing an iPod......................................................176 Button Functions.....................................................176 OPERATING TIPS...........................................................177 Tips About The Audio System..........................................177 Understanding Radio Reception........................................177 Care of The Compact Discs............................................177 TROUBLESHOOTING..........................................................178
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2 reviews for KOMATSU 730E TROLLEY DUMP TRUCK OPERATION MAINTENANCE MANUAL (SN:A30600 – A30616) KOMATSU 730E – PDF DOWNLOAD
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Knox Mauricio –
OK so far
Gael Kane –
I have only had one issue with a manual and that was it downloaded in Spanish. Not much good to me but I did get the English version at no charge.