Komatsu 730E Operation & Maintenance Manual
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Komatsu 730E Operation & Maintenance Manual

Dump truck
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CEAM014901
Operation & Maintenance
Manual
DUMP TRUCK
A30310, A30312 - A30426
SERIAL NUMBERS
®

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Summary of Contents for Komatsu 730E

  • Page 1 CEAM014901 Operation & Maintenance Manual DUMP TRUCK A30310, A30312 - A30426 SERIAL NUMBERS ®...
  • Page 3 Komatsu warrants to the ultimate purchaser and each subsequent purchaser that the engine is designed, built and equipped so as to conform, at the time of sale by Komatsu, with all U.S. Federal emission regulations applicable at the time of manufacture and that it is free from defects in workmanship or material which would cause it not to meet these regulations within five years or 3,000 hours of operation, whichever occurs first, as measured from the date of delivery of the engine to the ultimate purchaser.
  • Page 4 RPM FAMILY EMISSION LIMIT LIMITE D’ÉMISSION DE INITIAL INJECTION DEG. BTDC DATE OF MANUFACTURE LA FAMILLE TIMING RÉGLAGE DE L’ALLUMAGE - _____________________________________________ KOMATSU LTD. INJECTION INITIALE DATE MADE IN JAPAN DE FABRICATION DEG. BTDC KOMATSU LTÉE FABRIQUÉ AU JAPON ENGINE DATAPLATE - ENGLISH / FRENCH...
  • Page 5 This manual should be kept in or near the machine for reference, and periodically reviewed by all personnel who will come into contact with it. This material is proprietary to Komatsu America Corp (KAC), and is not to be reproduced, used, or dis- closed except in accordance with written authorization from KAC.
  • Page 6 Komatsu is also aware of repair companies that will rework or modify an OEM part for reuse in critical systems. Komatsu does not generally authorize such repairs or modifications for the same reasons as noted above.

  • Page 7: Introduction

    (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.

  • Page 8: Truck Model Illustration

    Introduction - Section 1 OM1047 06/06 Page 10-2 TRUCK MODEL ILLUSTRATION KOMATSU MODEL 730E DUMP TRUCK...

  • Page 9: About This Manual

    The front cover of this manual includes a form number. This form number must be referenced when ordering addi- tional copies of this manual, or for any other correspondence regarding the coverage in this manual. Direct all inquiries to: Komatsu America Corp. Datakom, Peoria Technical Publications P.O. Box 240...

  • Page 10: Alerts Page

    Introduction - Section 1 OM1047 06/06 Page 10-4 ALERTS PAGE This ALERT symbol is used in this manual, along with the signal words CAUTION, DANGER, and WARNING, to alert the reader to hazards arising from improper operat- ing and maintenance practices. DANGER identifies a specific potential hazard WHICH WILL RESULT in either INJURY OR DEATH...

  • Page 11: Table Of Contents

    OM1047 06/06 Introduction - Section 1 Page 10-5 TABLE OF CONTENTS SUBJECT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -SECTION/PAGE INTRODUCTION .
  • Page 12 Introduction - Section 1 OM1047 06/06 Page 10-6 SUBJECT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION/PAGE MACHINE OPERATION SAFETY PRECAUTIONS .
  • Page 13 OM1047 06/06 Introduction - Section 1 Page 10-7 SUBJECT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -SECTION/PAGE CAB RADIO .
  • Page 14 Introduction - Section 1 OM1047 06/06 Page 10-8 SUBJECT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION/PAGE 100 HOUR LUBRICATION AND MAINTENANCE CHECKS .
  • Page 15 OM1047 06/06 Introduction - Section 1 Page 10-9 SUBJECT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -SECTION/PAGE OPERATING THE RADIO .
  • Page 16 Introduction - Section 1 OM1047 06/06 Page 10-10 NOTES...
  • Page 17 U.S. standard units are specified first, On Fasteners and Standard Torque Values with metric (SI) units in parentheses. The Komatsu engineering department does not References throughout the manual to standard torques recommend the use of special friction-reducing or other standard values will be to one of the following lubricants, such as Copper Coat, Never-Seez®, and...
  • Page 18 • RUST PREVENTIVE GREASE - CODE 312 from the Southwest Grease and Oil Company. NOTE: This list represents the current engineering approved sources for use in Komatsu manufacture. It is not exclusive. Other products may meet the same specifications of this list.
  • Page 19 OM1200 3/05 Standard Charts and Tables - Section 12 Page 12-3 TABLE IV. TABLE VI. TORQUE CHART FOR JIC 37° SWIVEL NUTS TORQUE CHART FOR WITH OR WITHOUT O-RING SEALS O-RING BOSS FITTINGS SIZE TUBE SIZE THREADS TORQUE SIZE TUBE SIZE THREADS TORQUE CODE...
  • Page 20 Standard Charts and Tables - Section 12 OM1200 3/05 Page 12-4 TABLE VIII. TORQUE CONVERSIONS Foot Pounds (ft. lbs.) to Newton-meters (N•m) ft lbs (N.m) 1.36 2.71 4.07 5.42 6.78 8.14 9.49 10.85 12.20 13.56 14.91 16.27 17.63 18.98 20.34 21.69 23.05 24.40...
  • Page 21 OM1200 3/05 Standard Charts and Tables - Section 12 Page 12-5 TABLE XI. PRESSURE CONVERSIONS Pounds per square inch (psi) to Megapascals (MPa) Formula: psi x 0.0069 = MPa (MPa) 0.069 0.14 0.21 0.28 0.34 0.41 0.48 0.55 0.62 0.69 0.76 0.83 0.90...
  • Page 22 Standard Charts and Tables - Section 12 OM1200 3/05 Page 12-6 Table XIII. TABLE XIII COMMON CONVERSION MULTIPLIERS COMMON CONVERSION MULTIPLIERS COMMON CONVERSION MULTIPLIERS ENGLISH TO METRIC METRIC TO ENGLISH To Convert Multiply Multiply From To Convert From inch – in. millimeter (mm) 25.40 millimeter (mm)

  • Page 23: General Safety

    Read and follow all safety precautions. Failure to do so may result in serious injury or death. • Before making any modification, consult your authorized regional Komatsu America Corp. PERSONAL SAFETY distributor. Komatsu will not be responsible for injury damage caused Safety Rules unauthorized modification.
  • Page 24 Safety - Section 20 OM2036 06/06 Page 20-2 Use the handrails and steps marked by arrows • To prevent hot engine oil spray: in the diagram below when climbing on or off 1. Stop the engine. the machine. 2. Wait for the oil temperature to cool. 3.
  • Page 25 It is designed not only to support the load of the machine, but also to • DO NOT use attachments that are not authorized absorb the energy of the impact. by Komatsu America Corp., or the authorized regional Komatsu distributor.

  • Page 26: Precautions For Truck Operation

    Only qualified opera- Preparing For Operation tors or technicians may attempt to operate or main- tain a Komatsu truck. • Mount and dismount while facing the truck. DO NOT attempt to mount or dismount the truck Safe practices start before the operator gets to the while it is in motion.

  • Page 27: Operating The Machine

    OM2036 06/06 Safety - Section 20 Page 20-5 OPERATING THE MACHINE In The Operator’s Cab - Before Starting The Engine Starting The Engine • DO NOT leave tools or spare parts lying around • DO NOT attempt to start the machine by shorting or allow trash to accumulate in the cab of the across the starter terminals.
  • Page 28 Safety - Section 20 OM2036 06/06 Page 20-6 • Check for flat tires periodically during a shift. If • If the engine stops while the truck is in motion, the truck has been operating on a flat, DO NOT the steering and brakes will continue to operate, park indoors until the tire cools.
  • Page 29 OM2036 06/06 Safety - Section 20 Page 20-7 Ensuring Good Visibility The following actions are effective in preventing acci- dents while working near high voltages: • When working in dark places, install work lamps and headlamps. • Wear shoes with rubber or leather soles. •...

  • Page 30: Towing

    Safety - Section 20 OM2036 06/06 Page 20-8 Parking The Machine • Batteries generate hydrogen gas. Hydrogen gas is very explosive and is easily ignited with a small • Choose a horizontal road surface to park the spark or flame. machine.

  • Page 31: Precautions For Maintenance

    1. To hold the dump body in the up position, raise warning tags around the machine, if necessary. the body to its maximum height. • These tags are available from your Komatsu 2. Remove cable (3) from its stored position on the distributor. Part No. 09963-03000.

  • Page 32: During Maintenance

    Safety - Section 20 OM2036 06/06 Page 20-10 DURING MAINTENANCE Rules To Follow When Adding Fuel Or Oil • Spilled fuel and oil may cause slipping. Clean up Personnel spills immediately. • Only authorized personnel may service and • Tighten the fuel cap and the oil cap securely. repair the machine.
  • Page 33 OM2036 06/06 Safety - Section 20 Page 20-11 Precautions With The Battery Maintenance Near High Temperatures And High Pressures • When repairing electrical system, • Immediately after stopping, the when welding, engine coolant and operating remove the negative (-) oils are at high temperature and terminal of the battery to may be pressurized.

  • Page 34: Tires

    When performing such mainte- nance, consult your authorized regional Komatsu dis- Improperly maintained or inflated tires can overheat tributor, or the tire manufacturer.

  • Page 35: Additional Job Site Rules

    OM2036 06/06 Safety - Section 20 Page 20-13 ADDITIONAL JOB SITE RULES • Use this space to add any additional job site rules not covered in any of the previous discussions. • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ • _______________________________________________________________________________________ •...

  • Page 36: When Repairs Are Necessary

    Operating Instructions - Towing. attempt repairs. 10. Drain, clean, and ventilate the fuel tanks and/or 2. Many components on the Komatsu truck are hydraulic tanks before welding. large and heavy. Ensure that the lifting equip- ment - hoists, slings, chains, lifting eyes - are of NOTE: If it is necessary to weld the hydraulic tank or adequate capacity.
  • Page 37 OM2036 06/06 Safety - Section 20 Page 20-15...
  • Page 38 Safety - Section 20 OM2036 06/06 Page 20-16 NOTES...

  • Page 39: Warnings And Cautions

    (CL). The CL is used to verify the accuracy of the individual PIN. FC - Character positions 10 and 11 identify the Fac- tory Code (FC). The FC identifies the Komatsu fac- tory in charge of claims for the product. The FC for electric drive trucks is 61.
  • Page 40 Safety - Section 22 OM2216 Page 22-2 Warnings and Cautions A warning decal surrounds the key switch. The warn- ing stresses the importance of reading the operator's manual before operation. Warning plates are attached to the hydraulic tank and the fuel tank. The decals alert technicians not to work on the truck with the body raised unless the body-up retention cable is in position.
  • Page 41 OM2216 Safety - Section 22 Warnings and Cautions Page 22-3 A warning plate is mounted on top of the radiator A plate on the side of the hydraulic tank provides surge tank cover near the radiator cap. The engine instructions for filling the hydraulic tank. cooling system is pressurized when the engine is on and/or when the system is hot.
  • Page 42 Safety - Section 22 OM2216 Page 22-4 Warnings and Cautions A warning plate is attached to the frame above the hydraulic system Auxiliary Power Unit (APU) quick Attached to the exterior of the battery compartment is disconnect fittings. The plate alerts technicians that a danger plate.
  • Page 43 OM2216 Safety - Section 22 Warnings and Cautions Page 22-5 The parking brake is spring-applied and hydraulically Before arc welding on the truck, disconnect the posi- released. It is designed to hold a stationary truck tive and negative battery cables of the vehicle. Fail- when the engine is off.
  • Page 44 Safety - Section 22 OM2216 Page 22-6 Warnings and Cautions This plate warns the technician to stop the engine, before loosening or disconnecting a brake line. Turn A decal plate is located on top of the center cross the key switch off, and open the drain valves on all tube.
  • Page 45 OM2216 Safety - Section 22 Warnings and Cautions Page 22-7 A wheel motor oil level decal is attached to the gear cover on both the electric wheel motors. This decal stresses that the truck must be on a level surface and parked for 20 minutes prior to checking the oil level.
  • Page 46 Safety - Section 22 OM2216 Page 22-8 Warnings and Cautions The lubrication chart is located on the right-hand side of the radiator grille. The chart specifies some of the critical maintenance items to be checked. Component location and service intervals are specified on the chart. The lube key lists the proper lubricants to be used.

  • Page 47: Operating Instructions

    Operators or technicians must be qualified to operate or maintain Verify the fan guard bolts are installed and a Komatsu truck. properly tightened. 5. Ensure the anchor end of the steering cylinder Safe practices start before the operator gets to the pin is properly greased and tightened.
  • Page 48 Operation - Section 30 OM3043 06/06 Page 30-2 Operating Instructions...
  • Page 49 OM3043 06/06 Operation - Section 30 Operating Instructions Page 30-3 8. Check the oil level in the hydraulic tank. With the 15. Move to the rear center of the truck. Open the engine stopped and the body down, hydraulic rear hatch cover, and turn on the work light, if fluid must be visible in the upper sight glass.
  • Page 50 Operation - Section 30 OM3043 06/06 Page 30-4 Operating Instructions 26. Move to the front of the radiator. 21. Move to the fuel tank. Remove any debris or foreign objects. Verify the fuel gauge on the tank agrees with Check for coolant leaks. the gauge in the cab.

  • Page 51: Engine Start-Up

    OM3043 06/06 Operation - Section 30 Operating Instructions Page 30-5 32. Clean the cab windows and mirrors. NOTE: If the truck is equipped with an engine prelube system, a noticeable time delay will occur Remove dirt or debris from the cab floor. (while the engine lube oil passages are being filled) Ensure the steering wheel, controls, and pedals before the starter engages.

  • Page 52: Machine Operation Safety Precautions

    Operation - Section 30 OM3043 06/06 Page 30-6 Operating Instructions 3. Check the gauges, warning lights, and instru- 1. Look to the rear before backing the truck. ments before moving the truck to ensure proper Watch for and obey the ground spotter's hand system operation and proper instrument func- signals before reversing.

  • Page 53: Loading

    OM3043 06/06 Operation - Section 30 Operating Instructions Page 30-7 LOADING 6. DO NOT stop or park on a haul road unless unavoidable. If you must stop, move the truck to 1. Pull into the loading area with caution. Remain a safe place, apply the parking brake, and shut at a safe distance while the truck ahead is being the engine off before leaving the cab.

  • Page 54: Dumping

    Operation - Section 30 OM3043 06/06 Page 30-8 Operating Instructions DUMPING 1. Approach the dump area with extreme caution. Ensure the area is clear of persons and obstructions, including overhead utility lines. Obey signals directed by the spotter, if present. If dumping very large rocks or sticky material, as described in the warning, slowly accelerate the Avoid unstable areas.

  • Page 55: Towing

    OM3043 06/06 Operation - Section 30 Operating Instructions Page 30-9 a. Move the hoist lever back to the HOIST posi- NOTE: If the dumped material builds up at the rear tion and fully raise the dump body. Continue of the body and the body cannot be lowered, then to hold the hoist lever until the body is com- perform steps c and d below: pletely raised.

  • Page 56: Safe Parking Procedures

    Operation - Section 30 OM3043 06/06 Page 30-10 Operating Instructions 3. Empty all material from dump body of truck that 2. Allow the engine to cool gradually at low idle for is to be towed. three to five minutes. 4. Determine that the towing vehicle has adequate 3.

  • Page 57: Sudden Loss Of Power

    OM3043 06/06 Operation - Section 30 Operating Instructions Page 30-11 SUDDEN LOSS OF POWER 6. When the engine shutdown timer has been activated, If the engine suddenly stops while the truck is in the timer delay indicator light motion, there is enough hydraulic pressure stored in in the overhead display the brake and steering accumulators to allow the panel will illuminate to indi-...

  • Page 58: Emergency Steering System

    Operation - Section 30 OM3043 06/06 Page 30-12 Operating Instructions EMERGENCY STEERING SYSTEM Testing This test can only be performed with an empty truck. Operation 1. Ensure no one is near the front tires during this The truck is equipped with an emergency steering test.

  • Page 59: Operator Cab And Controls

    OM3214 Operation - Section 32 Operator Cab and Controls Page 32-1 OPERATOR CAB AND CONTROLS FIGURE 32-1. CAB INTERIOR - OPERATOR VIEW 1. Steering Wheel and Controls 6. Heater/Air Conditioner and 11. Radio, AM/FM, Cassette 2. Service Brake Pedal Controls 12.

  • Page 60: Steering Wheel And Controls

    Operation - Section 32 OM3214 Page 32-2 Operator Cab and Controls STEERING WHEEL AND CONTROLS MULTI-FUNCTION TURN SIGNAL SWITCH STEERING WHEEL Steering wheel (1, Figure 32-2) will telescope in and out and adjust through a tilt angle to provide a com- fortable wheel position for most operators.

  • Page 61: Pedals

    OM3214 Operation - Section 32 Operator Cab and Controls Page 32-3 PEDALS When pedal (3) is partially depressed, dynamic retarding is activated (actuation is modulated). Pressing the pedal further applies full retarding. Dur- SERVICE BRAKE PEDAL ing full retarding the service brakes also begin to Service brake pedal (2, Figure 32-4) is a foot-operated apply.

  • Page 62: Cab Climate Control

    Operation - Section 32 OM3214 Page 32-4 Operator Cab and Controls CAB CLIMATE CONTROL Heater/Air Conditioner Selector Switch Heater/air conditioner selector switch (5, Figure 32-5) HEATER/AIR CONDITIONER VENTS allows the operator to select heat, A/C, or neither. The left position of the switch activates the air conditioning, The operator has complete control of the air flow in the and the right side of the switch activates the heater.

  • Page 63: Overhead Panel Controls And Components

    OM3214 Operation - Section 32 Operator Cab and Controls Page 32-5 OVERHEAD PANEL CONTROLS AND WARNING ALARM BUZZER COMPONENTS Warning alarm buzzer (10, Figure 32-1) will sound when activated by any one of several truck functions. GRADE/SPEED WARNING CHART Refer to Instrument Panel in this module for a detailed description of the functions and indicators Grade/Speed Warning chart (Figure 32-6) provides that will activate this alarm.

  • Page 64: Center Console

    Operation - Section 32 OM3214 Page 32-6 Operator Cab and Controls CENTER CONSOLE 1. Center Console 2. F-N-R Selector Switch 3. Hoist Control Lever 4. Ashtray 5. Cigarette Lighter 6. LH Window Control Switch 7. RH Window Control Switch 8. Engine Shutdown Switch 9.

  • Page 65: Console Switches And Controls

    OM3214 Operation - Section 32 Operator Cab and Controls Page 32-7 Hoist Control Lever Override Switch Hoist control lever (3, Figure 32-7) is a four-position, Override switch hand-operated lever located between the operator (9, Figure 32-7) seat and the center console. is spring-loaded to the OFF posi- Refer to Safety, Section 20, When Dumping, and...
  • Page 66 Operation - Section 32 OM3214 Page 32-8 Operator Cab and Controls Retard Speed Control (RSC) Dial Statex III Download Port RSC dial (12, Figure 32-7) allows the operator to vary Statex III download port (13, Figure 32-7) is used by the downhill truck speed that the retard speed control qualified personnel to access the STATEX III electric system will maintain when descending a grade.

  • Page 67: Payload Meter

    OM3214 Operation - Section 32 Operator Cab and Controls Page 32-9 PAYLOAD METER Payload meter (1, Figure 32-9) and payload meter download connector (2) are used to provide manage- ment with operational data, such as tonnage hauled and cycle times. Refer to Section 60, Payload Meter III, for a complete description of the payload meter and its functions.

  • Page 68: Operator Seat

    Operation - Section 32 OM3214 Page 32-10 Operator Cab and Controls OPERATOR SEAT The operator's seat provides a fully adjustable cush- ioned ride for the driver's comfort. ADJUSTMENT The following adjustments must be made while sitting in the seat. 1. Headrest: Move up, down, fore, or aft by mov- ing headrest (1, Figure 32-10) to the desired position.

  • Page 69: Instrument Panel

    OM3214 Operation - Section 32 Operator Cab and Controls Page 32-11 INSTRUMENT PANEL GENERAL INFORMATION The operator must understand the function and oper- ation of each instrument and control (Figure 32-11). Control functions are identified with international symbols that the operator must learn to recognize immediately.

  • Page 70: Control Switches And Gauges

    Operation - Section 32 OM3214 Page 32-12 Operator Cab and Controls CONTROL SWITCHES AND GAUGES FIGURE 32-11. PANEL, GAUGES, INDICATORS, AND CONTROLS 1. Key Switch 16. High Beam Headlight Indicator Light 2. Timer Delayed Engine Shutdown Switch 17. Left Turn Signal Indicator Light 3.
  • Page 71 OM3214 Operation - Section 32 Operator Cab and Controls Page 32-13 Engine Shutdown Switch With Timer Delay Engine Cold Weather Starting Aid Switch Engine shutdown switch with timer delay (2, Figure 32-11) is a three-position, rocker-type switch (OFF, Optional engine cold weather ON, MOMENTARY).
  • Page 72 Operation - Section 32 OM3214 Page 32-14 Operator Cab and Controls Digital Tachometer Digital tachometer (14, Figure 32-11) displays the engine crankshaft speed in revolutions per minute (rpm). The wheel brake lock is used at the shovel and Governed rpm: the dump only to hold the truck in position.
  • Page 73 OM3214 Operation - Section 32 Operator Cab and Controls Page 32-15 Voltmeter Gauge Headlight Switch Voltmeter gauge (19, Figure 32- Instrument panel lights, clear- 11) indicates the voltage of the ance lights, and headlights are 24V battery system. Normal indi- controlled by headlight switch cated voltage at high rpm is 27 to (27,...

  • Page 74: Overhead Status/Warning Indicator Light Panel

    Operation - Section 32 OM3214 Page 32-16 Operator Cab and Controls OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL FIGURE 32-12. STATUS/INDICATOR LIGHTS DESCRIPTION OF INDICATOR SYMBOLS Row/ Indicator Indicator Color Row/ Indicator Indicator Color Column Description Wire Index Column Description Wire Index High Hydraulic Oil Red - 12F/34TL Blank - For Future Use...

  • Page 75: Indicator Light Functions

    OM3214 Operation - Section 32 Operator Cab and Controls Page 32-17 INDICATOR LIGHT FUNCTIONS Amber indicator lights alert the operator the indicated truck function requires some precaution when lighted. If the low steering warning light continues to illu- Red indicator lights alert the operator the indicated minate and the alarm continues to sound, low truck function requires immediate action.
  • Page 76 Operation - Section 32 OM3214 Page 32-18 Operator Cab and Controls Electric System Fault Warning Circuit Breaker Tripped Electric system fault warning light Circuit breaker tripped light (C2) (D1) will flash on and off when a will illuminate if any of the circuit malfunction occurs in the electri- breakers in the relay circuit con- cal system.
  • Page 77 OM3214 Operation - Section 32 Operator Cab and Controls Page 32-19 Body Up Indicator Backup Indicator Amber body up indicator light Amber backup indicator light (C3), when illuminated, indicates (B4) will illuminate when backup the body is not completely at rest light switch (5, Figure 32-11) is on the frame.
  • Page 78 OFF position. immediate attention is required. For diagnostic tests of a Komatsu engine equipped • Warning faults (light on) are ones that require with the Centry™ fuel control, refer to Centry™ Diag- attention in the near future, but in most nostics at the end of this section.

  • Page 79: Centry™ Fuel System Diagnostics

    OM3214 Operation - Section 32 Operator Cab and Controls Page 32-21 CENTRY™ FUEL SYSTEM Lamp test/diagnostic test switch (8, Figure 32-12) may be used to activate the Centry™ fuel system DIAGNOSTICS diagnostic codes. When the Centry™ fuel system detects a fault and service engine indicator light (D6, GENERAL OPERATION Figure 32-12) illuminates, this switch will permit iden- Service engine indicator light (D6, Figure 32-12)

  • Page 80: Exiting The Diagnostics Mode

    Operation - Section 32 OM3214 Page 32-22 Operator Cab and Controls EXITING THE DIAGNOSTICS MODE 3. If there is an active fault after releasing the switch, there will be a short pause, followed by Starting the engine or turning the key switch to the OFF the first fault code.

  • Page 81: Lubrication And Service

    Lubrication and Service Page 40-1 LUBRICATION AND SERVICE GENERAL INFORMATION Komatsu trucks are equipped with an automatic lubri- cation system. The system is designed to automatically The recommended preventive maintenance will con- deliver the proper amount of lubricant to a specified...

  • Page 82: Cooling System

    Maintenance - Section 40 OM4042 Page 40-2 Lubrication and Service COOLING SYSTEM Antifreeze Temperature Recommendations Coolant Level Check COOLING SYSTEM ANTIFREEZE Check the coolant sight gauge. If the coolant cannot be seen in the sight gauge, add coolant to the cooling sys- RECOMMENDATIONS tem before operating the truck.

  • Page 83: Lubrication Chart

    OM4042 Maintenance - Section 40 Lubrication and Service Page 40-3 LUBRICATION CHART...

  • Page 84: Hour Lube And Maintenance Checks

    Maintenance - Section 40 OM4042 Page 40-4 Lubrication and Service 10 HOUR LUBE AND MAINTENANCE CHECKS Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS MACHINE - Inspect the entire truck for leaks, worn parts, and damage.

  • Page 85: 50 Hour Lubrication And Maintenance Checks

    OM4042 Maintenance - Section 40 Lubrication and Service Page 40-5 50 HOUR LUBRICATION AND MAINTENANCE CHECKS Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS FAN - After the first 50 hours of operation (new truck or new fan installation), check the tightness of the fan mounting cap screws - 122 N·m (90 ft lbs).

  • Page 86: 100 Hour Lubrication And Maintenance Checks

    Maintenance - Section 40 OM4042 Page 40-6 Lubrication and Service 100 HOUR LUBRICATION AND MAINTENANCE CHECKS Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS HYDRAULIC SYSTEM OIL FILTERS - Change the fil- ter elements after the initial 100 hours of operation and again at 250 hours.
  • Page 87 OM4042 Maintenance - Section 40 Lubrication and Service Page 40-7 250 HOUR LUBRICATION AND MAINTENANCE CHECKS Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS ENGINE - Refer to the engine operation and mainte- nance manual for the complete specifications regard- ing the engine lube oil specifications.

  • Page 88: 250 Hour Lubrication And Maintenance Checks

    Maintenance - Section 40 OM4042 Page 40-8 Lubrication and Service 250 HOUR LUBRICATION AND MAINTENANCE CHECKS 11. GREASE RESERVOIR - Add grease to the in-frame grease reservoir. When grease is pumped out of the overflow tube, the reservoir is full. Use Lube Key D. 12.

  • Page 89: 500 Hour Lubrication And Maintenance Checks

    OM4042 Maintenance - Section 40 Lubrication and Service Page 40-9 500 HOUR LUBRICATION AND MAINTENANCE CHECKS Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS FINAL DRIVE CASE BREATHERS - Remove the breather elements from the motorized wheels. Clean or replace the elements.
  • Page 90 Maintenance - Section 40 OM4042 Page 40-10 Lubrication and Service 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS HYDRAULIC TANK - Drain the hydraulic oil, and clean the inlet strainer.
  • Page 91 OM4042 Maintenance - Section 40 Lubrication and Service Page 40-11 2500 HOUR LUBRICATION AND MAINTENANCE CHECKS Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS WHEEL MOTORS - Check for spline and gear wear. Refer to Motorized Wheel Maintenance Schedule in Section P of the shop manual.
  • Page 92 Maintenance - Section 40 OM4042 Page 40-12 Lubrication and Service 10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS WHEEL MOTORS - Clean the area around the grease ports to prevent dirt or other contaminates from entering.

  • Page 93: Automatic Lubrication System

    OM4206 06/06 Maintenance - Section 42 Automatic Lubrication System Page 42-1 AUTOMATIC LUBRICATION SYSTEM GENERAL DESCRIPTION During the down stroke, the pump cylinder is extended into the grease. Through the combination of The automatic lubrication system is a pressurized shovel action and vacuum generated in the pump cyl- lubricant delivery system which delivers a controlled inder, the grease is forced into the pump cylinder.

  • Page 94: System Components

    Maintenance - Section 42 06/06 0M4206 Page 42-2 Automatic Lubrication System Hydraulic inlet pressure must not exceed 20685 kPa (3000 psi). Exceeding the rated pressure may result in damage to system components and pos- sible personal injury. Specifications are as follows: Maximum hydraulic oil inlet pressure: .
  • Page 95 OM4206 06/06 Maintenance - Section 42 Automatic Lubrication System Page 42-3 FIGURE 42-3. AUTO LUBRICATION SYSTEM (FRONT AND REAR VIEW) 1. Vent Valve 7. Reservoir Vent Tube 13. Dirty Filter Indicator 20. Unloader Valve 2. Vent Valve/Vent Hose 8. Hydraulic Oil Return 14.
  • Page 96 Maintenance - Section 42 06/06 0M4206 Page 42-4 Automatic Lubrication System Solenoid Valve Unloader Valve Solenoid valve (19), when energized, allows oil to Unloader valve (20) is mounted on a tee fitting with flow to the hydraulic motor. pump cutoff pressure switch (21). This valve will relieve grease pressure in the pump if pressure Vent Valve exceeds 27,600 kPa (4000 psi).
  • Page 97 OM4206 06/06 Maintenance - Section 42 Automatic Lubrication System Page 42-5 FIGURE 42-4. REAR LUBRICATION INJECTORS 1. LH Lower Suspension 7. RH Anti-Sway Bar 13. RH Lower Suspension 2. LH Top Suspension 8. Rear Axle Pivot Pin 14. Grease Supply 3.

  • Page 98: System Operation

    Maintenance - Section 42 06/06 0M4206 Page 42-6 Automatic Lubrication System SYSTEM OPERATION 6. When 20685 kPa (3000 psi) grease pressure reaches pressure switch (4, Figure 42-6) set- Normal Operation ting, the switch contacts will close and energize relay K1 (12), removing power from grease Refer to Figure 42-5 and 42-6: pump solenoid valve (5) and the pump will stop.
  • Page 99 OM4206 06/06 Maintenance - Section 42 Automatic Lubrication System Page 42-7 Pressure Failure Detection Circuits 3. If a problem occurs and the system is not able to attain 13.8 MPa (2000 psi), then time delay 1. When the lubrication cycle is initiated, 24VDC module (7) will energize relay RB6-K2 after 60 flows through relay RB6-K4 (8, Figure 42-6) N.C.

  • Page 100: General Instructions

    Maintenance - Section 42 06/06 0M4206 Page 42-8 Automatic Lubrication System GENERAL INSTRUCTIONS LUBRICANT PUMP Pump Housing Oil Level LUBRICANT REQUIRED FOR SYSTEM The pump housing must be filled to the proper level Grease requirements will depend on ambient tem- with SAE 10W-30 motor oil.
  • Page 101 OM4206 06/06 Maintenance - Section 42 Automatic Lubrication System Page 42-9 FILTER AND RESERVOIR Filter Assembly Element Filter assembly (2, Figure 42-8) is mounted on right Filter assembly element (5, Figure 42-9) must be upright (1) and filters the grease when the grease replaced if bypass indicator (2) shows excessive ele- supply is refilled through the quick fill fittings.

  • Page 102: Injectors (Sl-1 Series H)

    Maintenance - Section 42 06/06 0M4206 Page 42-10 Automatic Lubrication System INJECTORS (SL-1 Series H) Injector Specifications • Each lubrication injector services only one grease point. In case of pump malfunction, each injector is equipped with a covered grease fitting allow external lubricating...

  • Page 103: Injector Operation

    OM4206 06/06 Maintenance - Section 42 Automatic Lubrication System Page 42-11 INJECTOR OPERATION STAGE 1. STAGE 3. Injector piston (2) As injector piston (2) is in its normal or completes its stroke, rest position. Dis- it pushes slide valve charge chamber (5) past passage (4), (3) is filled with lu- cutting off further ad-...

  • Page 104: System Checkout

    Maintenance - Section 42 06/06 0M4206 Page 42-12 Automatic Lubrication System SYSTEM CHECKOUT To check the solid-state timer operation without wait- ing for the normal timer setting, proceed as follows: To check system operation, not including the timer, proceed as follows: NOTE: The timer incorporates a liquid and dust-tight cover which must be in place and secured at all times 1.

  • Page 105: Preventive Maintenance Inspection

    OM4206 06/06 Maintenance - Section 42 Automatic Lubrication System Page 42-13 Lubrication Cycle Timer Adjustment 250 Hour Inspection 1. Check all grease hoses from the SL-1 injectors The timer is set at the factory for a nominal 2.5 to the lubrication points. Refer to Figure 42-2. minute (off time) interval.
  • Page 106 Maintenance - Section 42 06/06 0M4206 Page 42-14 Automatic Lubrication System d. With the system pressurized, check each NOTE: With the engine on, the lubrication system will SL-1 injector assembly. The cycle indicator activate within five minutes. System pressure will pin will be retracted inside the injector body.

  • Page 107: System Troubleshooting Chart

    OM4206 06/06 Maintenance - Section 42 Automatic Lubrication System Page 42-15 SYSTEM TROUBLESHOOTING CHART NOTE: If the following procedures do not correct the problem, contact a factory authorized service center. PROBLEM POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION Lubrication system not grounded. Correct grounding connections to pump assembly and truck chassis.
  • Page 108 Maintenance - Section 42 06/06 0M4206 Page 42-16 Automatic Lubrication System PROBLEM POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION Pump Pressure Builds No signal at solenoid. Check timer. Very Slowly Or Not At All. Turn on electric power to pump. Power Controller Does Not LED must light, pump on LED must light No electric power to controller.

  • Page 109: Major Component Description

    Specifications - Section 50 Page 50-1 MAJOR COMPONENT DESCRIPTION The Komatsu model 730E dump truck is an electric drive, off-highway, rear dump truck whose gross vehicle weight is 324,322 kg (715,000 lbs) rated for a nominal payload of 185 t (203 tons). ENGINE...
  • Page 110 Specifications - Section 50 06/06 OM5037 Page 50-2 730E MAJOR COMPONENTS...
  • Page 111 Number of Cylinders ..... . . 16 Komatsu ....223... . .59 Operating Cycle.
  • Page 112 Capacity: Standard Komatsu Body . 25,612 ..(61,000) Struck ....77 m³ ..101 yds³...
  • Page 113 OM6008 08/06 Payload Meter III - Section 60 Page 60-1 PAYLOAD METER III SECTION 60 INDEX PAYLOAD METER III ............. . .60-5 Introduction .
  • Page 114 Setting the Komatsu Distributor ........
  • Page 115 OM6008 08/06 Payload Meter III - Section 60 Page 60-3 Sorting on Date Range ............60-26 Sorting on Time Range .
  • Page 116 Payload Meter III - Section 60 08/06 OM6008 Page 60-4 NOTES...
  • Page 117 OM6008 08/06 Payload Meter III - Section 60 Page 60-5 PAYLOAD METER III INTRODUCTION Data Gathering Windows 95/98/NT software is available to down- Payload Meter III (PLM III) measures, displays and load, store, and view payload and fault information. records the weight of material being carried by an off- The PC software will download an entire truck fleet highway truck.
  • Page 118 Payload Meter III - Section 60 08/06 OM6008 Page 60-6 COMPONENT DESCRIPTION System Diagram Suspension Pressure Sensors Operator Display PLM III uses a two-wire pressure sensor. The range The speedometer/display gauge is used as a speed- for the pressure sensor is 281 kPa (4000 psi) and the ometer and payload display.
  • Page 119 Connections flag the haul cycle record. All other functions will be to this serial port need to be approved by Komatsu. normal regardless of brake lock usage. The brake Several protocol options are available and detailed...
  • Page 120 Payload Meter III - Section 60 08/06 OM6008 Page 60-8 Key Switch Input Load Lights PLM III monitors the status of the key switch. 24VDC PLM III uses load lights to indicate to the shovel indicates that the key switch is ON. Open indicates operator the approximate weight of the material in the key switch is OFF.
  • Page 121 OM6008 08/06 Payload Meter III - Section 60 Page 60-9 Wiring and Termination TCI Outputs Most of the PLM III truck connections use a heavy- The GE drive system on the 930E/960E requires duty cable. This yellow multi-conductor cable uses a information from the payload meter regarding the 16awg, finely stranded wire designed for continuous loaded condition of the truck.
  • Page 122 Payload Meter III - Section 60 08/06 OM6008 Page 60-10 OPERATOR’S DISPLAY AND SWITCH Using the Operator ID The current operator ID number is recorded with Reading the Speedometer each haul cycle. The number can be between 0 and The top window of the speedometer/display gauge is 9999.
  • Page 123 OM6008 08/06 Payload Meter III - Section 60 Page 60-11 Total Load Counter The inclinometer displays whole degrees of incline. Positive incline is truck nose up. The gauge will The total load counter records the number of loads quickly display the type of information shown every hauled since the last time it was cleared.
  • Page 124 Payload Meter III - Section 60 08/06 OM6008 Page 60-12 PAYLOAD OPERATION AND The payload meter switches from loading to maneu- vering as soon as the truck begins moving. The CALCULATION maneuvering zone is 160m and is designed to allow Description of Haul Cycle States the operator to reposition the truck under the shovel.
  • Page 125 OM6008 08/06 Payload Meter III - Section 60 Page 60-13 SOURCES FOR PAYLOAD ERROR Load Calculation The final load calculation is different from the last Payload Error swingload calculation. The accuracy of the swing load The number one source of error in payload calcula- calculation depends on loading conditions and the tion is improperly serviced suspensions.
  • Page 126 The payload meter does not compensate for these changes. NOTE: Earlier 730E and 830E models are subject to incorrect speed data due to electrical interference. The incorrect speeds are generated while the truck is stopped.
  • Page 127 OM6008 08/06 Payload Meter III - Section 60 Page 60-15 Haul Cycle Data The following information is recorded for each haul cycle: Table 1: HAUL CYCLE DATA Data Unit Remark Truck # alpha- Up to 22 characters can be stored in this field to identify the truck. Typically this field will be just the numeric truck number.
  • Page 128 Payload Meter III - Section 60 08/06 OM6008 Page 60-16 Haul Cycle Warning Flags F: Final Zone to Dumping Transition The payload meter expects haul cycles to progress in This message is generated when the payload meter a particular way. When something unexpected takes senses a body-up while it is calculating the final pay- place, the system records a warning flag.

  • Page 129: Payload Meter

    OM6008 08/06 Payload Meter III - Section 60 Page 60-17 M: Haul Cycle Too Long Sprung Weight Data The haul_cycle_too_long flag indicates that the haul The payload meter is constantly monitoring the live cycle took longer than 18.2 hours to complete. The payload calculation.
  • Page 130 Payload Meter III - Section 60 08/06 OM6008 Page 60-18 Fault Code Data Table 2: Fault Code Name Description Left front pressure high Input current > 22 ma Left front pressure low Input current < 2 ma Right front pressure high Input current >...
  • Page 131 OM6008 08/06 Payload Meter III - Section 60 Page 60-19 PC SOFTWARE OVERVIEW Installing the PLM III Software The CD ROM containing the Payload Data Manage- PC Overview ment (PDM) Software will automatically begin instal- The PC software has several basic functions: lation when it is inserted into the drive on the PC.
  • Page 132 Payload Meter III - Section 60 08/06 OM6008 Page 60-20 DOWNLOADING DATA To download the payload meter: 1. Connect to the payload meter and start the PC PLM III records many types of data. The PLM III PC software. software is designed to download the data from a whole truck fleet.
  • Page 133 OM6008 08/06 Payload Meter III - Section 60 Page 60-21 PLM III SYSTEM CONFIGURATION Short Tons: Payload is displayed in short tons, dis- tances and speeds will be displayed in Miles. Starting Communications Metric Tons: Payload is displayed in metric tons, dis- The PDM software allows users to download and tances and speeds are displayed in Kilometers.
  • Page 134 Payload Meter III - Section 60 08/06 OM6008 Page 60-22 There are also many configuration and download Setting the Date and Time options available from this screen. The connection menu is updated only when the connection is first made. It does not update automatically. To view changes made while connected, the user must close the window and reconnect to the payload meter.
  • Page 135 This field in the haul cycle record can hold the name The payload units on the lower display can be of the Komatsu distributor that helped install the sys- changed from metric to short tons or long tons using tem. Komatsu also assigns a distributor number to the truck configuration screen.
  • Page 136 Payload Meter III - Section 60 08/06 OM6008 Page 60-24 Clean Truck Tare Inclinometer Calibration The payload meter uses the clean truck tare value to The inclinometer calibration procedure is designed to calculate carry-back load for each haul cycle. The compensate for variations in the mounting attitude of carry-back stored in the haul cycle record is the new the inclinometer.
  • Page 137 The truck type is the size of the truck from the family can be narrowed by selecting which trucks or types of Komatsu trucks. This allows the user to quickly to view and for what dates and times. view results from different types of trucks on the property.
  • Page 138 Payload Meter III - Section 60 08/06 OM6008 Page 60-26 Sorting on Date Range 2. Change the From date to January 5, 2000. The default query starts in 1995 and runs through the current date on the PC. To narrow the range to a specific date, change the From and To dates.
  • Page 139 OM6008 08/06 Payload Meter III - Section 60 Page 60-27 Creating Reports Reports can be generated and viewed on the screen Date Time or printed. These reports are generated from the Jan 5, 2000 Jan 6, 2000 Jan 7, 2000 Jan 8, 2000 Jan 9, 2000 0:00...
  • Page 140 Payload Meter III - Section 60 08/06 OM6008 Page 60-28 NOTE: Some haul cycles may contain the sensor input warning flag. This indicates that one of the four pressure sensors or inclinometer was not functioning properly during the haul cycle. Haul cycles with this warning are displayed in red on the payload summary window and are not included in the summary statistics for reports or display.
  • Page 141 OM6008 08/06 Payload Meter III - Section 60 Page 60-29 Creating Graphs Exporting Data The PLM III software can generate graphs that quickly summarize payload data. These graphs can be customized for printing. Just like the reports, the graphs are generated from the query displayed on the payload summary screen.
  • Page 142 Payload Meter III - Section 60 08/06 OM6008 Page 60-30 • Maximum - frame torque • Time when the maximum - frame torque occurred • Maximum sprung weight calculation • Time when maximum sprung weight calculation occurred • Left front tire-kilometer-hour •...
  • Page 143 OM6008 08/06 Payload Meter III - Section 60 Page 60-31 Compressed Deleting Haul Cycle Records To delete haul cycle records from the main database, press the "Delete" button at the bottom of the pay- load summary screen. The program will display a summary of the records from the displayed query.
  • Page 144 Payload Meter III - Section 60 08/06 OM6008 Page 60-32 Viewing Alarms Deleting Alarm Records From the payload summary screen, click the To delete alarm records from the main database, “Alarms” button to display the alarm screen. The press the "Delete" button at the bottom of the alarm alarms are sorted by the query settings from the pay- display screen.

  • Page 145: General Receiver Functions

    OM7004 4/05 Radio / Cassette Player - Section 70 Page 70-1 RADIO / CASSETTE PLAYER FIGURE 70-1. RADIO / CASSETTE PLAYER GENERAL RECEIVER FUNCTIONS Setting The Default Display 1. Press and hold DSPL/TM (9) for two seconds Turning The Power On And Off until the hour digits flash.

  • Page 146: Setting The Time

    Radio / Cassette Player - Section 70 OM7004 4/05 Page 70-2 SETTING THE TIME SEEK Mode 1. Turn the key switch ON. Hold either the TUNE or SEEK buttons for more 2. Press and hold DSPL/TM SET (9, Figure 70-1) than 0.5 seconds to enter the seek mode.
  • Page 147 OM7004 4/05 Radio / Cassette Player - Section 70 Page 70-3 ADJUSTING THE RECEIVER SETTINGS OPERATION OF THE WEATHERBAND (U.S.) VOLUME: Rotate ON/AUDIO (6, Figure 70-1) knob clockwise to increase the volume and counter-clock- NOAA - weather radio is a service of the National Weather Service.
  • Page 148 Radio / Cassette Player - Section 70 OM7004 4/05 Page 70-4 SATELLITE RADIO Operating Satellite Radio 1. Use the BAND button to select the proper satel- To use the satellite radio function on your radio, a subscription must be ordered from a provider. There lite radio band.
  • Page 149 OM7004 4/05 Radio / Cassette Player - Section 70 Page 70-5 CASSETTE PLAYER Cassette Functions The cassette player that the radio is equipped with The 4/REV button (17) rewinds the cassette. The works best with cassettes that range from 30 to 90 cassette will continue to rewind until the button is minutes long.
  • Page 150 Radio / Cassette Player - Section 70 OM7004 4/05 Page 70-6 Bad Tape Detect Cleaning The Cassette Player If the receiver detects a bad cassette, “BAD TAPE” After 35 hours of cassette play, the display will read will appear on the display and the tape will be TP CLEAN for five seconds.
  • Page 152 ® www.komatsuamerica.com Copyright 2006 Komatsu Komatsu America Corp. Printed in U.S.A. 2300 N.E. Adams Street Peoria, IL 61639 Phone: 309-672-7577 Fax: 309-672-7072...

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