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Komatsu Dump Truck 730E Trolley Operation & Maintenance Manual SN A30617 and up – PDF DOWNLOAD
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Komatsu Dump Truck 730E Trolley Operation & Maintenance Manual
Book Code :CEAM025201
Serial Numbers A30617 & UP
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Description
Komatsu Dump Truck 730E Trolley Operation & Maintenance Manual
TABLE OF CONTENTS:
Komatsu Dump Truck 730E Trolley Operation & Maintenance Manual
1 INTRODUCTION.................................................................. 14 FOREWORD.................................................................... 14 ABOUT THIS MANUAL........................................................... 15 ALERTS...................................................................... 16 TRUCK MODEL ILLUSTRATION.................................................... 17 NON-OEM PARTS IN CRITICAL SYSTEMS........................................... 18 2 STANDARD CHARTS AND TABLES.................................................... 20 GENERAL INFORMATION......................................................... 20 EFFECT OF SPECIAL LUBRICANTS............................................ 20 SUGGESTED SOURCES FOR RUST PREVENTIVE GREASE............................ 20 STANDARD TIGHTENING TORQUES................................................. 21 CLASS 10.9 CAP SCREWS & CLASS 10 NUTS................................... 21 SAE GRADE 5 AND GRADE 8 CAP SCREWS...................................... 22 SAE GRADE 9 CAP SCREWS.................................................. 23 T-BOLT CLAMPS........................................................... 23 SPLIT FLANGE CLAMPS..................................................... 24 FLARED TUBE AND HOSE FITTINGS........................................... 24 JIC 37° SWIVEL NUTS..................................................... 25 PIPE THREAD FITTINGS.................................................... 26 O-RING BOSS FITTINGS.................................................... 27 O-RING FACE SEAL FITTINGS............................................... 28 CONVERSION MULTIPLIERS...................................................... 29 METRIC TO ENGLISH....................................................... 29 ENGLISH TO METRIC....................................................... 30 TEMPERATURE CONVERSIONS................................................. 31 3 GENERAL SAFETY................................................................ 34 GENERAL SAFETY.............................................................. 34 Safety Rules............................................................ 34 Truck Safety Features................................................... 34 Clothing And Personal Items............................................. 34 Unauthorized Modification............................................... 34 Leaving The Operator’S Seat............................................. 34 Mounting And Dismounting................................................ 35 Fire Extinguishers And First Aid Kits................................... 35 Precautions For High Temperature Fluids................................. 35 Asbestos Dust Hazard Prevention......................................... 35 Fire Prevention......................................................... 35 Rops Precautions........................................................ 36 Preventing Injury From Work Equipment................................... 36 Precautions For Optional Attachments.................................... 36 Precautions When Starting The Machine................................... 36 PRECAUTIONS FOR TRUCK OPERATION............................................. 37 Safety Is Thinking Ahead................................................ 37 Safety At The Worksite.................................................. 37 Preparing For Operation................................................. 37 Ventilation For Enclosed Areas.......................................... 37 Mirrors, Windows, And Lights............................................ 37 Before Starting The Engine.............................................. 37 Seat Belts.............................................................. 38 Emergency Egress Ladders................................................ 38 OPERATING THE MACHINE....................................................... 39 General Information..................................................... 39 Starting The Engine..................................................... 39 Traveling In The Machine................................................ 39 Traveling In Reverse.................................................... 40 Traveling On Slopes..................................................... 40 Traveling On Snow....................................................... 40 Traveling Near High Voltage Cables...................................... 40 Traveling On Loose Ground............................................... 40 Ensuring Good Visibility................................................ 41 Avoid Damage To The Dump Body........................................... 41 Safe Parking Of The Machine............................................. 41 Loading The Machine..................................................... 41 Dumping The Machine..................................................... 41 Towing The Machine...................................................... 41 EXTERIOR LIGHTING....................................................... 42 Fog Lights.......................................................... 42 Headlights.......................................................... 42 Brake Light......................................................... 42 Retard Light........................................................ 43 Clearance/Turn Signal Lights........................................ 43 Backup Lights....................................................... 43 Retard Lights....................................................... 43 Brake Lights........................................................ 43 Backup Alarm........................................................ 44 PRECAUTIONS FOR MAINTENANCE................................................. 45 BEFORE PERFORMING MAINTENANCE........................................... 45 Securing The Dump Body.............................................. 45 DURING MAINTENANCE...................................................... 46 Warning Tag......................................................... 46 Proper Tools........................................................ 46 Attachments......................................................... 46 Working Under The Machine........................................... 46 Keeping The Machine Clean........................................... 46 Adding Fuel Or Oil To The Machine................................... 47 Radiator Coolant Level.............................................. 47 Use Of Lighting..................................................... 47 Handling High Pressure Hoses........................................ 47 Precautions With High Pressure Oil.................................. 47 Maintenance Near High Temperatures and High Pressures............... 47 Rotating Fan And Belts.............................................. 48 Waste Materials..................................................... 48 Use of Tie-Off Anchor During Maintenance............................ 48 Handling Tires...................................................... 48 Tire Maintenance.................................................... 49 Storing Tires After Removal......................................... 49 Battery Hazard Prevention........................................... 49 Jump Starting With Booster Cables............................... 50 Jump Starting With Receptacles.................................. 50 WHEN REPAIRS ARE NECESSARY.................................................. 52 Observe The Following Precautions....................................... 52 SPECIAL PRECAUTIONS......................................................... 53 Preliminary Procedures Before Welding or Performing Maintenance......... 53 Engine Shutdown Procedure Before Welding or Performing Maintenan........ 53 4 WARNING AND CAUTIONS.......................................................... 56 GENERAL INFORMATION......................................................... 56 PIN PLATE................................................................... 56 GRADE SPEED CHART........................................................... 57 MACHINE SAFETY.............................................................. 57 KEY SWITCH.................................................................. 60 OIL FILL AND CHECK.......................................................... 61 HIGH PRESSURES.............................................................. 62 BATTERY AND ISOLATION BOX................................................... 64 HIGH VOLTAGE................................................................ 65 WELDING..................................................................... 66 LIFTING POINTS.............................................................. 66 AUTOMATIC LUBRICATION FILL.................................................. 67 ROPS/FOPS................................................................... 68 LUBRICATION CHART........................................................... 68 5 OPERATING INSTRUCTIONS........................................................ 70 PREPARING FOR OPERATION..................................................... 70 Safety Is Thinking Ahead................................................ 70 Walk Around Inspection.................................................. 70 TRUCK OPERATION............................................................. 75 ENGINE START-UP SAFETY.................................................. 75 After Engine Has Started............................................ 75 MACHINE OPERATION SAFETY PRECAUTIONS.................................... 76 Machine Operation On The Haul Road.................................. 77 Starting On A Grade With A Loaded Truck............................. 77 Retarding On A Grade................................................ 77 Passing............................................................. 78 Loading............................................................. 78 Dumping............................................................. 79 Lowering The Dump Body (When Dumping On Flat Ground)................ 80 Lowering The Dump Body (When Dumping Over A Berm Or Into A Crush.... 80 SUDDEN LOSS OF ENGINE POWER............................................. 80 EMERGENCY STEERING SYSTEM............................................... 81 Operation........................................................... 81 Pre-Operation Testing............................................... 81 Additional Guidelines............................................... 82 SAFE PARKING PROCEDURES................................................. 82 NORMAL ENGINE SHUTDOWN PROCEDURE........................................ 82 DISABLED TRUCK CONNECTORS................................................... 84 GENERAL INFORMATION..................................................... 84 STEERING AND BRAKE SYSTEM............................................... 84 Components Required................................................. 84 Hookup.............................................................. 84 HOIST SYSTEM............................................................ 85 Hookup.............................................................. 85 Dumping Procedure................................................... 86 TOWING...................................................................... 87 Towing Procedure........................................................ 87 TROLLEY OPERATING INSTRUCTIONS.............................................. 88 AFTER THE ENGINE HAS STARTED............................................ 88 OPERATING IN DIESEL MODE................................................ 88 OPERATING IN TROLLEY LINE MODE.......................................... 88 GETTING ON LINE......................................................... 89 OPERATION ON TROLLEY.................................................... 90 GETTING OFF LINE........................................................ 91 LINE STATUS SIGNALS..................................................... 91 LINE STATUS SIGNAL MARKINGS............................................. 91 TRAFFIC CONSIDERATION FOR TROLLEY LINE OPERATION........................ 92 APPROACHING SLOW MOVING VEHICLES IN A TROLLEY ASSISTED TRUCK............ 92 OPERATING SLOW MOVING VEHICLES ON TROLLEY ASSIST RAMPS.................. 92 TRUCK FAILURE WHILE ON TROLLEY.......................................... 92 PAYLOAD METER III SYSTEM.................................................... 94 GENERAL INFORMATION..................................................... 94 Data Summary........................................................ 94 Data Gathering...................................................... 94 COMPONENT DESCRIPTION................................................... 94 Operator Display.................................................... 94 Operator Switch..................................................... 94 Brake Lock Switch................................................... 95 Payload Meter Module................................................ 95 Communications Ports................................................ 95 Load Lights......................................................... 95 OPERATORS DISPLAY AND SWITCH............................................ 95 Reading the Load Display............................................ 95 Setting the Operator ID............................................. 96 Load and Ton Counter................................................ 96 Viewing Live Sensor Data............................................ 96 Other Display Messages.............................................. 97 HAUL CYCLE WARNING FLAGS................................................ 97 Haul Cycle Data..................................................... 97 Haul Cycle Warning Flags............................................ 99 PC SOFTWARE OVERVIEW....................................................100 SYSTEM CONFIGURATION....................................................101 Connecting to the Payload Meter.....................................101 Displayed Payload Units.............................................101 Connection Menu.....................................................101 Configure the Payload Meter.........................................102 Setting the Date and Time...........................................102 Setting the Truck Type and Serial Number............................103 Setting the Gauge Display Units.....................................103 Setting the Carryback Alarm Threshold...............................103 Setting the Truck Number............................................104 Setting the Komatsu Distributor.....................................104 Setting the Komatsu Customer........................................104 Clean Truck Tare Calibration........................................104 Inclinometer Calibration............................................105 DOWNLOADING PAYLOAD DATA................................................105 UPLOADING DATA..........................................................106 DATA ANALYSIS...........................................................107 Creating a Query....................................................107 Payload Detail Screen...............................................108 Creating Reports....................................................108 Creating Graphs.....................................................108 Exporting Data......................................................109 Importing Data......................................................110 Deleting Haul Cycle Records.........................................110 Viewing Alarms......................................................110 Deleting Alarm Records..............................................110 Patent Acknowledment................................................110 AUTOMATIC LUBRICATION SYSTEM................................................111 GENERAL INFORMATION.....................................................111 COMPONENT DESCRIPTION...................................................111 Filter..............................................................112 Vent Valve..........................................................113 Flow Control Valve..................................................113 Grease Reservoir....................................................113 Pressure Reducing Valve.............................................113 Hydraulic Motor and Pump............................................113 Solenoid Valve......................................................113 Pressure Cut Off Switch.............................................113 Injectors...........................................................114 Grease Pressure Failure Switch......................................115 Relief Valve (unloader valve).......................................115 Lubrication Cycle Timer.............................................115 SYSTEM OPERATION........................................................115 Filling The Reservoir...............................................115 Priming The Automatic Lubrication System............................116 PREVENTIVE MAINTENANCE PROCEDURES.......................................117 Daily Lubrication System Inspection.................................117 250 Hour Inspection.................................................117 1000 Hour Inspection................................................118 SYSTEM CHECKOUT.........................................................118 General Checks......................................................118 Lubrication Controller Components...................................118 RESERVE ENGINE OIL SYSTEM (Optional)........................................120 Operation...............................................................120 Changing Oil............................................................120 6 OPERATOR CAB AND CONTROLS.....................................................124 CAB INTERIOR................................................................124 STEERING WHEEL AND CONTROLS.................................................125 Horn Button.............................................................125 Tilt / Telescope Lever..................................................125 Multi-Function Turn Signal Switch.......................................125 Turn Signal Operation...................................................125 High Beam Headlight Operation...........................................125 Windshield Wiper Operation..............................................126 PEDALS......................................................................127 SERVICE BRAKE PEDAL.....................................................127 DYNAMIC RETARD PEDAL....................................................127 Dynamic Retarding.......................................................127 ACCELERATOR PEDAL.......................................................127 OVERHEAD PANEL AND DISPLAYS.................................................129 RADIO SPEAKERS..........................................................129 WARNING ALARM BUZZER....................................................129 CAB RADIO...............................................................129 WARNING LIGHT DIMMER CONTROL............................................129 STATUS/WARNING INDICATOR LIGHT PANEL....................................129 AIR CLEANER VACUUM GAUGES...............................................129 WINDSHIELD WIPERS.......................................................129 CENTER CONSOLE..............................................................130 FNR CONTROL LEVER.......................................................130 Lowering The Dump Body..................................................131 WINDOW CONTROL SWITCHES.................................................131 ENGINE STOP SWITCH......................................................131 OVERRIDE/FAULT RESET SWITCH.............................................131 RETARD SPEED CONTROL (RSC) SWITCH.......................................131 RETARD SPEED CONTROL (RSC) ADJUST DIAL..................................131 DATA STORE BUTTON.......................................................132 DIAGNOSTIC PORTS............................................................133 ENGINE (CENTRY).........................................................133 ENGINE (CENSE)..........................................................133 STATEX III..............................................................133 KOMTRAX Plus AND PAYLOAD METER..........................................133 INTERFACE MODULE .......................................................134 OPERATOR’S SEAT (Standard)..................................................135 SEAT BELTS..............................................................135 ADJUSTMENT..............................................................135 HEATER / AIR CONDITIONER CONTROLS...........................................137 Fan Speed Control Knob..................................................137 Temperature Control Knob................................................137 Air Flow Directional Knob...............................................137 Heater/Air Conditioner Vents............................................137 INSTRUMENT PANEL ...........................................................138 CONTROL SYMBOLS.........................................................138 Key Switch..............................................................139 Engine Shutdown Switch..................................................140 Fog Light Swich.........................................................140 Ladder Light Switch.....................................................140 Backup Light Switch.....................................................140 Panel Illumination Lights...............................................140 Cab Air Conditioner/Heater Vents........................................140 Engine Cold Weather Starting Aid Switch.................................140 Rotating Beacon Light Switch (Optional).................................140 Heated Mirror Switch (Optional).........................................140 Leakage Test Switch (Trolley Only)......................................141 Wheel Brake Lock Control Switch.........................................141 Parking Brake Switch....................................................141 Tachometer..............................................................141 Right Turn Signal Indicator.............................................141 High Beam Indicator.....................................................142 Left Turn Signal Indicator..............................................142 Speedometer/Payload Meter Display.......................................142 Voltmeter Gauge.........................................................142 Engine Oil Pressure Gauge...............................................142 Water Temperature Gauge.................................................142 Fuel Level Gauge........................................................142 Hourmeter...............................................................142 Headlight Switch........................................................143 Panel Light Dimmer......................................................143 Payload Meter Switch....................................................143 OVERHEAD STATUS/WARNING INDICATOR...........................................144 STATUS / WARNING INDICATOR LIGHT SYMBOLS................................145 High Hydraulic Oil Temperature......................................145 Low Steering Pressure...............................................145 Low Accumulator Precharge Pressure..................................146 No Power............................................................146 Low Brake Pressure..................................................147 Low Hydraulic Tank Level............................................147 Automatic Lubrication System Pressure...............................147 Circuit Breaker Tripped.............................................147 Hydraulic Oil Filter Monitor........................................147 Low Fuel............................................................147 Parking Brake.......................................................148 Service Brake.......................................................148 Body Up.............................................................148 Dynamic Retarding...................................................148 Stop Engine.........................................................148 Manual Backup Lights................................................149 Engine Shutdown Timer...............................................149 Retard Speed Control (RSC) Indicator................................149 Check Engine........................................................149 Service Engine Indicator (AEM)......................................149 Propulsion System Temperature.......................................149 Blower Fault........................................................149 Service Engine Indicator (CENSE)....................................150 Hazard Light Switch.................................................150 Lamp Test Switch....................................................150 TROLLEY INDICATOR LIGHT SYMBOLS.........................................150 Diesel Power Indicator..............................................150 Ready For Trolley Indicator.........................................150 On Trolley Indicator................................................150 Trolley Fault Indicator.............................................151 Left Limit Indicator (Optional).....................................151 Max Speed Indicator.................................................151 High Speed Indicator................................................151 Med. Speed Indicator................................................151 Low Speed Indicator.................................................152 Right Limit Indicator (Optional)....................................152 CENTRYTM FUEL SYSTEM DIAGNOSTICS............................................153 GENERAL OPERATION.......................................................153 DETERMINING FAULT CODES.................................................153 EXITING THE DIAGNOSTICS MODE............................................154 7 LUBRICATION AND SERVICE.......................................................156 GENERAL INFORMATION.........................................................156 HYDRAULIC SYSTEM SERVICE................................................156 Hydraulic Tank......................................................156 Hydraulic Filters...................................................157 Hydraulic Pump Drive Shaft..........................................157 WHEEL MOTOR SERVICE.....................................................157 COOLANT LEVEL SERVICE...................................................157 Radiator Filling Procedure..........................................157 Coolant Specifications..............................................158 Unacceptable Practices..............................................158 RESERVE ENGINE OIL SERVICE (If Equipped)................................158 Reserve Oil Tank Filling Procedure (Remote Fill)....................158 CAB AIR FILTER SERVICE..................................................159 FUEL SYSTEM SERVICE.....................................................159 Fuel Tank Cleaning..................................................159 Fuel Filter Service.................................................160 INTAKE AIR CLEANER SERVICE..............................................160 FRONT WHEEL SERVICE.....................................................162 Oil Sampling........................................................162 FRONT ENGINE MOUNT TRUNION SERVICE......................................162 QUICK FILL SERVICE CENTER...............................................162 LUBRICATION CHART...........................................................164 EVERY 10 HOUR (DAILY) MAINTENANCE...........................................165 INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION......................167 INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION.....................168 EVERY 250 HOUR LUBRICATION AND MAINTENANCE..................................169 EVERY 500 HOUR LUBRICATION AND MAINTENANCE..................................171 EVERY 1000 HOURS LUBRICATION AND MAINTENANCE................................173 EVERY 2500 HOUR MAINTENANCE.................................................174 EVERY 5000 HOUR MAINTENANCE.................................................175 EVERY 10,000 HOUR MAINTENANCE...............................................176 8 SPECIFICATIONS................................................................178 MAJOR COMPONENT DESCRIPTION.................................................178 Truck And Engine........................................................178 Alternator (GTA-22).....................................................178 Wheel Motors (GE 788)...................................................178 Blower..................................................................178 Suspension..............................................................178 Operator's Cab..........................................................178 Power Steering..........................................................178 Dynamic Retarding Gird..................................................178 Brake System............................................................178 SPECIFICATIONS..............................................................179 Engine..................................................................179 Electric Drive System...................................................179 Dynamic Retarding.......................................................179 Battery Electric System.................................................179 Service Capacities......................................................179 Hydraulic Systems.......................................................179 Service Brakes..........................................................179 Steering................................................................179 Standard Dump Body Capacities And Dimensions............................180 Tires...................................................................180 Weight Distribution.....................................................180 Overall Truck Dimensions................................................180 9 RADIO.........................................................................184 RADIO OPERATION.............................................................184 GENERAL RADIO RECEIVER FUNCTIONS........................................184 Turning On the Power....................................................184 One-Hour Timer..........................................................185 Finding a Station.......................................................185 Setting the Presets.....................................................185 Adjusting the Receiver Audio Settings...................................186 Display.................................................................186 Adjusting the Receiver Menu Settings....................................186 Front Auxiliary Mode....................................................187 Rear Auxiliary Mode.....................................................187 CLOCK.......................................................................188 Clock/Alarm Button......................................................188 Setting the Clock.......................................................188 Setting the Alarm.......................................................188 Turning the Alarm Off...................................................189 Activating Snooze.......................................................189 CD PLAYER...................................................................190 Playing A Compact Disc..................................................190 Playing an MP3 DISC.....................................................190 CD Mode Displays........................................................190 Button Functions........................................................190 MP3 PLAYER..................................................................192 Playing MP3 Files.......................................................192 MP3 Mode Displays.......................................................192 Button Functions........................................................193 iPod®.......................................................................194 Playing an iPod®........................................................194 iPod® Mode Displays.....................................................194 Button Functions........................................................194 WEATHERBAND (USA Only)......................................................196 TROUBLESHOOTING.............................................................197 Tips About The Audio System.............................................197 Understanding Radio Reception...........................................197 Care of The Compact Discs...............................................197
KOMATSU DUMP TRUCK 730E TROLLEY OPERATION & MAINTENANCE MANUAL SN A30617 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu Dump Truck 730E Trolley Operation & Maintenance Manual
FOREWORD:
This manual is written for use by the operator and/or the service technician and is designed to help these persons become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel must read and understand the materials in this manual before operating the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings and cautions are to be understood and followed when operating or accomplishing repairs on the truck.
- The illustrations used in this manual are typical of the component shown and may not be an exact reproduction of what is found on the truck. A product identification plate is located on the frame in front of the right side front wheel and designates the truck model number, product identification number (vehicle serial number), and maximum GVW (Gross Vehicle Weight) rating. The KOMATSU truck model designation consists of three numbers and one letter (i.e. 830E).
- The three numbers represent the basic truck model. The letter “M”, when present, designates a Mechanical drive system; The letter “E”, when present, designates an Electrical wheel motor drive system. The product identification number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit.
- This complete number will be necessary for proper ordering of many service parts and/or warranty consideration. The GVW is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the total maximum GVW.
- GVW is TOTAL WEIGHT: the Empty Vehicle Weight + the fuel & lubricants + the payload. To determine allowable payload: Service all lubricants for proper level and fill fuel tank of empty truck (which includes all accessories, body liners, tailgates, etc.) and then weigh truck. Record this value and subtract from the GVW rating. The result is the allowable payload.
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