Complete Operation & Maintenance Manuals for Komatsu Dump Trucks 730E, with all the shop information to maintain & oeprate your trucks.
CEAM006700 – Dump Truck 730E Operation & Maintenance Manual.pdf
CEAM010301 – Dump Truck with Trolley Assist 730E Operation & Maintenance Manual.pdf
CEAM011001 – Dump Truck 730E Operation & Maintenance Manual.pdf
CEAM011200 – Dump Truck with Trolley Assist 730E Operation & Maintenance Manual.pdf
CEAM013300 – Dump Truck 730E Operation & Maintenance Manual.pdf
CEAM014800 – Dump Truck 730E Operation & Maintenance Manual.pdf
CEAM014901 – Dump Truck 730E Operation & Maintenance Manual.pdf
CEAM016402 – Dump Truck 730E Trolley Operation & Maintenance Manual.pdf
CEAM018100 – Dump Truck 730E Operation & Maintenance Manual.pdf
CEAM018301 – Dump Truck 730E Trolley Operation & Maintenance Manual.pdf
CEAM020001- Dump Truck 730E Operation & Maintenance Manual.pdf
CEAM020701 – Dump Truck 730E Trolley Operation & Maintenance Manual.pdf
CEAM020902 – Dump Truck 730E Operation & Maintenance Manual.pdf
CEAM022201 – Dump Truck 730E Operation & Maintenance Manual.pdf
CEAM024000 – Dump Truck 730E Trolley Operation & Maintenance Manual.pdf
CEAM024802 – Dump Truck 730E Operation & Maintenance Manual.pdf
CEAM024900 – Dump Truck 730E Trolley Operation & Maintenance Manual.pdf
CEAM025201 – Dump Truck 730E Trolley Operation & Maintenance Manual.pdf
CEAM025901 – Dump Truck 730E Operation & Maintenance Manual.pdf
CEAM026301 – Dump Truck 730E Trolley Operation & Maintenance Manual.pdf
CEAM027700 – Dump Truck 730E Operation & Maintenance Manual.pdf
CEAW004103 – Dump Truck 730E Field Assembly Manual.pdf
CEAW007800 – Dump Truck 730E-8 Field Assembly Manual.pdf
DG756 – Dump Truck 730E Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 4,311 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
INTRODUCTION . . SECTION 1
Foreword . . 10-1
ALERTS Page – a description of the DANGER, WARNING, and CAUTION symbols used in this manual. . 10-2
TABLE OF CONTENTS . . 10-3
Truck Model Illustration . . 10-6
About This Manual . . 10-7
STANDARD CHARTS and TABLES. . 12-1
SAFETY . . SECTION 2
Safety records of most organizations will show that the greatest percentage of accidents are caused by unsafe acts
of persons. The remainder are caused by unsafe mechanical or physical conditions. Report all unsafe conditions to
the proper authority. These safety rules are provided as a guide for the Komatsu truck operator. However, local
conditions and regulations may add many more to this list.
GENERAL SAFETY . . 20-1
PRECAUTIONS DURING OPERATION . . 20-4
Before Starting Engine . . 20-4
Operating Machine . . 20-4
Battery . . 20-6
Towing . . 20-7
PRECAUTIONS FOR MAINTENANCE . . 20-8
Before Carrying Out Maintenance . . 20-8
During Maintenance . . 20-8
Tires . . 20-11
ADDITIONAL JOB SITE RULES . . 20-12
WHEN REPAIRS ARE NECESSARY . . 20-13
WARNING, CAUTION, and Instruction Plates / Decals . . 22-1
OPERATION . . SECTION 3
This portion of the manual covers Identification, location, and operation of the controls, switches, and indicators in
the Operator’s Cab and use / function of these controls, switches, and indicators.
OPERATING INSTRUCTIONS
Preparing For Operation . .
Safety Is Thinking Ahead . .
At The Truck – Ground Level Walk-Around Inspection . .
ENGINE START-UP SAFETY PRACTICES . .
AFTER ENGINE HAS STARTED . . 30-5
MACHINE OPERATION SAFETY PRECAUTIONS . . 30-5
LOADING . . 30-6
HAULING . . 30-6
PASSING . . 30-7
DUMPING . . 30-7
OPERATION (Continued) . . SECTION 3
TOWING . .30-9
SAFE PARKING PROCEDURES . .30-9
SHUTDOWN PROCEDURE . .30-9
DELAYED ENGINE SHUTDOWN PROCEDURE . .30-10
SUDDEN LOSS OF ENGINE POWER . .30-10
OPERATOR CAB and CONTROLS . .32-1
STEERING WHEEL AND CONTROLS. .32-2
SERVICE BRAKE PEDAL. .32-3
DYNAMIC RETARDER PEDAL. .32-3
THROTTLE PEDAL. .32-3
HEATER / AIR CONDITIONER VENTS . .32-3
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS. .32-4
OVER HEAD PANEL AND DISPLAYS . .32-5
CENTER CONSOLE . .32-6
OPERATOR SEAT . .32-10
INSTRUMENT PANEL AND INDICATOR LIGHTS . . 32-11
Control Symbols . . 32-11
INSTRUMENT PANEL . . 32-11
PANEL GAUGES, INDICATORS, AND CONTROLS . .32-12
OVERHEAD STATUS / WARNING INDICATOR LIGHT PANEL. .32-17
INDICATOR LIGHT SYMBOLS . .32-18
Hazard Warning Lights . .32-22
Lamp Test Switch / CentryTM Diagnostic Test Switch . .32-22
CENTRYTM FUEL SYSTEM DIAGNOSTICS . .32-23
DETERMINING FAULT CODES . .32-23
EXITING THE DIAGNOSTICS MODE . .32-24
MAINTENANCE . . SECTION 4
This portion of the manual pertains mainly to the periodic Lubrication and Service required to keep the truck oper-
ating at its design potential. Routine lubrication and maintenance procedures are provided in this section. For
major repairs, refer to the appropriate section in the Truck Service Manual. Refer to the engine manufacturer’s ser-
vice manual when servicing the engine.
Lubrication and Service. .40-1
Service Capacities. .40-1
Hydraulic Tank Service . .40-1
Coolant Level Check . .40-2
Radiator Filling Procedure . .40-2
Cooling System Recommendations . .40-2
Lubrication Chart . .40-3
10 HOUR (SHIFT) Lubrication And Maintenance Checks. .40-4
50 HOUR Lubrication And Maintenance Checks . .40-6
MAINTENANCE (Continued) . . SECTION 4
100 HOUR Lubrication And Maintenance Checks . .
250 HOUR Lubrication And Maintenance Checks . .
500 HOUR Lubrication And Maintenance Checks . .
1000 HOUR Lubrication And Maintenance Checks . .
5000 HOUR Lubrication And Maintenance Checks . .
Lincoln Automatic Lubrication System (OPTIONAL) . . 42-1
General Description . . 42-3
System Components . . 42-4
System Operation. . 42-4
General Instructions . . 42-7
System Priming . . 42-7
Lubricant Pump . . 42-7
Filter and Reservoir . . 42-8
Injectors. . 42-9
System Checkout . . 42-10
24 VDC Solid State Timer Checkout & Adjustment . . 42-10
Pump Rebuild . . 42-11
Disassembly . . 42-11
Cleaning and Inspection . . 42-11
Assembly. . 42-13
Preventative Maintenance Procedure . . 42-17
SPECIFICATIONS . . SECTION 5
This portion of the manual covers major component descriptions and truck specifications.
Major Component Descriptions . . 50-1
Specifications . . 50-3
OPTIONAL EQUIPMENT . . SECTION 6 & 7
This portion of the manual covers operation/maintenance of OPTIONAL EQUIPMENT.
PAYLOAD METER III (Refer to separate PAYLOAD METER III Index) . . 60-1
RADIO, AM/FM STEREO CASSETTE. . 70-1
…
CEAM006700 – Dump Truck 730E Operation & Maintenance Manual…3
COVER…3
INTRODUCTION…8
FOREWARD…8
ALERTS…9
TABLE OF CONTENTS…10
TRUCK MODEL ILLUSTRATION…13
ABOUT THIS MANUAL…14
STANDARD CHARTS AND TABLES…16
SAFETY…22
GENERAL SAFETY RULES…22
PRECAUTIONS DURING OPERATION…26
Before Starting Engine…26
Operating Machine…27
Battery…30
Towing…31
PRECAUTIONS FOR MAINTENANCE…32
Before Carrying Out Maintenance…32
During Maintenance…33
Tires…36
ADDITIONAL JOB SITE RULES…37
WHEN REPAIRS ARE NECESSARY…38
WARNING, CAUTION, AND INSTRUCTION PLATES / DECALS…40
OPERATION…48
OPERATING INSTRUCTIONS…48
Preparing For Operation…48
Safety Is Thinking Ahead…48
At The Truck – Ground Level Walk-Around Inspection…48
ENGINE START-UP SAFETY PRACTICES…51
AFTER ENGINE HAS STARTED…52
MACHINE OPERATION SAFETY PRECAUTIONS…53
LOADING…53
HAULING…54
PASSING…54
DUMPING…55
TOWING…57
SAFE PARKING PROCEDURES…57
SHUTDOWN PROCEDURE…58
DELAYED ENGINE SHUTDOWN PROCEDURE…58
SUDDEN LOSS OF ENGINE POWER…59
OPERATOR CAB AND CONTROLS…60
STEERING WHEEL AND CONTROLS…61
SERVICE BRAKE PEDAL…62
DYNAMIC RETARDER PEDAL…62
THROTTLE PEDAL…62
HEATER / AIR CONDITIONER VENTS…62
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS…63
OVER HEAD PANEL AND DISPLAYS…64
CENTER CONSOLE…65
OPERATOR SEAT…69
INSTRUMENT PANEL AND INDICATOR LIGHTS…70
CONTROL SYMBOLS…70
INSTRUMENT PANEL…71
PANEL GAUGES, INDICATORS AND CONTROLS…71
OVER HEAD STATUS / WARNING INDICATOR LIGHT PANEL…77
INDICATOR LIGHT SYMBOLS…78
HAZARD WARNING LIGHTS…84
LAMP TEST SWITCH / CENTRY DIAGNOSTIC TEST SWITCH…84
CUMMINS ENGINE CENTRY FUEL SYSTEM DIAGNOSTICS…85
DETERMINING FAULT CODES…85
EXITING THE DIAGNOSTIC MODE…86
MAINTENANCE…88
LUBRICATION AND SERVICE…88
Service Capacities…88
Hydraulic Tank Service…88
Coolant Level Check…89
Radiator Filling Procedure…89
Cooling System Recommendations…89
Lubrication Chart…90
10 HOUR (SHIFT) Lubrication and Maintenance Checks…91
50 HOUR Lubrication and Maintenance Checks…93
100 HOUR Lubrication and Maintenance Checks …94
250 HOUR Lubrication and Maintenance Checks…95
500 HOUR Lubrication and Maintenance Checks…97
1000 HOUR Lubrication and Maintenance Checks…98
5000 HOUR Lubrication and Maintenance Checks…99
LINCOLN AUTOMATIC SYSTEM (OPTIONAL)…100
General Description…100
System Components…102
System Operation…103
General Instructions…106
System Priming…106
Lubricant Pump…106
Filter and Reservoir…107
Injectors…108
System Checkout…109
24 VDC Solid State Timer Checkout & Adjustment…109
Pump Rebuild…110
Disassembly…110
Cleaning and Inspection…110
Assembly…112
Preventative Maintenance Procedure…116
SPECIFICATIONS…118
MAJOR COMPONENT DESCRIPTION…118
SPECIFICATIONS…120
OPTIONAL EQUIPMENT…122
PAYLOAD METER II…124
General Information…124
Lights, Switches, and Components…125
Tips for Operation…126
External Display Lights…126
Theory of Operation…127
Basic Description…127
Linkage Factor…127
Brake Lock…128
Sources of Error…128
Typical Data From Service Check Mode…128
Example Calculation of Payload…129
Calculation of the Calibration Load…129
Types of Data Stored…130
Cycle Data…130
Engine ON/OFF Data…131
Fault Codes and Warning Data…131
Engine Operation…132
Total Payload and Total Number of Cycles…132
Other Data…132
Operator Functions…133
Using the Operator Load Counter…133
Description…133
Viewing the Operator Load Counter…133
Clearing the Operator Load Counter…133
Dimming the Lights on the Display…133
Initial Setup of Payload Meter…134
Switch Settings…134
Checking the Operator Check Mode…134
Checking the Service Check Mode…135
Setting "UP:00"…135
Setting "PL:00"…135
Checking the Gt Setting…135
Checking the Inclinometer Settings…135
Calibrating a Truck…136
Displays at Start-Up…137
Setup and Maintenance…138
Setting the Speed Limit…138
Setting the Option Code…138
Setting the Machine I.D…138
Setting the Operator I.D…139
Setting the Time and Date…139
Download of Payload and Fault Codes…139
Display of Fault Codes…140
Charts of Error Codes and Other Information…142
Service Check Mode…143
Monitoring Input Signals…143
UP Factor – Payload Calculation Gain…144
PL Mode – Load Calculation Timing…144
Final Gear Ration Selection…145
Battery Replacement Procedure…146
Replacing the Battery…146
After Replacing the Battery…147
Suspension Pressure Sensor…147
Removal…147
Installation…148
Inclinometer…148
Removal…148
Installation…148
Scoreboard…149
Description…149
Making Connections…149
Wiring Diagram…150
Normal Operation of the Scoreboard…151
Payload Meter Back Panel…151
Connections (AMP Pin Identification)…152
Payload Circuit Numbers…153
Payload Meter II Reinitalization Procedure…154
RADIO, AM / FM CASSETTE…156
CEAM010301 – Dump Truck with Trolley Assist 730E Operation & Maintenance Manual…163
COVER…163
INTRODUCTION…168
FOREWARD…168
ALERTS PAGE…169
TABLE OF CONTENTS…170
TRUCK MODEL ILLUSTRATION…173
ABOUT THIS MANUAL…174
STANDARD CHARTS AND TABLES…176
SAFETY…182
GENERAL SAFETY RULES…182
PRECAUTIONS DURING OPERATION…186
BEFORE STARTING ENGINE…186
OPERATING MACHINE…187
BATTERY…190
TOWING…191
PRECAUTIONS FOR MAINTENANCE…192
BEFORE CARRYING OUT MAINTENANCE…192
DURING MAINTENANCE…193
TIRES…196
ADDITIONAL JOB SITE RULES…197
WHEN REPAIRS ARE NECESSARY…198
WARNING, CAUTION, AND INSTRUCTION PLATES / DECALS…200
OPERATION…208
OPERATING INSTRUCTIONS…208
PREPARING FOR OPERATION…208
SAFETY IS THINKING AHEAD…208
AT THE TRUCK – GROUND LEVEL WALK AROUND INSPECTION…208
ENGINE START-UP SAFETY PRACTICES…212
AFTER ENGINE HAS STARTED…212
MACHINE OPERATION SAFETY PRECAUTIONS…213
LOADING…214
HAULING…214
PASSING…215
DUMPING…215
TOWING…217
SAFE PARKING PROCEDURES…217
SHUTDOWN PROCEDURE…218
DELAYED ENGINE SHUTDOWN PROCEDURE…218
SUDDEN LOSS OF POWER…219
OPERATOR CAB AND CONTROLS…220
STEERING WHEEL AND CONTROLS…221
SERVICE BRAKE PEDAL…222
DYNAMIC RETARDER PEDAL…222
THROTTLE PEDAL…222
HEATER / AIR CONDITIONER VENTS…222
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS…223
OVERHEAD PANEL AND DISPLAYS…224
CENTER CONSOLE…225
OPERATOR SEAT…229
INSTRUMENT PANEL AND INDICATOR LIGHTS…230
CONTROL SYMBOLS…230
INSTRUMENT PANEL…230
PANEL GUAGES, INDICATORS, AND CONTROLS…231
OVERHEAD STATUS / WARNING INDICATOR LIGHT PANEL…237
INDICATOR LIGHT SYMBOLS…238
TROLLEY INDICATOR LIGHTS…244
HAZARD WARNING LIGHTS…246
LAMP TEST SWITCH / CENTRY FUEL SYSTEM…246
CUMMINS ENGINE CENTRY FUEL SYSTEM DIAGNOSTICS…247
DETERMINING FAULT CODES…247
EXITING THE DIAGNOSTIC MODE…248
TROLLEY OPERATING INSTRUCTIONS…250
AFTER ENGINE HAS STARTED…250
OPERATING IN DIESEL MODE…250
OPERATING IN TROLLEY LINE MODE…251
GETTING ON LINE…251
GETTING OFF LINE…253
LINE STATUS SIGNALS…254
LINE STATUS SIGNAL MARKINGS…254
TRAFFIC CONSIDERATION FOR TROLLEY LINE OPERATION…254
APPROACHING SLOW MOVING VEHICLES WHILE ON TROLLEY…255
OPERATING SLOW MOVING VEHICLES WHILE ON TROLLEY…255
PROCEDURES FOR TRUCK BREAKDOWNS WHILE ON TROLLEY…255
MAINTENANCE…256
LUBRICATION AND SERVICE…256
SERVICE CAPACITIES…256
HYDRAULIC TANK SERVICE…256
COOLANT LEVEL CHECK…257
RADIATOR FILLING PROCEDURE…257
COOLING SYSTEM RECOMMENDATIONS…257
LUBRICATION CHART…258
10 HOUR (SHIFT) LUBRICATION AND MAINTENANCE CHECKS…259
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…261
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…262
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…263
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…265
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…266
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS…267
LINCOLN AUTOMATIC LUBRICATION SYSTEM (OPTIONAL)…268
GENERAL DESCRIPTION…268
SYSTEM COMPONENTS…270
SYSTEM OPERATION…271
GENERAL INSTRUCTIONS…274
SYSTEM PRIMING…274
LUBRICANT PUMP…274
FILTER AND RESERVOIR…275
INJECTORS…276
SYSTEM CHECKOUT…277
24 VDC SOLID STATE TIMER CHECKOUT & ADJUSTMENT…277
PUMP REBUILD…278
DISASSEMBLY…278
CLEANING AND INSPECTION…278
ASSEMBLY…280
PREVENTATIVE MAINTENANCE PROCEDURE…284
SPECIFICATIONS…286
MAJOR COMPONENT DESCRIPTIONS…286
SPECIFICATIONS…288
OPTIONAL EQUIPMENT…290
PAYLOAD METER 3…290
OPERATION SECTION…292
INTRODUCTION…292
DATA SUMMARY…292
DATA GATHERING…292
COMPONENT DESCRIPTION…293
SYSTEM DIAGRAM…293
SUSPENSION PRESSURE SENSORS…293
INCLINOMETER…293
OPERATOR DISPLAY…293
OPERATOR SWITCH…294
SPEED INPUT…294
BODY-UP SWITCH…294
BRAKE LOCK SWITCH…294
PAYLOAD METER…294
COMMUNICATIONS PORTS…294
KEYSWITCH INPUT…295
PAYLOAD METER POWER…295
LOAD LIGHTS…295
WIRING AND TERMINATION…296
TCI OUTPUTS…296
OPERATOR'S DISPLAY AND SWITCH…297
READING THE SPEEDOMETER…297
READING THE LOAD DISPLAY…297
USING THE OPERATOR ID…297
USING THE LOAD AND TON COUNTER…297
TOTAL TON COUNTER…297
TOTAL LOAD COUNTER…298
CLEARING THE COUNTERS…298
VIEWING LIVE SENSOR DATA…298
OTHER DISPLAY MESSAGES…298
PAYLOAD OPERATION & CALCULATION…299
DESCRIPTION OF HAUL CYCLES STATES…299
"STATES" OR STAGES OF A TYPICAL HAUL CYCLE…299
HAUL CYCLE DESCRIPTION…299
LOAD CALCULATION…300
CARRY BACK…300
MEASUREMENT ACCURACY…300
SOURCES FOR PAYLOAD ERROR…300
PAYLOAD ERROR…300
LOADING CONDITIONS…301
PRESSURE SENSORS…301
SWINGLOADS…301
SPEED AND DISTANCE…301
HAUL CYCLE DATA…301
HAUL CYCLE DATA…302
HAUL CYCLE WARNING FLAGS…303
ALARM RECORDS…304
FRAME TORQUE DATA…304
SPRUNG WEIGHT DATA…305
MAXIMUM SPEED DATA…305
PC SOFTWARE OVERVIEW…305
PC OVERVIEW…305
SYSTEM CONFIGURATION…305
INSTALLING THE PAYLOAD METER 3 SOFTWARE…305
DOWNLOADING DATA…306
PLM3 SYSTEM CONFIGURATION…307
STARTING COMMUNICATIONS…307
DISPLAYED PAYLOAD UNITS…307
TIME UNITS…307
CONNECTION MENU…307
CONNECTING TO THE PAYLOAD METER…308
CONFIGURE THE PAYLOAD METER…308
SETTING THE DATE AND TIME…308
SETTING THE TRUCK TYPE…309
SETTING THE GAUGE DISPLAY UNITS…309
SETTING THE FRAME SERIAL NUMBER…309
SETTING THE TRUCK NUMBER…309
SETTING THE KMS DISTRIBUTOR…309
SETTING THE KMS CUSTOMER…309
CLEAN TRUCK TARE…310
INCLINOMETER CALIBRATION…310
DATA ANALYSIS…311
CREATING A QUERY…311
SORTING ON TRUCK UNIT NUMBER…311
SORTING ON TRUCK TYPE…311
SORTING ON DATE RANGE…312
SORTING ON TIME RANGE…312
PAYLOAD DETAIL SCREEN…313
CREATING REPORTS…313
SUMMARY – ONE PAGE REPORT…314
DETAILED – MULTI-PAGE REPORT…314
CREATING GRAPHS…315
EXPORTING DATA…315
CSV EXPORT…315
COMPRESSED…316
IMPORTING DATA…317
DELETING HAUL CYCLE RECORDS…317
VIEWING ALARMS…318
DELETING ALARM RECORDS…318
RADIO, AM / FM CASSETTE…320
CEAM011001 – Dump Truck 730E Operation & Maintenance Manual…327
COVER…327
INTRODUCTION…330
FOREWORD…330
ALERTS…331
TABLE OF CONTENTS…332
TRUCK MODEL ILLUSTRATION…335
ABOUT THIS MANUAL…336
STANDARD CHARTS AND TABLES…338
SAFETY…344
GENERAL SAFETY…344
PRECAUTIONS DURING OPERATION…348
BEFORE STARTING ENGINE…348
OPERATING MACHINE…349
BATTERY…352
TOWING…353
PRECAUTIONS FOR MAINTENANCE…354
BEFORE CARRYING OUT MAINTENANCE…354
DURING MAINTENANCE…355
TIRES…358
ADDITIONAL JOB SITE RULES…359
WHEN REPAIRS ARE NECESSARY…360
WARNINGS AND CAUTIONS…362
OPERATION…370
OPERATING INSTRUCTIONS…370
Preparing for Operation…370
Safety is Thinking Ahead…370
At The Truck – Ground Level Walk Around Inspection…370
ENGINE START-UP SAFETY PRACTICES…373
AFTER ENGINE HAS STARTED…374
MACHINE OPERATION SAFETY PRECAUTIONS…375
LOADING…375
HAULING…376
PASSING…376
DUMPING…377
TOWING…379
SAFE PARKING PROCEDURES…379
ENGINE SHUTDOWN PROCEDURE…380
DELAYED ENGINE SHUTDOWN PROCEDURE…380
SUDDEN LOSS OF POWER…381
OPERATOR CAB AND CONTROLS…383
STEERING WHEEL AND CONTROLS…383
SERVICE BRAKE PEDAL…384
DYNAMIC RETARDER PEDAL…384
THROTTLE PEDAL…384
HEATER / AIR CONDITIONER VENTS…384
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS…385
OVER HEAD PANEL AND DISPLAYS…386
CENTER CONSOLE…387
OPERATOR SEAT…391
INSTRUMENT PANEL AND INDICATOR LIGHTS…392
Control Symbols…392
INSTRUMENT PANEL (Figure 3-6)…392
PANEL GAUGES, INDICATORS, AND CONTROLS (Figure 3-6)…393
OVERHEAD STATUS / WARNING INDICATOR LIGHT PANEL…399
INDICATOR LIGHT SYMBOLS…400
(9) HAZARD WARNING LIGHTS…406
(10) LAMP TEST SWITCH / Centry™ Diagnostic Test Switch…406
CENTRY™ FUEL SYSTEM DIAGNOSTICS…407
DETERMINING "FAULT" CODES…407
EXITING THE DIAGNOSTICS MODE…408
MAINTENANCE…410
LUBRICATION AND SERVICE…410
SERVICE CAPACITIES…410
HYDRAULIC TANK SERVICE…410
COOLANT LEVEL CHECK…411
RADIATOR FILLING PROCEDURE…411
COOLING SYSTEM RECOMMENDATIONS…411
LUBRICATION CHART…412
10 HOUR (SHIFT) LUBRICATION AND MAINTENANCE CHECKS…413
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…415
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…416
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…417
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…419
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…420
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS…421
LINCOLN AUTOMATIC LUBRICATION SYSTEM…422
GENERAL DESCRIPTION…422
SYSTEM COMPONENTS…424
SYSTEM OPERATION…425
GENERAL INSTRUCTIONS…428
SYSTEM PRIMING…428
LUBRICANT PUMP…428
FILTER AND RESERVOIR…429
INJECTORS…430
SYSTEM CHECKOUT…431
24 VDC SOLID STATE TIMER CHECKOUT & ADJUSTMENT…431
PUMP REBUILD…432
DISASSEMBLY…432
CLEANING AND INSPECTION…432
ASSEMBLY…434
PREVENTATIVE MAINTENANCE PROCEDURE…438
SPECIFICATIONS…440
MAJOR COMPONENT DESCRIPTION…440
SPECIFICATIONS…442
OPTIONAL EQUIPMENT…444
PAYLOAD METER III TM…444
OPERATION SECTION…446
Introduction…446
Data Summary…446
Data Gathering…446
Component Description…447
System Diagram…447
Suspension Pressure Sensors…447
Inclinometer…447
Operator Display…447
Operator Switch…448
Speed Input…448
Body-Up Switch…448
Brake Lock Switch…448
Payload Meter…448
Communications Ports…448
Keyswitch Input…449
Payload Meter Power…449
Load Lights…449
Wiring and Termination…450
TCI Outputs…450
Operator's Display and Switch…451
Reading the Speedometer…451
Reading the Load Display…451
Using the Operator ID…451
Using the Load and Ton Counter…451
Total Ton Counter…451
Total Load Counter…452
Clearing the Counters…452
Viewing Live Sensor Data…452
Other Display Messages…452
Payload Operation & Calculation…453
Description of Haul Cycle States…453
Haul Cycle Description…453
Load Calculation…454
Carry Back…454
Measurement Accuracy…454
Sources for Payload Error…454
Payload Error…454
Loading Conditions…455
Pressure Sensors…455
Swingloads…455
Speed and Distance…455
HAUL CYCLE DATA…455
Haul Cycle Data…456
Haul Cycle Warning Flags…456
Alarm Records…458
Frame Torque Data…458
Sprung Weight Data…459
Maximum Speed Data…459
PC Software Overview…459
PC Overview…459
System Configuration…459
Installing the PLMIII Software…459
Downloading Data…460
PLMIII System Configuration…461
Starting Communications…461
Displayed Payload Units…461
Time Units…461
Connection Menu…461
Connecting to the Payload Meter…462
Configure the Payload Meter…462
Setting the Date and Time…462
Setting the Truck Type…463
Setting the Gauge Display Units…463
Setting the Frame Serial Number…463
Setting the Truck Number…463
Setting the Komatsu Distributor…463
Setting the Komatsu Customer…463
Clean Truck Tare…464
Inclinometer Calibration…464
Data Analysis…465
Creating a Query…465
Sorting on Truck Unit Number…465
Sorting on Truck Type…465
Sorting on Date Range…466
Sorting on Time Range…466
Payload Detail Screen…467
Creating Reports…467
Summary – one page report…468
Detailed – multi-page report…468
Creating Graphs…469
To export data in ZIP format:…471
Importing Data…471
Deleting Haul Cycle Records…471
Viewing Alarms…472
Deleting Alarm Records…472
RADIO, AM / FM STEREO CASSETTE…474
CEAM011200 – Dump Truck with Trolley Assist 730E Operation & Maintenance Manual…481
COVER…481
INTRODUCTION…487
FOREWARD…487
ALERTS PAGE…488
TABLE OF CONTENTS…489
TRUCK MODEL ILLUSTRATION…492
ABOUT THIS MANUAL…493
STANDARD CHARTS AND TABLES…495
SAFETY…501
GENERAL SAFETY RULES…501
PRECAUTIONS DURING OPERATION…505
BEFORE STARTING ENGINE…505
OPERATING MACHINE…506
BATTERY…509
TOWING…510
PRECAUTIONS FOR MAINTENANCE…511
BEFORE CARRYING OUT MAINTENANCE…511
DURING MAINTENANCE…512
TIRES…515
ADDITIONAL JOB SITE RULES…516
WHEN REPAIRS ARE NECESSARY…517
WARNING, CAUTION, AND INSTRUCTION PLATES / DECALS…519
OPERATION…527
OPERATING INSTRUCTIONS…527
PREPARING FOR OPERATION…527
SAFETY IS THINKING AHEAD…527
AT THE TRUCK – GROUND LEVEL WALK AROUND INSPECTION…527
ENGINE START-UP SAFETY PRACTICES…531
AFTER ENGINE HAS STARTED…531
MACHINE OPERATION SAFETY PRECAUTIONS…532
LOADING…533
HAULING…533
PASSING…534
DUMPING…534
TOWING…536
SAFE PARKING PROCEDURES…536
SHUTDOWN PROCEDURE…537
DELAYED ENGINE SHUTDOWN PROCEDURE…537
SUDDEN LOSS OF POWER…538
OPERATOR CAB AND CONTROLS…539
STEERING WHEEL AND CONTROLS…540
SERVICE BRAKE PEDAL…541
DYNAMIC RETARDER PEDAL…541
THROTTLE PEDAL…541
HEATER / AIR CONDITIONER VENTS…541
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS…542
OVERHEAD PANEL AND DISPLAYS…543
CENTER CONSOLE…544
OPERATOR SEAT…548
INSTRUMENT PANEL AND INDICATOR LIGHTS…549
CONTROL SYMBOLS…549
INSTRUMENT PANEL…549
PANEL GUAGES, INDICATORS, AND CONTROLS…550
OVERHEAD STATUS / WARNING INDICATOR LIGHT PANEL…556
INDICATOR LIGHT SYMBOLS…557
TROLLEY INDICATOR LIGHTS…563
HAZARD WARNING LIGHTS…565
LAMP TEST SWITCH / CENTRY FUEL SYSTEM…565
CUMMINS ENGINE CENTRY FUEL SYSTEM DIAGNOSTICS…566
DETERMINING FAULT CODES…566
EXITING THE DIAGNOSTIC MODE…567
TROLLEY OPERATING INSTRUCTIONS…569
AFTER ENGINE HAS STARTED…569
OPERATING IN DIESEL MODE…569
OPERATING IN TROLLEY LINE MODE…570
GETTING ON LINE…570
GETTING OFF LINE…572
LINE STATUS SIGNALS…573
LINE STATUS SIGNAL MARKINGS…573
TRAFFIC CONSIDERATION FOR TROLLEY LINE OPERATION…573
APPROACHING SLOW MOVING VEHICLES WHILE ON TROLLEY…574
OPERATING SLOW MOVING VEHICLES WHILE ON TROLLEY…574
PROCEDURES FOR TRUCK BREAKDOWNS WHILE ON TROLLEY…574
MAINTENANCE…575
LUBRICATION AND SERVICE…575
SERVICE CAPACITIES…575
HYDRAULIC TANK SERVICE…575
COOLANT LEVEL CHECK…576
RADIATOR FILLING PROCEDURE…576
COOLING SYSTEM RECOMMENDATIONS…576
LUBRICATION CHART…577
10 HOUR (SHIFT) LUBRICATION AND MAINTENANCE CHECKS…578
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…580
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…581
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…582
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…584
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…585
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS…586
LINCOLN AUTOMATIC LUBRICATION SYSTEM (OPTIONAL)…587
GENERAL DESCRIPTION…587
SYSTEM COMPONENTS…589
SYSTEM OPERATION…590
GENERAL INSTRUCTIONS…593
SYSTEM PRIMING…593
LUBRICANT PUMP…593
FILTER AND RESERVOIR…594
INJECTORS…595
SYSTEM CHECKOUT…596
24 VDC SOLID STATE TIMER CHECKOUT & ADJUSTMENT…596
PUMP REBUILD…597
DISASSEMBLY…597
CLEANING AND INSPECTION…597
ASSEMBLY…599
PREVENTATIVE MAINTENANCE PROCEDURE…603
SPECIFICATIONS…605
MAJOR COMPONENT DESCRIPTIONS…605
SPECIFICATIONS…607
OPTIONAL EQUIPMENT…609
PAYLOAD METER 3…609
OPERATION SECTION…611
INTRODUCTION…611
DATA SUMMARY…611
DATA GATHERING…611
COMPONENT DESCRIPTION…612
SYSTEM DIAGRAM…612
SUSPENSION PRESSURE SENSORS…612
INCLINOMETER…612
OPERATOR DISPLAY…612
OPERATOR SWITCH…613
SPEED INPUT…613
BODY-UP SWITCH…613
BRAKE LOCK SWITCH…613
PAYLOAD METER…613
COMMUNICATIONS PORTS…613
KEYSWITCH INPUT…614
PAYLOAD METER POWER…614
LOAD LIGHTS…614
WIRING AND TERMINATION…615
TCI OUTPUTS…615
OPERATOR'S DISPLAY AND SWITCH…616
READING THE SPEEDOMETER…616
READING THE LOAD DISPLAY…616
USING THE OPERATOR ID…616
USING THE LOAD AND TON COUNTER…616
TOTAL TON COUNTER…616
TOTAL LOAD COUNTER…617
CLEARING THE COUNTERS…617
VIEWING LIVE SENSOR DATA…617
OTHER DISPLAY MESSAGES…617
PAYLOAD OPERATION & CALCULATION…618
DESCRIPTION OF HAUL CYCLES STATES…618
"STATES" OR STAGES OF A TYPICAL HAUL CYCLE…618
HAUL CYCLE DESCRIPTION…618
LOAD CALCULATION…619
CARRY BACK…619
MEASUREMENT ACCURACY…619
SOURCES FOR PAYLOAD ERROR…619
PAYLOAD ERROR…619
LOADING CONDITIONS…620
PRESSURE SENSORS…620
SWINGLOADS…620
SPEED AND DISTANCE…620
HAUL CYCLE DATA…620
HAUL CYCLE DATA…621
HAUL CYCLE WARNING FLAGS…622
ALARM RECORDS…623
FRAME TORQUE DATA…623
SPRUNG WEIGHT DATA…624
MAXIMUM SPEED DATA…624
PC SOFTWARE OVERVIEW…624
PC OVERVIEW…624
SYSTEM CONFIGURATION…624
INSTALLING THE PAYLOAD METER 3 SOFTWARE…624
DOWNLOADING DATA…625
PLMIII SYSTEM CONFIGURATION…626
STARTING COMMUNICATIONS…626
DISPLAYED PAYLOAD UNITS…626
TIME UNITS…626
CONNECTION MENU…626
CONNECTING TO THE PAYLOAD METER…627
CONFIGURE THE PAYLOAD METER…627
SETTING THE DATE AND TIME…627
SETTING THE TRUCK TYPE…628
SETTING THE GAUGE DISPLAY UNITS…628
SETTING THE FRAME SERIAL NUMBER…628
SETTING THE TRUCK NUMBER…628
SETTING THE KMS DISTRIBUTOR…628
SETTING THE KMS CUSTOMER…628
CLEAN TRUCK TARE…629
INCLINOMETER CALIBRATION…629
DATA ANALYSIS…630
CREATING A QUERY…630
SORTING ON TRUCK UNIT NUMBER…630
SORTING ON TRUCK TYPE…630
SORTING ON DATE RANGE…631
SORTING ON TIME RANGE…631
PAYLOAD DETAIL SCREEN…632
CREATING REPORTS…632
SUMMARY – ONE PAGE REPORT…633
DETAILED – MULTI-PAGE REPORT…633
CREATING GRAPHS…634
EXPORTING DATA…634
CSV EXPORT…634
COMPRESSED…635
IMPORTING DATA…636
DELETING HAUL CYCLE RECORDS…636
VIEWING ALARMS…637
DELETING ALARM RECORDS…637
RADIO, AM / FM CASSETTE…639
CEAM013300 – Dump Truck 730E Operation & Maintenance Manual…647
COVER…647
INTRODUCTION…650
FOREWORD…650
ALERTS…651
TABLE OF CONTENTS…652
TRUCK MODEL ILLUSTRATION…655
ABOUT THIS MANUAL…656
STANDARD CHARTS AND TABLES…658
SAFETY…664
GENERAL SAFETY…664
PRECAUTIONS DURING OPERATION…668
BEFORE STARTING ENGINE…668
OPERATING MACHINE…669
BATTERY…672
TOWING…673
PRECAUTIONS FOR MAINTENANCE…674
BEFORE CARRYING OUT MAINTENANCE…674
DURING MAINTENANCE…675
TIRES…678
ADDITIONAL JOB SITE RULES…679
WHEN REPAIRS ARE NECESSARY…680
WARNINGS AND CAUTIONS…682
OPERATION…690
OPERATING INSTRUCTIONS…690
Preparing for Operation…690
Safety is Thinking Ahead…690
At The Truck – Ground Level Walk Around Inspection…690
ENGINE START-UP SAFETY PRACTICES…693
AFTER ENGINE HAS STARTED…694
MACHINE OPERATION SAFETY PRECAUTIONS…695
LOADING…695
HAULING…696
PASSING…696
DUMPING…697
TOWING…699
SAFE PARKING PROCEDURES…699
ENGINE SHUTDOWN PROCEDURE…700
DELAYED ENGINE SHUTDOWN PROCEDURE…700
SUDDEN LOSS OF POWER…701
OPERATOR CAB AND CONTROLS…703
STEERING WHEEL AND CONTROLS…703
SERVICE BRAKE PEDAL…704
DYNAMIC RETARDER PEDAL…704
THROTTLE PEDAL…704
HEATER / AIR CONDITIONER VENTS…704
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS…705
OVER HEAD PANEL AND DISPLAYS…706
CENTER CONSOLE…707
OPERATOR SEAT…711
INSTRUMENT PANEL AND INDICATOR LIGHTS…712
Control Symbols…712
INSTRUMENT PANEL (Figure 3-6)…712
PANEL GAUGES, INDICATORS, AND CONTROLS (Figure 3-6)…713
OVERHEAD STATUS / WARNING INDICATOR LIGHT PANEL…719
INDICATOR LIGHT SYMBOLS…720
(9) HAZARD WARNING LIGHTS…726
(10) LAMP TEST SWITCH / Centry™ Diagnostic Test Switch…726
CENTRY™ FUEL SYSTEM DIAGNOSTICS…727
DETERMINING "FAULT" CODES…727
EXITING THE DIAGNOSTICS MODE…728
MAINTENANCE…730
LUBRICATION AND SERVICE…730
SERVICE CAPACITIES…730
HYDRAULIC TANK SERVICE…730
COOLANT LEVEL CHECK…731
RADIATOR FILLING PROCEDURE…731
COOLING SYSTEM RECOMMENDATIONS…731
LUBRICATION CHART…732
10 HOUR (SHIFT) LUBRICATION AND MAINTENANCE CHECKS…733
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…735
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…736
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…737
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…739
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…740
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS…741
LINCOLN AUTOMATIC LUBRICATION SYSTEM…742
GENERAL DESCRIPTION…742
SYSTEM COMPONENTS…744
SYSTEM OPERATION…745
GENERAL INSTRUCTIONS…748
SYSTEM PRIMING…748
LUBRICANT PUMP…748
FILTER AND RESERVOIR…749
INJECTORS…750
SYSTEM CHECKOUT…751
24 VDC SOLID STATE TIMER CHECKOUT & ADJUSTMENT…751
PUMP REBUILD…752
DISASSEMBLY…752
CLEANING AND INSPECTION…752
ASSEMBLY…754
PREVENTATIVE MAINTENANCE PROCEDURE…758
SPECIFICATIONS…760
MAJOR COMPONENT DESCRIPTION…760
SPECIFICATIONS…762
OPTIONAL EQUIPMENT…764
PAYLOAD METER III TM…764
OPERATION SECTION…766
Introduction…766
Data Summary…766
Data Gathering…766
Component Description…767
System Diagram…767
Suspension Pressure Sensors…767
Inclinometer…767
Operator Display…767
Operator Switch…768
Speed Input…768
Body-Up Switch…768
Brake Lock Switch…768
Payload Meter…768
Communications Ports…768
Keyswitch Input…769
Payload Meter Power…769
Load Lights…769
Wiring and Termination…770
TCI Outputs…770
Operator's Display and Switch…771
Reading the Speedometer…771
Reading the Load Display…771
Using the Operator ID…771
Using the Load and Ton Counter…771
Total Ton Counter…771
Total Load Counter…772
Clearing the Counters…772
Viewing Live Sensor Data…772
Other Display Messages…772
Payload Operation & Calculation…773
Description of Haul Cycle States…773
Haul Cycle Description…773
Load Calculation…774
Carry Back…774
Measurement Accuracy…774
Sources for Payload Error…774
Payload Error…774
Loading Conditions…775
Pressure Sensors…775
Swingloads…775
Speed and Distance…775
HAUL CYCLE DATA…775
Haul Cycle Data…776
Haul Cycle Warning Flags…776
Alarm Records…778
Frame Torque Data…778
Sprung Weight Data…779
Maximum Speed Data…779
PC Software Overview…779
PC Overview…779
System Configuration…779
Installing the PLMIII Software…779
Downloading Data…780
PLMIII System Configuration…781
Starting Communications…781
Displayed Payload Units…781
Time Units…781
Connection Menu…781
Connecting to the Payload Meter…782
Configure the Payload Meter…782
Setting the Date and Time…782
Setting the Truck Type…783
Setting the Gauge Display Units…783
Setting the Frame Serial Number…783
Setting the Truck Number…783
Setting the Komatsu Distributor…783
Setting the Komatsu Customer…783
Clean Truck Tare…784
Inclinometer Calibration…784
Data Analysis…785
Creating a Query…785
Sorting on Truck Unit Number…785
Sorting on Truck Type…785
Sorting on Date Range…786
Sorting on Time Range…786
Payload Detail Screen…787
Creating Reports…787
Summary – one page report…788
Detailed – multi-page report…788
Creating Graphs…789
To export data in ZIP format:…791
Importing Data…791
Deleting Haul Cycle Records…791
Viewing Alarms…792
Deleting Alarm Records…792
RADIO, AM / FM STEREO CASSETTE…794
CEAM014800 – Dump Truck 730E Operation & Maintenance Manual…801
COVER…801
INTRODUCTION…804
FOREWORD…804
ALERTS…801
TABLE OF CONTENTS…806
TRUCK MODEL ILLUSTRATION…809
ABOUT THIS MANUAL…810
STANDARD CHARTS AND TABLES…812
SAFETY…818
GENERAL SAFETY…818
PRECAUTIONS DURING OPERATION…821
BEFORE STARTING ENGINE…821
OPERATING MACHINE…821
BATTERY…823
TOWING…824
PRECAUTIONS FOR MAINTENANCE…825
BEFORE CARRYING OUT MAINTENANCE…825
DURING MAINTENANCE…825
TIRES…828
ADDITIONAL JOB SITE RULES…829
WHEN REPAIRS ARE NECESSARY…830
WARNINGS AND CAUTIONS…832
OPERATION…840
OPERATING INSTRUCTIONS…840
Preparing for Operation…840
Safety is Thinking Ahead…840
At The Truck – Ground Level Walk Around Inspection…840
ENGINE START-UP SAFETY PRACTICES…843
AFTER ENGINE HAS STARTED…844
MACHINE OPERATION SAFETY PRECAUTIONS…844
LOADING…845
HAULING…845
PASSING…846
DUMPING…846
TOWING…848
SAFE PARKING PROCEDURES…848
ENGINE SHUTDOWN PROCEDURE…848
DELAYED ENGINE SHUTDOWN PROCEDURE…849
SUDDEN LOSS OF POWER…849
OPERATOR CAB AND CONTROLS…850
STEERING WHEEL AND CONTROLS…851
SERVICE BRAKE PEDAL…852
DYNAMIC RETARDER PEDAL…852
THROTTLE PEDAL…852
HEATER / AIR CONDITIONER VENTS…852
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS…853
OVER HEAD PANEL AND DISPLAYS…854
CENTER CONSOLE…855
OPERATOR SEAT…859
INSTRUMENT PANEL AND INDICATOR LIGHTS…860
Control Symbols…860
INSTRUMENT PANEL…860
PANEL GAUGES, INDICATORS, AND CONTROLS (Figure 3-11)…861
OVERHEAD STATUS / WARNING INDICATOR LIGHT PANEL…866
INDICATOR LIGHT SYMBOLS…867
(9) HAZARD WARNING LIGHTS…871
(10) LAMP TEST SWITCH / Centry™ Diagnostic Test Switch…871
CENTRY™ FUEL SYSTEM DIAGNOSTICS…872
DETERMINING "FAULT" CODES…872
EXITING THE DIAGNOSTICS MODE…873
MAINTENANCE…874
LUBRICATION AND SERVICE…874
SERVICE CAPACITIES…874
HYDRAULIC TANK SERVICE…874
COOLANT LEVEL CHECK…875
RADIATOR FILLING PROCEDURE…875
COOLING SYSTEM RECOMMENDATIONS…875
LUBRICATION CHART…876
10 HOUR (SHIFT) LUBRICATION AND MAINTENANCE CHECKS…877
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…879
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…879
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…880
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…882
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…883
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS…883
LINCOLN AUTOMATIC LUBRICATION SYSTEM…884
GENERAL DESCRIPTION…884
SYSTEM COMPONENTS…886
SYSTEM OPERATION…887
GENERAL INSTRUCTIONS…890
SYSTEM PRIMING…890
LUBRICANT PUMP…890
FILTER AND RESERVOIR…891
INJECTORS…892
SYSTEM CHECKOUT…893
24 VDC SOLID STATE TIMER CHECKOUT & ADJUSTMENT…893
PUMP REBUILD…894
DISASSEMBLY…894
CLEANING AND INSPECTION…894
ASSEMBLY…896
PREVENTATIVE MAINTENANCE PROCEDURE…900
SPECIFICATIONS…902
MAJOR COMPONENT DESCRIPTION…902
SPECIFICATIONS…904
OPTIONAL EQUIPMENT…906
PAYLOAD METER III TM…906
INDEX…906
OPERATION SECTION…908
Introduction…908
Data Summary…908
Data Gathering…908
Component Description…909
System Diagram…909
Suspension Pressure Sensors…909
Inclinometer…909
Operator Display…909
Operator Switch…910
Speed Input…910
Body-Up Switch…910
Brake Lock Switch…910
Payload Meter…910
Communications Ports…910
Keyswitch Input…911
Payload Meter Power…911
Load Lights…911
Wiring and Termination…912
TCI Outputs…912
Operator's Display and Switch…913
Reading the Speedometer…913
Reading the Load Display…913
Using the Operator ID…913
Using the Load and Ton Counter…913
Total Ton Counter…913
Total Load Counter…914
Clearing the Counters…914
Viewing Live Sensor Data…914
Other Display Messages…914
Payload Operation & Calculation…915
Description of Haul Cycle States…915
Haul Cycle Description…915
Load Calculation…916
Carry Back…916
Measurement Accuracy…916
Sources for Payload Error…916
Payload Error…916
Loading Conditions…917
Pressure Sensors…917
Swingloads…917
Speed and Distance…917
HAUL CYCLE DATA…917
Haul Cycle Data…918
Haul Cycle Warning Flags…918
Alarm Records…920
Frame Torque Data…920
Sprung Weight Data…921
Maximum Speed Data…921
PC Software Overview…921
PC Overview…921
System Configuration…921
Installing the PLMIII Software…921
Downloading Data…922
PLMIII System Configuration…923
Starting Communications…923
Displayed Payload Units…923
Time Units…923
Connection Menu…923
Connecting to the Payload Meter…924
Configure the Payload Meter…924
Setting the Date and Time…924
Setting the Truck Type…925
Setting the Gauge Display Units…925
Setting the Frame Serial Number…925
Setting the Truck Number…925
Setting the Komatsu Distributor…925
Setting the Komatsu Customer…925
Clean Truck Tare…926
Inclinometer Calibration…926
Data Analysis…927
Creating a Query…927
Sorting on Truck Unit Number…927
Sorting on Truck Type…927
Sorting on Date Range…928
Sorting on Time Range…928
Payload Detail Screen…929
Creating Reports…929
Summary – one page report…930
Detailed – multi-page report…930
Creating Graphs…931
To export data in ZIP format:…933
Importing Data…933
Deleting Haul Cycle Records…933
Viewing Alarms…934
Deleting Alarm Records…934
RADIO, AM / FM STEREO CASSETTE…936
CEAM014901 – Dump Truck 730E Operation & Maintenance Manual…943
COVER…943
SECTION 10 – INTRODUCTION…949
FOREWORD…949
TRUCK MODEL ILLUSTRATION…950
ABOUT THIS MANUAL…951
ALERTS PAGE…952
TABLE OF CONTENTS…953
SECTION 12 – STANDARD CHARTS AND TABLES…959
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…959
STANDARD ASSEMBLY TORQUES For 12-Point, Grade 9 Cap screws (SAE)…960
STANDARD ASSEMBLY TORQUES For Class 10.9 Cap screws & Class 10 Nuts…960
SECTION 20 – GENERAL SAFETY…965
PERSONAL SAFETY…965
Safety Rules…965
Truck Safety Features…965
Clothing And Personal Items…965
Unauthorized Modification…965
Leaving The Operator’s Seat…965
Mounting And Dismounting…965
Fire Extinguishers And First Aid Kits…966
Precautions For High Temperature Fluids…966
Asbestos Dust Hazard Prevention…966
Fire Prevention For Fuel And Oil…966
ROPS Precautions…967
Preventing Injury From Work Equipment…967
Precautions For Optional Attachments…967
Precautions When Starting The Machine…967
PRECAUTIONS FOR TRUCK OPERATION…968
Safety Is Thinking Ahead…968
Safety At The Work Site…968
Fire Prevention…968
Preparing For Operation…968
Ventilation For Enclosed Areas…968
Mirrors, Windows, And Lights…968
In The Operator’s Cab – Before Starting The Engine…969
OPERATING THE MACHINE…969
Starting The Engine…969
Truck Operation – General…969
Traveling In The Truck…970
Precautions When Traveling In Reverse…970
Traveling On Slopes…970
Ensuring Good Visibility…971
Operating On Snow…971
Avoid Damage To The Dump Body…971
Driving Near High-Voltage Cables…971
When Loading The Truck…971
When Dumping…971
Working On Loose Ground…971
Parking The Machine…972
TOWING…972
WORKING NEAR BATTERIES…972
Battery Hazard Prevention…972
Jump-Starting With Booster Cables…972
PRECAUTIONS FOR MAINTENANCE…973
BEFORE PERFORMING MAINTENANCE…973
Stopping The Engine Before Service…973
Warning Tag…973
Proper Tools…973
Securing The Dump Body…973
DURING MAINTENANCE…974
Personnel…974
Attachments…974
Working Under The Machine…974
Keeping The Machine Clean…974
Rules To Follow When Adding Fuel Or Oil…974
Radiator Coolant Level…974
Use Of Lighting…974
Precautions With The Battery…975
Handling High-Pressure Hoses…975
Precautions With High-Pressure Oil…975
Maintenance Near High Temperatures And High Pressures…975
Rotating Fan And Belts…975
Waste Materials…975
TIRES…976
Handling Tires…976
Tire Maintenance…976
Storing Tires After Removal…976
ADDITIONAL JOB SITE RULES…977
WHEN REPAIRS ARE NECESSARY…978
SECTION 22 – WARNINGS AND CAUTIONS…981
SECTION 30 – OPERATING INSTRUCTIONS…989
PREPARING FOR OPERATION…989
SAFETY IS THINKING AHEAD…989
WALK-AROUND INSPECTION…989
ENGINE START-UP…993
AFTER ENGINE HAS STARTED…993
MACHINE OPERATION SAFETY PRECAUTIONS…994
LOADING…995
HAULING…995
PASSING…995
DUMPING…996
To Raise The Dump Body:…996
To Lower The Dump Body: (When dumping over a berm or into a crusher):…996
To Lower The Dump Body (When dumping on flat ground):…997
TOWING…997
SAFE PARKING PROCEDURES…998
ENGINE SHUTDOWN PROCEDURE…998
DELAYED ENGINE SHUTDOWN PROCEDURE…998
SUDDEN LOSS OF POWER…999
EMERGENCY STEERING SYSTEM…1000
Operation…1000
Testing…1000
SECTION 32 – OPERATOR CAB AND CONTROLS…1001
STEERING WHEEL AND CONTROLS…1002
STEERING WHEEL…1002
HORN BUTTON…1002
TILT/TELESCOPE LEVER…1002
M ULTI-FUNCTION TURN SIGNAL SWITCH…1002
Turn Signal Operation…1002
High Beam Headlight Operation…1002
Windshield Wiper Operation…1002
PEDALS…1003
SERVICE BRAKE PEDAL…1003
DYNAMIC RETARDER PEDAL…1003
Optional – Dual Function/Single Pedal…1003
THROTTLE PEDAL…1003
CAB CLIMATE CONTROL…1004
HEATER/AIR CONDITIONER VENTS…1004
HEATER/AIR CONDITIONER CONTROLS AND VENTS…1004
Defroster Vent Control Switch…1004
Heat Control Switch…1004
Temperature Control Knob…1004
Fan Control Knob…1004
Heater/Air Conditioner Selector Switch…1004
Heater/Air Conditioner Vents…1004
OVERHEAD PANEL CONTROLS AND COMPONENTS…1005
GRADE/SPEED WARNING CHART…1005
RADIO SPEAKERS…1005
WARNING ALARM BUZZER…1005
CAB RADIO…1005
WARNING LIGHTS DIMMER CONTROL…1005
WARNING/STATUS INDICATOR LIGHT PANEL…1005
AIR CLEANER VACUUM GAUGES…1005
WINDSHIELD WIPERS…1005
CENTER CONSOLE…1006
TRUCK CONTROLS…1006
F-N-R Selector Switch…1006
Hoist Control Lever…1007
CONSOLE SWITCHES AND CONTROLS…1007
Ashtray…1007
Cigarette Lighter…1007
Left-Hand Window Control Switch…1007
Right-Hand Window Control Switch…1007
Engine Shutdown Switch…1007
Override Switch…1007
Retard Speed Control (RSC) Switch…1007
Retard Speed Control (RSC) Dial…1008
Statex III Download Port…1008
Engine Diagnostic Port (CENSE)…1008
Modular Mining Port…1008
Modular mining port (15, Figure 32-7) is used if the optional modular mining system is installed on the truck…1008
Passenger Seat…1008
Engine Diagnostic Connectors…1008
Engine Diagnostics Connector…1008
Data Storage Button…1008
PAYLOAD METER…1009
Payload Meter Download Connector…1009
OPERATOR SEAT…1010
ADJUSTMENT…1010
INSTRUMENT PANEL…1011
GENERAL INFORMATION…1011
CONTROL SYMBOLS…1011
CONTROL SWITCHES AND GAUGES…1012
Key Switch…1012
Engine Shutdown Switch With Timer Delay…1013
Fog Light Switch…1013
Ladder Light Switch…1013
Backup Light Switch…1013
Backup light switch (5, Figure 32-11) allows the backup lights to be turned ON providing added visibility and safety when the se….1013
Panel Illumination Lights…1013
Cab Air Conditioner/Heater Vents…1013
Engine Cold Weather Starting Aid Switch…1013
Rotating Beacon Light Switch…1013
Heated Mirror Switch…1013
Wheel Brake Lock Switch…1013
Parking Brake Switch…1014
Digital Tachometer…1014
Right Turn Signal Indicator Light…1014
High Beam Headlight Indicator Light…1014
Left Turn Signal Indicator Light…1014
Digital Speedometer/Payload Meter Display…1014
Voltmeter Gauge…1015
Engine Oil Pressure Gauge…1015
Engine Water Temperature Gauge…1015
Fuel Gauge…1015
Engine Hourmeter…1015
Headlight Switch…1015
Panel Illumination Lights Dimmer Rheostat…1015
Payload Meter Switch…1015
OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL…1016
DESCRIPTION OF INDICATOR SYMBOLS…1016
INDICATOR LIGHT FUNCTIONS…1017
High Hydraulic Oil Temperature…1017
Low Steering Pressure…1017
Low Accumulator Precharge Pressure Warning…1017
Electric System Fault Warning…1018
Low Brake Pressure Indicator…1018
Low Hydraulic Tank Level…1018
Low Automatic Lubrication System Pressure…1018
Circuit Breaker Tripped…1018
Hydraulic Oil Filter…1018
Low Fuel Indicator…1018
Parking Brake Indicator…1018
Service Brake Indicator…1018
Body Up Indicator…1019
Dynamic Retarding Indicator…1019
Stop Engine Warning…1019
Backup Indicator…1019
Engine Shutdown Timer Switch- Five Minute Idle…1019
Retard Speed Control…1019
Service Engine Indicator (AEM)…1019
High Wheel Motor Temperature Indicator…1019
Blower Fault Warning…1020
Service Engine Indicator (CENSE)…1020
Komatsu Engines w/Centry™ Fuel Control…1020
Hazard Warning Light Switch…1020
Lamp Test Switch/Centry™ Diagnostic Test Switch…1020
CENTRY™ FUEL SYSTEM DIAGNOSTICS…1021
GENERAL OPERATION…1021
DETERMINING FAULT CODES…1021
EXITING THE DIAGNOSTICS MODE…1022
SECTION 40 – LUBRICATION AND SERVICE…1023
GENERAL INFORMATION…1023
HYDRAULIC TANK SERVICE…1023
Adding Oil…1023
COOLING SYSTEM…1024
Coolant Level Check…1024
Radiator Filling Procedure…1024
Antifreeze Temperature Recommendations…1024
LUBRICATION CHART…1025
10 HOUR LUBE AND MAINTENANCE CHECKS…1026
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…1027
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…1028
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…1029
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…1031
1,000 HOUR LUBRICATION AND MAINTENANCE CHECKS…1032
1,500 HOUR LUBRICATION AND MAINTENANCE CHECKS…1032
2,500 HOUR LUBRICATION AND MAINTENANCE CHECKS…1033
5,000 HOUR LUBRICATION AND MAINTENANCE CHECKS…1033
10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS…1034
SECTION 42 – AUTOMATIC LUBRICATION SYSTEM…1035
GENERAL DESCRIPTION…1035
SYSTEM COMPONENTS…1036
Filter Assembly…1036
Hydraulic Motor and Grease Pump…1036
Reservoir…1036
Fixed Pressure Reducing Valve…1036
Flow Control Valve…1036
Solenoid Valve…1038
Vent Valve…1038
Time Delay Module…1038
Pump Cutoff Pressure Switch…1038
Unloader Valve…1038
Pressure Switch…1038
Pressure Gauge…1038
Manual Override Button…1038
Injectors…1038
SYSTEM OPERATION…1040
Normal Operation…1040
Pressure Failure Detection Circuits…1041
GENERAL INSTRUCTIONS…1042
LUBRICANT REQUIRED FOR SYSTEM…1042
SYSTEM PRIMING…1042
LUBRICANT PUMP…1042
Pump Housing Oil Level…1042
Pump Pressure Control…1042
FILTER AND RESERVOIR…1043
Filter Assembly Element…1043
INJECTORS (SL-1 Series H)…1044
Injector Specifications…1044
Injector Adjustment…1044
INJECTOR OPERATION…1045
SYSTEM CHECKOUT…1046
Lubrication Cycle Timer Check…1046
Lubrication Cycle Timer Adjustment…1047
PREVENTIVE MAINTENANCE INSPECTION…1047
10 Hour Lubrication System Inspection…1047
250 Hour Inspection…1047
1000 Hour Inspection…1048
SYSTEM TROUBLESHOOTING CHART…1049
SECTION 50 – MAJOR COMPONENT DESCRIPTION…1051
SECTION 60 – PAYLOAD METER III…1055
PAYLOAD METER III…1059
Introduction…1059
Data Summary…1059
Data Gathering…1059
COMPONENT DESCRIPTION…1060
System Diagram…1060
Suspension Pressure Sensors…1060
Inclinometer…1060
Operator Display…1060
Payload Operator Switch…1061
Speed Input…1061
Body-Up Switch…1061
Brake Lock Switch…1061
Payload Meter…1061
Communications Ports…1061
Key Switch Input…1062
Payload Meter Power…1062
Load Lights…1062
Wiring and Termination…1063
TCI Outputs…1063
OPERATOR’S DISPLAY AND SWITCH…1064
Reading the Speedometer…1064
Reading the Load Display…1064
Using the Operator ID…1064
Using the Load and Ton Counter…1064
Total Ton Counter…1064
Total Load Counter…1065
Clearing the Counters…1065
Viewing Live Sensor Data…1065
Other Display Messages…1065
PAYLOAD OPERATION AND CALCULATION…1066
Description of Haul Cycle States…1066
Haul Cycle Description…1066
Load Calculation…1067
Carry Back…1067
Measurement Accuracy…1067
SOURCES FOR PAYLOAD ERROR…1067
Payload Error…1067
Loading Conditions…1068
Pressure Sensors…1068
Swingloads…1068
Speed and Distance…1068
HAUL CYCLE DATA…1068
Haul Cycle Data…1069
Haul Cycle Warning Flags…1070
M: Haul Cycle Too Long…1071
N: Sensor Input Error…1071
Frame Torque Data…1071
Sprung Weight Data…1071
Maximum Speed Data…1071
Alarm Records…1071
Fault Code Data…1072
PC SOFTWARE OVERVIEW…1073
PC Overview…1073
System Configuration…1073
Installing the PLM III Software…1073
DOWNLOADING DATA…1074
PLM III SYSTEM CONFIGURATION…1075
Starting Communications…1075
Displayed Payload Units…1075
Time Units…1075
Connection Menu…1075
Connecting to the Payload Meter…1076
Configure the Payload Meter…1076
Setting the Date and Time…1076
Setting the Truck Type…1077
Setting the Gauge Display Units…1077
Setting the Frame Serial Number…1077
Setting the Truck Number…1077
Setting the Komatsu Distributor…1077
Setting the Komatsu Customer…1077
Clean Truck Tare…1078
Inclinometer Calibration…1078
DATA ANALYSIS…1079
Creating a Query…1079
Sorting on Truck Unit Number…1079
Sorting on Truck Type…1079
Sorting on Date Range…1080
Sorting on Time Range…1080
Payload Detail Screen…1081
Creating Reports…1081
Summary – One Page Report…1082
Detailed – Multi-Page Report…1082
Creating Graphs…1083
Exporting Data…1083
CSV Export…1083
Compressed…1085
Importing Data…1085
Deleting Haul Cycle Records…1085
Viewing Alarms…1086
Deleting Alarm Records…1086
SECTION 70 – RADIO / CASSETTE PLAYER…1087
GENERAL RECEIVER FUNCTIONS…1087
Turning The Power On And Off…1087
Display…1087
Setting The Default Display…1087
Adjusting Display Brightness…1087
SETTING THE TIME…1088
OPERATING THE RADIO…1088
BAND…1088
TUNE/SEEK…1088
Manual Tuning…1088
SEEK Mode…1088
SCAN…1088
AUTO…1088
ADJUSTING THE RECEIVER SETTINGS…1089
PROGRAMMING PRESET STATIONS…1089
OPERATION OF THE WEATHERBAND (U.S.)…1089
SATELLITE RADIO…1090
Operating Satellite Radio…1090
Program Type Search (PTY)…1090
CASSETTE PLAYER…1091
Playing A Cassette…1091
Cassette Functions…1091
Programmable Eject Default…1091
Bad Tape Detect…1092
Cleaning The Cassette Player…1092
CEAM016402 – Dump Truck 730E Trolley Operation & Maintenance Manual…1095
COVER …1095
INTRODUCTION…1099
FOREWORD…1099
ABOUT THIS MANUAL…1101
ALERTS PAGE…1102
TABLE OF CONTENTS…1103
TORQUE TABLES AND CONVERSION CHARTS…1113
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…1114
STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts…1114
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws…1115
STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws…1116
GENERAL SAFETY…1123
PERSONAL SAFETY…1123
Safety Rules…1123
Truck Safety Features…1123
Clothing And Personal Items…1123
Unauthorized Modification…1123
Leaving The Operator’s Seat…1123
Mounting And Dismounting…1123
Fire Extinguishers And First Aid Kits…1124
Precautions For High Temperature Fluids…1124
Asbestos Dust Hazard Prevention…1124
Fire Prevention For Fuel And Oil…1124
ROPS Precautions…1125
Preventing Injury From Work Equipment…1125
Precautions For Optional Attachments…1125
Precautions When Starting The Machine…1125
PRECAUTIONS FOR TRUCK OPERATION…1126
Safety Is Thinking Ahead…1126
Safety At The Work Site…1126
Fire Prevention…1126
Preparing For Operation…1126
Ventilation For Enclosed Areas…1126
Mirrors, Windows, And Lights…1126
In The Operator’s Cab – Before Starting The Engine…1127
Seat Belts…1127
OPERATING THE MACHINE…1127
Starting The Engine…1127
Truck Operation – General…1127
Traveling In The Truck…1128
Precautions When Traveling In Reverse…1128
Traveling On Slopes…1128
Ensuring Good Visibility…1129
Operating On Snow…1129
Avoid Damage To The Dump Body…1129
Driving Near High-Voltage Cables…1129
When Loading The Truck…1129
When Dumping…1129
Working On Loose Ground…1129
Parking The Machine…1130
TOWING…1130
WORKING NEAR BATTERIES…1130
Battery Hazard Prevention…1130
Jump-Starting With Booster Cables…1131
Jump Starting With Receptacles…1131
PRECAUTIONS FOR MAINTENANCE…1132
BEFORE PERFORMING MAINTENANCE…1132
Stopping The Engine Before Service…1132
Warning Tag…1132
Proper Tools…1132
Securing The Dump Body…1132
DURING MAINTENANCE…1133
Personnel…1133
Attachments…1133
Working Under The Machine…1133
Keeping The Machine Clean…1133
Rules To Follow When Adding Fuel Or Oil…1133
Radiator Coolant Level…1133
Use Of Lighting…1133
Precautions With The Battery…1134
Handling High-Pressure Hoses…1134
Precautions With High-Pressure Oil…1134
Maintenance Near High Temperatures And High Pressures…1134
Rotating Fan And Belts…1134
Waste Materials…1134
Use of Tie-Off Anchor During Maintenance and Repair…1134
TIRES…1135
Handling Tires…1135
Tire Maintenance…1136
Storing Tires After Removal…1136
ADDITIONAL JOB SITE RULES…1137
WHEN REPAIRS ARE NECESSARY…1138
WARNINGS AND CAUTIONS…1141
OPERATING INSTRUCTIONS…1149
PREPARING FOR OPERATION…1149
SAFETY IS THINKING talkAHEAD…1149
WALK AROUND INSPECTION…1149
ENGINE START-UP…1153
AFTER ENGINE HAS STARTED…1154
EMERGENCY STEERING SYSTEM…1155
Operation…1155
Pre-Operation Testing…1155
Additional Guidelines…1156
MACHINE OPERATION SAFETY PRECAUTIONS…1156
LOADING…1157
HAULING…1157
PASSING…1158
DUMPING…1158
To Raise The Dump Body:…1158
To Lower The Dump Body: (When dumping over a berm or into a crusher):…1159
To Lower The Dump Body (When dumping on flat ground):…1159
SAFE PARKING PROCEDURES…1160
ENGINE SHUTDOWN PROCEDURE…1160
DELAYED ENGINE SHUTDOWN PROCEDURE…1161
SUDDEN LOSS OF POWER…1161
DISABLED TRUCK OPERATION…1162
GENERAL…1162
STEERING AND BRAKE SYSTEM…1162
Components Required…1162
Hookup…1163
DISABLED TRUCK DUMPING PROCEDURE…1164
Hookup…1164
Raising the Body…1164
Lowering the Body…1164
TOWING…1165
TROLLEY OPERATING INSTRUCTIONS…1165
AFTER THE ENGINE HAS STARTED…1165
OPERATING IN DIESEL MODE…1166
OPERATING IN TROLLEY LINE MODE…1166
GETTING ON LINE…1167
Operating On Trolley…1168
GETTING OFF LINE…1170
LINE STATUS SIGNALS…1170
LINE STATUS SIGNAL MARKINGS…1171
TRAFFIC CONSIDERATION FOR TROLLEY LINE OPERATION…1171
APPROACHING SLOW MOVING VEHICLES IN A TROLLEY ASSISTED TRUCK…1171
OPERATING SLOW MOVING VEHICLES ON TROLLEY ASSIST RAMPS…1172
TRUCK FAILURE WHILE ON TROLLEY…1172
OPERATOR CAB AND CONTROLS…1173
STEERING WHEEL AND CONTROLS…1174
Horn Button…1174
Multi-Function Turn Signal Switch…1174
SERVICE BRAKE PEDAL…1175
DYNAMIC RETARDER PEDAL…1175
Optional – Dual Function / Single Pedal…1175
THROTTLE PEDAL…1175
HEATER / AIR CONDITIONER VENTS…1175
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS…1176
Defroster Vent Control Switch…1176
Heat Control Switch…1176
Temperature Control Knob…1176
Fan Control Knob…1176
Heater / Air Conditioner Selector Switch…1176
Heater / Air Conditioner Vents…1176
INSTRUMENT PANEL…1177
GRADE / SPEED WARNING CHART…1177
RADIO SPEAKERS…1177
WARNING ALARM BUZZER…1177
CAB RADIO…1177
WARNING LIGHTS DIMMER CONTROL…1177
WARNING INDICATOR LIGHT PANEL…1177
AIR CLEANER VACUUM GAUGES…1177
WINDSHIELD WIPERS…1177
Data Storage Button…1178
Data storage button (1, Figure 32-7) is for use by qualified maintenance personnel to record in memory a “snap-shot” of the Statex III drive system…1178
Trolley Master Control Lever…1178
F-N-R Selector Switch…1178
Hoist Control Lever…1179
Retard Speed Control (RSC) Adjust Dial…1179
Retard Speed Control (RSC) Off / On Switch…1180
Override Switch…1180
Engine Shutdown Switch…1180
Window Control Switches…1180
Ash Tray…1180
Lighter…1180
Passenger Seat…1180
Download Ports and Connectors…1181
Engine Diagnostics Port…1181
Engine diagnostics port (12) is used by qualified personnel to access engine diagnostic information…1181
Komatsu Engine CENSE Connector…1181
CENSE Connector (13) is a three-pin connector is for use by qualified personnel to access engine diagnostic information for the CENSE system. Refer to the engine manufacturer’s service publications for troubleshooting information…1181
Statex III Downlad Port…1181
Modular Mining Port (Optional)…1181
Modular mining port location is used if the optional Modular Mining System is installed on the truck…1181
Centry™ Fuel Control…1181
Diagnostics Download Port (Optional)…1181
Payload Meter…1181
Payload Meter Download Connector…1181
CENTER CONSOLE …1178
OPERATOR SEAT…1182
INSTRUMENT PANEL AND INDICATOR LIGHTS…1183
CONTROL SYMBOLS…1183
INSTRUMENT PANEL…1183
PANEL GAUGES, INDICATORS, AND CONTROLS…1184
Key Switch…1184
Engine Shut down Switch with Timer Delay…1185
Fog Lights (Optional)…1185
Ladder Light Switch…1185
Manual Backup Switch…1185
Manual backup switch (5) allows the backup lights to be turned on providing added visibility and safety when the selector switch is not in the REV position. When the switch is pressed toward the on position, the manual backup light indicator (B4, Ove….1185
Panel Illumination Lights…1185
Cab Air Conditioner / Heater Vents…1185
Engine Cold Weather Starting Aid (Optional)…1186
Rotating Beacon Light Switch (Optional)…1186
Heated Mirror Switch (Optional)…1186
Leakage Test Switch (Trolley Option Only)…1186
Wheel Brake Lock Control…1186
Parking Brake Control…1186
Tachometer…1187
Right Turn Signal Indicator…1187
High Beam Indicator…1187
Left Turn Signal Indicator…1187
Speedometer / Payload Meter Display…1187
Voltmeter…1187
Engine Oil Pressure Gauge…1187
Water Temperature Gauge…1187
Fuel Gauge…1187
Blank (Not Used)…1187
Hourmeter…1187
Blank (Not Used)…1187
Blank (Not Used)…1187
Light Switch…1188
Panel Light Dimmer…1188
Payload Meter Switch…1188
OVERHEAD STATUS / WARNING INDICATOR LIGHT PANEL…1189
INDICATOR LIGHT SYMBOLS…1190
TROLLEY INDICATOR LIGHTS…1194
Hazard Warning Light Switch…1196
Lamp Test Switch / Centry™ Diagnostic Test Switch…1196
REAR AXLE LIGHT BAR…1197
Backup Lights…1197
Retard Lights…1197
Brake Light…1197
Backup Alarm…1197
CENTRY™ FUEL SYSTEM DIAGNOSTICS…1198
DETERMINING FAULT CODES…1198
EXITING THE DIAGNOSTICS MODE…1199
LUBRICATION AND SERVICE…1201
GENERAL INFORMATION…1201
HYDRAULIC TANK SERVICE…1201
Adding Oil…1201
COOLING SYSTEM SERVICE…1202
Radiator Filling Procedure…1202
Coolant Specifications…1202
Unacceptable Practices…1202
WHEEL MOTOR SERVICE…1202
RESERVE ENGINE OIL SYSTEM (IF EQUIPPED)…1203
Reserve Oil Tank Filling Procedure (Remote fill)…1203
Inline Screen…1203
QUICK FILL SERVICE CENTER…1204
LEFT-HAND FUEL RECEIVER – OPTIONAL (WIGGINS QUICK FILL)…1205
LUBRICATION CHART…1206
10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS…1207
10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS (Continued)…1208
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…1209
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…1209
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…1210
250 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)…1211
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…1212
500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)…1213
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…1214
1500 HOUR LUBRICATION AND MAINTENANCE CHECKS…1215
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS…1215
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS…1216
10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS…1217
AUTOMATIC LUBRICATION SYSTEM…1219
GENERAL DESCRIPTION…1219
SYSTEM COMPONENTS…1220
Filter Assembly…1220
Hydraulic Motor and Grease Pump…1220
Reservoir…1220
Fixed Pressure Reducing Valve…1220
Flow Control Valve…1220
Solenoid Valve…1222
Vent Valve…1222
Time Delay Module…1222
Pump Cutoff Pressure Switch…1222
Unloader Valve…1222
Pressure Switch…1222
Pressure Gauge…1222
Manual Override Button…1222
Injectors…1222
SYSTEM OPERATION…1224
Normal Operation…1224
Pressure Failure Detection Circuits…1225
GENERAL INSTRUCTIONS…1226
LUBRICANT REQUIRED FOR SYSTEM…1226
SYSTEM PRIMING…1226
LUBRICANT PUMP…1226
Pump Housing Oil Level…1226
Pump Pressure Control…1226
FILTER AND RESERVOIR…1227
Filter Assembly Element…1227
INJECTORS (SL-1 Series H)…1228
Injector Specifications…1228
Injector Adjustment…1228
INJECTOR OPERATION…1229
SYSTEM CHECKOUT…1230
Lubrication Cycle Timer Check…1230
Lubrication Cycle Timer Adjustment…1231
PREVENTIVE MAINTENANCE INSPECTION…1231
10 Hour Lubrication System Inspection…1231
250 Hour Inspection…1231
1000 Hour Inspection…1232
SYSTEM TROUBLESHOOTING CHART…1233
MAJOR COMPONENT DESCRIPTION…1235
SPECIFICATIONS…1237
PAYLOAD METER III…1239
PAYLOAD METER III…1243
Introduction…1243
Data Summary…1243
Data Gathering…1243
COMPONENT DESCRIPTION…1244
System Diagram…1244
Suspension Pressure Sensors…1244
Inclinometer…1244
Operator Display…1244
Payload Operator Switch…1245
Speed Input…1245
Body-Up Switch…1245
Brake Lock Switch…1245
Payload Meter…1245
Communications Ports…1245
Key Switch Input…1246
Payload Meter Power…1246
Load Lights…1246
Wiring and Termination…1247
TCI Outputs…1247
OPERATOR’S DISPLAY AND SWITCH…1248
Reading the Speedometer…1248
Reading the Load Display…1248
Using the Operator ID…1248
Using the Load and Ton Counter…1248
Total Ton Counter…1248
Total Load Counter…1249
Clearing the Counters…1249
Viewing Live Sensor Data…1249
Other Display Messages…1249
PAYLOAD OPERATION AND CALCULATION…1250
Description of Haul Cycle States…1250
Haul Cycle Description…1250
Load Calculation…1251
Carry Back…1251
Measurement Accuracy…1251
SOURCES FOR PAYLOAD ERROR…1251
Payload Error…1251
Loading Conditions…1252
Pressure Sensors…1252
Swingloads…1252
Speed and Distance…1252
HAUL CYCLE DATA…1252
Haul Cycle Data…1253
Haul Cycle Warning Flags…1254
M: Haul Cycle Too Long…1255
N: Sensor Input Error…1255
Frame Torque Data…1255
Sprung Weight Data…1255
Maximum Speed Data…1255
Alarm Records…1255
Fault Code Data…1256
PC SOFTWARE OVERVIEW…1257
PC Overview…1257
System Configuration…1257
Installing the PLM III Software…1257
DOWNLOADING DATA…1258
PLM III SYSTEM CONFIGURATION…1259
Starting Communications…1259
Displayed Payload Units…1259
Time Units…1259
Connection Menu…1259
Connecting to the Payload Meter…1260
Configure the Payload Meter…1260
Setting the Date and Time…1260
Setting the Truck Type…1261
Setting the Gauge Display Units…1261
Setting the Frame Serial Number…1261
Setting the Truck Number…1261
Setting the Komatsu Distributor…1261
Setting the Komatsu Customer…1261
Clean Truck Tare…1262
Inclinometer Calibration…1262
DATA ANALYSIS…1263
Creating a Query…1263
Sorting on Truck Unit Number…1263
Sorting on Truck Type…1263
Sorting on Date Range…1264
Sorting on Time Range…1264
Payload Detail Screen…1265
Creating Reports…1265
Summary – One Page Report…1266
Detailed – Multi-Page Report…1266
Creating Graphs…1267
Exporting Data…1267
CSV Export…1267
Compressed…1269
Importing Data…1269
Deleting Haul Cycle Records…1269
Viewing Alarms…1270
Deleting Alarm Records…1270
RADIO / CASSETTE PLAYER…1271
GENERAL RECEIVER FUNCTIONS…1271
Turning The Power On And Off…1271
Display…1271
Setting The Default Display…1271
Adjusting Display Brightness…1271
SETTING THE TIME…1272
OPERATING THE RADIO…1272
BAND…1272
TUNE/SEEK…1272
Manual Tuning…1272
SEEK Mode…1272
SCAN…1272
AUTO…1272
ADJUSTING THE RECEIVER SETTINGS…1273
PROGRAMMING PRESET STATIONS…1273
OPERATION OF THE WEATHERBAND (U.S.)…1273
SATELLITE RADIO…1274
Operating Satellite Radio…1274
Program Type Search (PTY)…1274
CASSETTE PLAYER…1275
Playing A Cassette…1275
Cassette Functions…1275
Programmable Eject Default…1275
Bad Tape Detect…1276
Cleaning The Cassette Player…1276
CEAM018100 – Dump Truck 730E Operation & Maintenance Manual…1279
COVER…1279
SECTION 10 – INTRODUCTION…1285
FOREWORD…1285
ABOUT THIS MANUAL…1287
ALERTS PAGE…1288
TABLE OF CONTENTS…1289
SECTION 12 – STANDARD CHARTS AND TABLES…1301
SECTION 20 – GENERAL SAFETY…1307
PERSONAL SAFETY…1307
Safety Rules…1307
Truck Safety Features…1307
Clothing And Personal Items…1307
Unauthorized Modification…1307
Leaving The Operator’s Seat…1307
Mounting And Dismounting…1307
Fire Extinguishers And First Aid Kits…1308
Precautions For High Temperature Fluids…1308
Asbestos Dust Hazard Prevention…1308
Fire Prevention For Fuel And Oil…1308
ROPS Precautions…1309
Preventing Injury From Work Equipment…1309
Precautions For Optional Attachments…1309
Precautions When Starting The Machine…1309
PRECAUTIONS FOR TRUCK OPERATION…1310
Safety Is Thinking Ahead…1310
Safety At The Work Site…1310
Fire Prevention…1310
Preparing For Operation…1310
Ventilation For Enclosed Areas…1310
Mirrors, Windows, And Lights…1310
In The Operator’s Cab – Before Starting The Engine…1311
OPERATING THE MACHINE…1311
Starting The Engine…1311
Truck Operation – General…1311
Traveling In The Truck…1312
Precautions When Traveling In Reverse…1312
Traveling On Slopes…1312
Ensuring Good Visibility…1313
Operating On Snow…1313
Avoid Damage To The Dump Body…1313
Driving Near High-Voltage Cables…1313
When Loading The Truck…1313
When Dumping…1313
Working On Loose Ground…1313
Parking The Machine…1314
TOWING…1314
WORKING NEAR BATTERIES…1314
Battery Hazard Prevention…1314
Jump-Starting With Booster Cables…1314
PRECAUTIONS FOR MAINTENANCE…1315
BEFORE PERFORMING MAINTENANCE…1315
Stopping The Engine Before Service…1315
Warning Tag…1315
Proper Tools…1315
Securing The Dump Body…1315
DURING MAINTENANCE…1316
Personnel…1316
Attachments…1316
Working Under The Machine…1316
Keeping The Machine Clean…1316
Rules To Follow When Adding Fuel Or Oil…1316
Radiator Coolant Level…1316
Use Of Lighting…1316
Precautions With The Battery…1317
Handling High-Pressure Hoses…1317
Precautions With High-Pressure Oil…1317
Maintenance Near High Temperatures And High Pressures…1317
Rotating Fan And Belts…1317
Waste Materials…1317
TIRES…1318
Handling Tires…1318
Tire Maintenance…1318
Storing Tires After Removal…1318
ADDITIONAL JOB SITE RULES…1319
WHEN REPAIRS ARE NECESSARY…1320
SECTION 22 – WARNINGS AND CAUTIONS…1323
SECTION 30 – OPERATING INSTRUCTIONS…1331
PREPARING FOR OPERATION…1331
SAFETY IS THINKING AHEAD…1331
WALK-AROUND INSPECTION…1331
ENGINE START-UP…1335
AFTER ENGINE HAS STARTED…1335
MACHINE OPERATION SAFETY PRECAUTIONS…1336
LOADING…1337
HAULING…1337
PASSING…1337
DUMPING…1338
To Raise The Dump Body:…1338
To Lower The Dump Body: (When dumping over a berm or into a crusher):…1338
To Lower The Dump Body (When dumping on flat ground):…1339
TOWING…1339
SAFE PARKING PROCEDURES…1340
ENGINE SHUTDOWN PROCEDURE…1340
DELAYED ENGINE SHUTDOWN PROCEDURE…1340
SUDDEN LOSS OF POWER…1341
EMERGENCY STEERING SYSTEM…1342
Operation…1342
Testing…1342
SECTION 32 – OPERATOR CAB AND CONTROLS…1343
STEERING WHEEL AND CONTROLS…1344
STEERING WHEEL…1344
HORN BUTTON…1344
TILT/TELESCOPE LEVER…1344
MULTI-FUNCTION TURN SIGNAL SWITCH…1344
Turn Signal Operation…1344
High Beam Headlight Operation…1344
Windshield Wiper Operation…1344
PEDALS…1345
SERVICE BRAKE PEDAL…1345
DYNAMIC RETARDER PEDAL…1345
Optional – Dual Function/Single Pedal…1345
THROTTLE PEDAL…1345
CAB CLIMATE CONTROL…1346
HEATER/AIR CONDITIONER VENTS…1346
HEATER/AIR CONDITIONER CONTROLS AND VENTS…1346
Defroster Vent Control Switch…1346
Heat Control Switch…1346
Temperature Control Knob…1346
Fan Control Knob…1346
Heater/Air Conditioner Selector Switch…1346
Heater/Air Conditioner Vents…1346
OVERHEAD PANEL CONTROLS AND COMPONENTS…1347
GRADE/SPEED WARNING CHART…1347
RADIO SPEAKERS…1347
WARNING ALARM BUZZER…1347
CAB RADIO…1347
WARNING LIGHTS DIMMER CONTROL…1347
WARNING/STATUS INDICATOR LIGHT PANEL…1347
AIR CLEANER VACUUM GAUGES…1347
WINDSHIELD WIPERS…1347
TRUCK CONTROLS…1348
F-N-R Selector Switch…1348
Hoist Control Lever…1349
CONSOLE SWITCHES AND CONTROLS…1349
Ashtray…1349
Cigarette Lighter…1349
Left-Hand Window Control Switch…1349
Right-Hand Window Control Switch…1349
Engine Shutdown Switch…1349
Override Switch…1349
Retard Speed Control (RSC) Switch…1349
Retard Speed Control (RSC) Dial…1350
Statex III Download Port…1350
Engine Diagnostic Port (CENSE)…1350
Modular Mining Port…1350
Modular mining port (15, Figure 32-7) is used if the optional modular mining system is installed on the truck…1350
Passenger Seat…1350
Engine Diagnostic Connectors…1350
Engine Diagnostics Connector…1350
Data Storage Button…1350
PAYLOAD METER…1351
Payload Meter Download Connector…1351
OPERATOR SEAT…1352
ADJUSTMENT…1352
INSTRUMENT PANEL…1353
GENERAL INFORMATION…1353
CONTROL SYMBOLS…1353
CONTROL SWITCHES AND GAUGES…1354
Key Switch…1354
Engine Shutdown Switch With Timer Delay…1355
Fog Light Switch…1355
Ladder Light Switch…1355
Backup Light Switch…1355
Backup light switch (5, Figure 32-11) allows the backup lights to be turned ON providing added visibility and safety when the se….1355
Panel Illumination Lights…1355
Cab Air Conditioner/Heater Vents…1355
Engine Cold Weather Starting Aid Switch…1355
Rotating Beacon Light Switch…1355
Heated Mirror Switch…1355
Wheel Brake Lock Switch…1355
Parking Brake Switch…1356
Digital Tachometer…1356
Right Turn Signal Indicator Light…1356
High Beam Headlight Indicator Light…1356
Left Turn Signal Indicator Light…1356
Digital Speedometer/Payload Meter Display…1356
Voltmeter Gauge…1357
Engine Oil Pressure Gauge…1357
Engine Water Temperature Gauge…1357
Fuel Gauge…1357
Engine Hourmeter…1357
Headlight Switch…1357
Panel Illumination Lights Dimmer Rheostat…1357
Payload Meter Switch…1357
OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL…1358
DESCRIPTION OF INDICATOR SYMBOLS…1358
INDICATOR LIGHT FUNCTIONS…1359
High Hydraulic Oil Temperature…1359
Low Steering Pressure…1359
Low Accumulator Precharge Pressure Warning…1359
Electric System Fault Warning…1360
Low Brake Pressure Indicator…1360
Low Hydraulic Tank Level…1360
Low Automatic Lubrication System Pressure…1360
Circuit Breaker Tripped…1360
Hydraulic Oil Filter…1360
Low Fuel Indicator…1360
Parking Brake Indicator…1360
Service Brake Indicator…1360
Body Up Indicator…1361
Dynamic Retarding Indicator…1361
Stop Engine Warning…1361
Backup Indicator…1361
Engine Shutdown Timer Switch- Five Minute Idle…1361
Retard Speed Control…1361
Service Engine Indicator (AEM)…1361
High Wheel Motor Temperature Indicator…1361
Blower Fault Warning…1362
Service Engine Indicator (CENSE)…1362
Komatsu Engines w/Centry™ Fuel Control…1362
Hazard Warning Light Switch…1362
Lamp Test Switch/Centry™ Diagnostic Test Switch…1362
CENTRY™ FUEL SYSTEM DIAGNOSTICS…1363
GENERAL OPERATION…1363
DETERMINING FAULT CODES…1363
EXITING THE DIAGNOSTICS MODE…1364
VEHICLE HEALTH MONITORING SYSTEM (VHMS)…1365
BASIC PRECAUTIONS…1365
OPERATION…1365
INTERFACE MODULE…1366
Interface module (3, Figure 32-17) is located inside control cabinet (1, Figure 32-16). The interface module is attached inside door (2)…1366
LUBRICATION CHART…1371
SECTION 40 -LUBRICATION AND SERVICE…1369
GENERAL INFORMATION…1369
HYDRAULIC TANK SERVICE…1369
Adding Oil…1369
COOLING SYSTEM…1370
Coolant Level Check…1370
Radiator Filling Procedure…1370
Antifreeze Temperature Recommendations…1370
10 HOUR LUBE AND MAINTENANCE CHECKS…1372
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…1373
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…1374
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…1375
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…1377
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…1378
1500 HOUR LUBRICATION AND MAINTENANCE CHECKS…1379
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS…1379
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS…1380
10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS…1380
SECTION 42 – AUTOMATIC LUBRICATION SYSTEM…1381
GENERAL DESCRIPTION…1381
SYSTEM COMPONENTS…1382
Filter Assembly…1382
Hydraulic Motor and Grease Pump…1382
Reservoir…1382
Fixed Pressure Reducing Valve…1382
Flow Control Valve…1382
Solenoid Valve…1384
Vent Valve…1384
Time Delay Module…1384
Pump Cutoff Pressure Switch…1384
Unloader Valve…1384
Pressure Switch…1384
Pressure Gauge…1384
Manual Override Button…1384
Injectors…1384
SYSTEM OPERATION…1386
Normal Operation…1386
Pressure Failure Detection Circuits…1387
GENERAL INSTRUCTIONS…1388
LUBRICANT REQUIRED FOR SYSTEM…1388
SYSTEM PRIMING…1388
LUBRICANT PUMP…1388
Pump Housing Oil Level…1388
Pump Pressure Control…1388
FILTER AND RESERVOIR…1389
Filter Assembly Element…1389
INJECTORS (SL-1 Series H)…1390
Injector Specifications…1390
Injector Adjustment…1390
INJECTOR OPERATION…1391
SYSTEM CHECKOUT…1392
Lubrication Cycle Timer Check…1392
Lubrication Cycle Timer Adjustment…1393
PREVENTIVE MAINTENANCE INSPECTION…1393
10 Hour Lubrication System Inspection…1393
250 Hour Inspection…1393
1000 Hour Inspection…1394
SYSTEM TROUBLESHOOTING CHART…1395
SECTION 50 -MAJOR COMPONENT DESCRIPTION…1397
ENGINE…1397
ALTERNATOR (GE GTA-22)…1397
WHEEL MOTORS (GE 788)…1397
BLOWER…1397
OPERATOR'S CAB…1397
POWER STEERING…1397
DYNAMIC RETARDING…1397
BRAKE SYSTEM…1397
SUSPENSION…1397
SPECIFICATIONS…1399
ENGINE…1399
ELECTRIC DRIVE SYSTEM…1399
DYNAMIC RETARDING…1399
BATTERY ELECTRIC SYSTEM…1399
SERVICE CAPACITIES…1399
HYDRAULIC SYSTEM…1399
SERVICE BRAKES…1399
STEERING…1399
STANDARD DUMP BODY*…1400
TIRES…1400
WEIGHT DISTRIBUTION…1400
SECTION 60 -PAYLOAD METER III…1401
PAYLOAD METER III…1405
Introduction…1405
Data Summary…1405
Data Gathering…1405
COMPONENT DESCRIPTION…1406
System Diagram…1406
Suspension Pressure Sensors…1406
Inclinometer…1406
Operator Display…1406
Payload Operator Switch…1407
Speed Input…1407
Body-Up Switch…1407
Brake Lock Switch…1407
Payload Meter…1407
Communications Ports…1407
Key Switch Input…1408
Payload Meter Power…1408
Load Lights…1408
Wiring and Termination…1409
TCI Outputs…1409
OPERATOR’S DISPLAY AND SWITCH…1410
Reading the Speedometer…1410
Reading the Load Display…1410
Using the Operator ID…1410
Using the Load and Ton Counter…1410
Total Ton Counter…1410
Total Load Counter…1411
Clearing the Counters…1411
Viewing Live Sensor Data…1411
Other Display Messages…1411
PAYLOAD OPERATION AND CALCULATION…1412
Description of Haul Cycle States…1412
Haul Cycle Description…1412
Load Calculation…1413
Carry Back…1413
Measurement Accuracy…1413
SOURCES FOR PAYLOAD ERROR…1413
Payload Error…1413
Loading Conditions…1414
Pressure Sensors…1414
Swingloads…1414
Speed and Distance…1414
HAUL CYCLE DATA…1414
Haul Cycle Data…1415
Haul Cycle Warning Flags…1416
M: Haul Cycle Too Long…1417
N: Sensor Input Error…1417
Frame Torque Data…1417
Sprung Weight Data…1417
Maximum Speed Data…1417
Alarm Records…1417
Fault Code Data…1418
PC SOFTWARE OVERVIEW…1419
PC Overview…1419
System Configuration…1419
Installing the PLM III Software…1419
DOWNLOADING DATA…1420
PLM III SYSTEM CONFIGURATION…1421
Starting Communications…1421
Displayed Payload Units…1421
Time Units…1421
Connection Menu…1421
Connecting to the Payload Meter…1422
Configure the Payload Meter…1422
Setting the Date and Time…1422
Setting the Truck Type…1423
Setting the Gauge Display Units…1423
Setting the Frame Serial Number…1423
Setting the Truck Number…1423
Setting the Komatsu Distributor…1423
Setting the Komatsu Customer…1423
Clean Truck Tare…1424
Inclinometer Calibration…1424
DATA ANALYSIS…1425
Creating a Query…1425
Sorting on Truck Unit Number…1425
Sorting on Truck Type…1425
Sorting on Date Range…1426
Sorting on Time Range…1426
Payload Detail Screen…1427
Creating Reports…1427
Summary – One Page Report…1428
Detailed – Multi-Page Report…1428
Creating Graphs…1429
Exporting Data…1429
CSV Export…1429
Compressed…1431
Importing Data…1431
Deleting Haul Cycle Records…1431
Viewing Alarms…1432
Deleting Alarm Records…1432
SECTION 70 -RADIO / CASSETTE PLAYER…1433
GENERAL RECEIVER FUNCTIONS…1433
Turning The Power On And Off…1433
Display…1433
Setting The Default Display…1433
Adjusting Display Brightness…1433
SETTING THE TIME…1434
OPERATING THE RADIO…1434
BAND…1434
TUNE/SEEK…1434
Manual Tuning…1434
SEEK Mode…1434
SCAN…1434
AUTO…1434
ADJUSTING THE RECEIVER SETTINGS…1435
PROGRAMMING PRESET STATIONS…1435
OPERATION OF THE WEATHERBAND (U.S.)…1435
SATELLITE RADIO…1436
Operating Satellite Radio…1436
Program Type Search (PTY)…1436
CASSETTE PLAYER…1437
Playing A Cassette…1437
Cassette Functions…1437
Programmable Eject Default…1437
Bad Tape Detect…1438
Cleaning The Cassette Player…1438
CEAM018301 – Dump Truck 730E Trolley Operation & Maintenance Manual…1441
COVER…1441
INTRODUCTION…1445
FORWARD…1445
TRUCK MODEL ILLUSTRATION…1446
ABOUT THIS MANUAL…1447
ALERTS PAGE…1448
TABLE OF CONTENTS…1449
TORQUE TABLES AND CONVERSION CHARTS…1459
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…1460
STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts…1460
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws…1461
STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws…1462
GENERAL SAFETY…1469
PERSONAL SAFETY…1469
Safety Rules…1469
Truck Safety Features…1469
Clothing And Personal Items…1469
Unauthorized Modification…1469
Leaving The Operator’s Seat…1469
Mounting And Dismounting…1469
Fire Extinguishers And First Aid Kits…1470
Precautions For High Temperature Fluids…1470
Asbestos Dust Hazard Prevention…1470
Fire Prevention For Fuel And Oil…1470
ROPS Precautions…1471
Preventing Injury From Work Equipment…1471
Precautions For Optional Attachments…1471
Precautions When Starting The Machine…1471
PRECAUTIONS FOR TRUCK OPERATION…1472
Safety Is Thinking Ahead…1472
Safety At The Work Site…1472
Fire Prevention…1472
Preparing For Operation…1472
Ventilation For Enclosed Areas…1472
Mirrors, Windows, And Lights…1472
In The Operator’s Cab – Before Starting The Engine…1473
Seat Belts…1473
OPERATING THE MACHINE…1473
Starting The Engine…1473
Truck Operation – General…1473
Traveling In The Truck…1474
Precautions When Traveling In Reverse…1474
Traveling On Slopes…1474
Ensuring Good Visibility…1475
Operating On Snow…1475
Avoid Damage To The Dump Body…1475
Driving Near High-Voltage Cables…1475
When Loading The Truck…1475
When Dumping…1475
Working On Loose Ground…1475
Parking The Machine…1476
TOWING…1476
WORKING NEAR BATTERIES…1476
Battery Hazard Prevention…1476
Jump-Starting With Booster Cables…1477
Jump Starting With Receptacles…1477
PRECAUTIONS FOR MAINTENANCE…1478
BEFORE PERFORMING MAINTENANCE…1478
Stopping The Engine Before Service…1478
Warning Tag…1478
Proper Tools…1478
Securing The Dump Body…1478
DURING MAINTENANCE…1479
Personnel…1479
Attachments…1479
Working Under The Machine…1479
Keeping The Machine Clean…1479
Rules To Follow When Adding Fuel Or Oil…1479
Radiator Coolant Level…1479
Use Of Lighting…1479
Precautions With The Battery…1480
Handling High-Pressure Hoses…1480
Precautions With High-Pressure Oil…1480
Maintenance Near High Temperatures And High Pressures…1480
Rotating Fan And Belts…1480
Waste Materials…1480
Use of Tie-Off Anchor During Maintenance and Repair…1480
TIRES…1481
Handling Tires…1481
Tire Maintenance…1482
Storing Tires After Removal…1482
ADDITIONAL JOB SITE RULES…1483
WHEN REPAIRS ARE NECESSARY…1484
WARNINGS AND CAUTIONS…1487
OPERATING INSTRUCTIONS…1495
PREPARING FOR OPERATION…1495
SAFETY IS THINKING talkAHEAD…1495
WALK AROUND INSPECTION…1495
ENGINE START-UP…1499
AFTER ENGINE HAS STARTED…1500
EMERGENCY STEERING SYSTEM…1501
Operation…1501
Pre-Operation Testing…1501
Additional Guidelines…1502
MACHINE OPERATION SAFETY PRECAUTIONS…1502
LOADING…1503
HAULING…1503
PASSING…1504
DUMPING…1504
To Raise The Dump Body:…1504
To Lower The Dump Body: (When dumping over a berm or into a crusher):…1505
To Lower The Dump Body (When dumping on flat ground):…1505
SAFE PARKING PROCEDURES…1506
ENGINE SHUTDOWN PROCEDURE…1506
DELAYED ENGINE SHUTDOWN PROCEDURE…1507
SUDDEN LOSS OF POWER…1507
DISABLED TRUCK OPERATION…1508
GENERAL…1508
STEERING AND BRAKE SYSTEM…1508
Components Required…1508
Hookup…1509
DISABLED TRUCK DUMPING PROCEDURE…1510
Hookup…1510
Raising the Body…1510
Lowering the Body…1510
TOWING…1511
TROLLEY OPERATING INSTRUCTIONS…1511
AFTER THE ENGINE HAS STARTED…1511
OPERATING IN DIESEL MODE…1512
OPERATING IN TROLLEY LINE MODE…1512
GETTING ON LINE…1513
Operating On Trolley…1514
GETTING OFF LINE…1516
LINE STATUS SIGNALS…1516
LINE STATUS SIGNAL MARKINGS…1517
TRAFFIC CONSIDERATION FOR TROLLEY LINE OPERATION…1517
APPROACHING SLOW MOVING VEHICLES IN A TROLLEY ASSISTED TRUCK…1517
OPERATING SLOW MOVING VEHICLES ON TROLLEY ASSIST RAMPS…1518
TRUCK FAILURE WHILE ON TROLLEY…1518
OPERATOR CAB AND CONTROLS…1519
STEERING WHEEL AND CONTROLS…1520
Horn Button…1520
Multi-Function Turn Signal Switch…1520
SERVICE BRAKE PEDAL…1521
DYNAMIC RETARDER PEDAL…1521
Optional – Dual Function / Single Pedal…1521
THROTTLE PEDAL…1521
HEATER / AIR CONDITIONER VENTS…1521
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS…1522
Defroster Vent Control Switch…1522
Heat Control Switch…1522
Temperature Control Knob…1522
Fan Control Knob…1522
Heater / Air Conditioner Selector Switch…1522
Heater / Air Conditioner Vents…1522
CENTER CONSOLE…1524
INSTRUMENT PANEL…1523
GRADE / SPEED WARNING CHART…1523
RADIO SPEAKERS…1523
WARNING ALARM BUZZER…1523
CAB RADIO…1523
WARNING LIGHTS DIMMER CONTROL…1523
WARNING INDICATOR LIGHT PANEL…1523
AIR CLEANER VACUUM GAUGES…1523
WINDSHIELD WIPERS…1523
Data Storage Button…1524
Data storage button (1, Figure 32-7) is for use by qualified maintenance personnel to record in memory a “snap-shot” of the Statex III drive system…1524
Trolley Master Control Lever…1524
F-N-R Selector Switch…1524
Hoist Control Lever…1525
Retard Speed Control (RSC) Adjust Dial…1525
Retard Speed Control (RSC) Off / On Switch…1526
Override Switch…1526
Engine Shutdown Switch…1526
Window Control Switches…1526
Ash Tray…1526
Lighter…1526
Passenger Seat…1526
Download Ports and Connectors…1527
Engine Diagnostics Port…1527
Engine diagnostics port (12) is used by qualified personnel to access engine diagnostic information…1527
Komatsu Engine CENSE Connector…1527
CENSE Connector (13) is a three-pin connector is for use by qualified personnel to access engine diagnostic information for the CENSE system. Refer to the engine manufacturer’s service publications for troubleshooting information…1527
Statex III Downlad Port…1527
Modular Mining Port (Optional)…1527
Modular mining port location is used if the optional Modular Mining System is installed on the truck…1527
Centry™ Fuel Control…1527
Diagnostics Download Port (Optional)…1527
Payload Meter…1527
Payload Meter Download Connector…1527
OPERATOR SEAT…1528
INSTRUMENT PANEL AND INDICATOR LIGHTS…1529
CONTROL SYMBOLS…1529
INSTRUMENT PANEL…1529
PANEL GAUGES, INDICATORS, AND CONTROLS…1530
Key Switch…1530
Engine Shut down Switch with Timer Delay…1531
Fog Lights (Optional)…1531
Ladder Light Switch…1531
Manual Backup Switch…1531
Manual backup switch (5) allows the backup lights to be turned on providing added visibility and safety when the selector switch is not in the REV position. When the switch is pressed toward the on position, the manual backup light indicator (B4, Ove….1531
Panel Illumination Lights…1531
Cab Air Conditioner / Heater Vents…1531
Engine Cold Weather Starting Aid (Optional)…1532
Rotating Beacon Light Switch (Optional)…1532
Heated Mirror Switch (Optional)…1532
Leakage Test Switch (Trolley Option Only)…1532
Wheel Brake Lock Control…1532
Parking Brake Control…1532
Tachometer…1533
Right Turn Signal Indicator…1533
High Beam Indicator…1533
Left Turn Signal Indicator…1533
Speedometer / Payload Meter Display…1533
Voltmeter…1533
Engine Oil Pressure Gauge…1533
Water Temperature Gauge…1533
Fuel Gauge…1533
Blank (Not Used)…1533
Hourmeter…1533
Blank (Not Used)…1533
Blank (Not Used)…1533
Light Switch…1534
Panel Light Dimmer…1534
Payload Meter Switch…1534
OVERHEAD STATUS / WARNING INDICATOR LIGHT PANEL…1535
INDICATOR LIGHT SYMBOLS…1536
TROLLEY INDICATOR LIGHTS…1540
Hazard Warning Light Switch…1542
Lamp Test Switch / Centry™ Diagnostic Test Switch…1542
CENTRY™ FUEL SYSTEM DIAGNOSTICS…1543
DETERMINING FAULT CODES…1543
EXITING THE DIAGNOSTICS MODE…1544
LUBRICATION AND SERVICE…1545
GENERAL INFORMATION…1545
HYDRAULIC TANK SERVICE…1545
Adding Oil…1545
COOLING SYSTEM SERVICE…1546
Radiator Filling Procedure…1546
Coolant Specifications…1546
Unacceptable Practices…1546
WHEEL MOTOR SERVICE…1546
RESERVE ENGINE OIL SYSTEM (IF EQUIPPED)…1547
Reserve Oil Tank Filling Procedure (Remote fill)…1547
Inline Screen…1547
QUICK FILL SERVICE CENTER…1548
LEFT-HAND FUEL RECEIVER – OPTIONAL (WIGGINS QUICK FILL)…1549
LUBRICATION CHART…1550
10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS…1551
10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS (Continued)…1552
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…1553
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…1553
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…1554
250 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)…1555
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…1556
500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)…1557
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…1558
1500 HOUR LUBRICATION AND MAINTENANCE CHECKS…1559
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS…1559
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS…1560
10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS…1561
AUTOMATIC LUBRICATION SYSTEM…1563
GENERAL DESCRIPTION…1563
SYSTEM COMPONENTS…1564
Filter Assembly…1564
Hydraulic Motor and Grease Pump…1564
Reservoir…1564
Fixed Pressure Reducing Valve…1564
Flow Control Valve…1564
Solenoid Valve…1566
Vent Valve…1566
Time Delay Module…1566
Pump Cutoff Pressure Switch…1566
Unloader Valve…1566
Pressure Switch…1566
Pressure Gauge…1566
Manual Override Button…1566
Injectors…1566
SYSTEM OPERATION…1568
Normal Operation…1568
Pressure Failure Detection Circuits…1569
GENERAL INSTRUCTIONS…1570
LUBRICANT REQUIRED FOR SYSTEM…1570
SYSTEM PRIMING…1570
LUBRICANT PUMP…1570
Pump Housing Oil Level…1570
Pump Pressure Control…1570
FILTER AND RESERVOIR…1571
Filter Assembly Element…1571
INJECTORS (SL-1 Series H)…1572
Injector Specifications…1572
Injector Adjustment…1572
INJECTOR OPERATION…1573
SYSTEM CHECKOUT…1574
Lubrication Cycle Timer Check…1574
Lubrication Cycle Timer Adjustment…1575
PREVENTIVE MAINTENANCE INSPECTION…1575
10 Hour Lubrication System Inspection…1575
250 Hour Inspection…1575
1000 Hour Inspection…1576
SYSTEM TROUBLESHOOTING CHART…1577
MAJOR COMPONENT DESCRIPTION…1579
SPECIFICATIONS…1581
PAYLOAD METER III…1583
PAYLOAD METER III…1587
Introduction…1587
Data Summary…1587
Data Gathering…1587
COMPONENT DESCRIPTION…1588
System Diagram…1588
Suspension Pressure Sensors…1588
Inclinometer…1588
Operator Display…1588
Payload Operator Switch…1589
Speed Input…1589
Body-Up Switch…1589
Brake Lock Switch…1589
Payload Meter…1589
Communications Ports…1589
Key Switch Input…1590
Payload Meter Power…1590
Load Lights…1590
Wiring and Termination…1591
TCI Outputs…1591
OPERATOR’S DISPLAY AND SWITCH…1592
Reading the Speedometer…1592
Reading the Load Display…1592
Using the Operator ID…1592
Using the Load and Ton Counter…1592
Total Ton Counter…1592
Total Load Counter…1593
Clearing the Counters…1593
Viewing Live Sensor Data…1593
Other Display Messages…1593
PAYLOAD OPERATION AND CALCULATION…1594
Description of Haul Cycle States…1594
Haul Cycle Description…1594
Load Calculation…1595
Carry Back…1595
Measurement Accuracy…1595
SOURCES FOR PAYLOAD ERROR…1595
Payload Error…1595
Loading Conditions…1596
Pressure Sensors…1596
Swingloads…1596
Speed and Distance…1596
HAUL CYCLE DATA…1596
Haul Cycle Data…1597
Haul Cycle Warning Flags…1598
M: Haul Cycle Too Long…1599
N: Sensor Input Error…1599
Frame Torque Data…1599
Sprung Weight Data…1599
Maximum Speed Data…1599
Alarm Records…1599
Fault Code Data…1600
PC SOFTWARE OVERVIEW…1601
PC Overview…1601
System Configuration…1601
Installing the PLM III Software…1601
DOWNLOADING DATA…1602
PLM III SYSTEM CONFIGURATION…1603
Starting Communications…1603
Displayed Payload Units…1603
Time Units…1603
Connection Menu…1603
Connecting to the Payload Meter…1604
Configure the Payload Meter…1604
Setting the Date and Time…1604
Setting the Truck Type…1605
Setting the Gauge Display Units…1605
Setting the Frame Serial Number…1605
Setting the Truck Number…1605
Setting the Komatsu Distributor…1605
Setting the Komatsu Customer…1605
Clean Truck Tare…1606
Inclinometer Calibration…1606
DATA ANALYSIS…1607
Creating a Query…1607
Sorting on Truck Unit Number…1607
Sorting on Truck Type…1607
Sorting on Date Range…1608
Sorting on Time Range…1608
Payload Detail Screen…1609
Creating Reports…1609
Summary – One Page Report…1610
Detailed – Multi-Page Report…1610
Creating Graphs…1611
Exporting Data…1611
CSV Export…1611
Compressed…1613
Importing Data…1613
Deleting Haul Cycle Records…1613
Viewing Alarms…1614
Deleting Alarm Records…1614
RADIO / CASSETTE PLAYER…1615
GENERAL RECEIVER FUNCTIONS…1615
Turning The Power On And Off…1615
Display…1615
Setting The Default Display…1615
Adjusting Display Brightness…1615
SETTING THE TIME…1616
OPERATING THE RADIO…1616
BAND…1616
TUNE/SEEK…1616
Manual Tuning…1616
SEEK Mode…1616
SCAN…1616
AUTO…1616
ADJUSTING THE RECEIVER SETTINGS…1617
PROGRAMMING PRESET STATIONS…1617
OPERATION OF THE WEATHERBAND (U.S.)…1617
SATELLITE RADIO…1618
Operating Satellite Radio…1618
Program Type Search (PTY)…1618
CASSETTE PLAYER…1619
Playing A Cassette…1619
Cassette Functions…1619
Programmable Eject Default…1619
Bad Tape Detect…1620
Cleaning The Cassette Player…1620
CEAM020001- Dump Truck 730E Operation & Maintenance Manual…1623
COVER…1623
INTRODUCTION…1627
FOREWORD…1627
TRUCK MODEL ILLUSTRATION…1628
ABOUT THIS MANUAL…1629
ALERTS PAGE…1630
TABLE OF CONTENTS…1631
TORQUE TABLES AND CONVERSION CHARTS…1641
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…1642
STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts…1642
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws…1643
STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws…1644
GENERAL SAFETY…1651
PERSONAL SAFETY…1651
Safety Rules…1651
Truck Safety Features…1651
Clothing And Personal Items…1651
Unauthorized Modification…1651
Leaving The Operator’s Seat…1651
Mounting And Dismounting…1651
Fire Extinguishers And First Aid Kits…1652
Precautions For High Temperature Fluids…1652
Asbestos Dust Hazard Prevention…1652
Fire Prevention For Fuel And Oil…1652
ROPS Precautions…1653
Preventing Injury From Work Equipment…1653
Precautions For Optional Attachments…1653
Precautions When Starting The Machine…1653
PRECAUTIONS FOR TRUCK OPERATION…1654
Safety Is Thinking Ahead…1654
Safety At The Work Site…1654
Fire Prevention…1654
Preparing For Operation…1654
Ventilation For Enclosed Areas…1654
Mirrors, Windows, And Lights…1654
In The Operator’s Cab – Before Starting The Engine…1655
Seat Belts…1655
OPERATING THE MACHINE…1655
Starting The Engine…1655
Truck Operation – General…1655
Traveling In The Truck…1656
Precautions When Traveling In Reverse…1656
Traveling On Slopes…1656
Ensuring Good Visibility…1657
Operating On Snow…1657
Avoid Damage To The Dump Body…1657
Driving Near High-Voltage Cables…1657
When Loading The Truck…1657
When Dumping…1657
Working On Loose Ground…1657
Parking The Machine…1658
TOWING…1658
WORKING NEAR BATTERIES…1658
Battery Hazard Prevention…1658
Jump-Starting With Booster Cables…1659
Jump Starting With Receptacles…1659
PRECAUTIONS FOR MAINTENANCE…1660
BEFORE PERFORMING MAINTENANCE…1660
Stopping The Engine Before Service…1660
Warning Tag…1660
Proper Tools…1660
Securing The Dump Body…1660
DURING MAINTENANCE…1661
Personnel…1661
Attachments…1661
Working Under The Machine…1661
Keeping The Machine Clean…1661
Rules To Follow When Adding Fuel Or Oil…1661
Radiator Coolant Level…1661
Use Of Lighting…1661
Precautions With The Battery…1662
Handling High-Pressure Hoses…1662
Precautions With High-Pressure Oil…1662
Maintenance Near High Temperatures And High Pressures…1662
Rotating Fan And Belts…1662
Waste Materials…1662
TIRES…1663
Handling Tires…1663
Tire Maintenance…1664
Storing Tires After Removal…1664
ADDITIONAL JOB SITE RULES…1665
WHEN REPAIRS ARE NECESSARY…1666
WARNINGS AND CAUTIONS…1669
OPERATING INSTRUCTIONS…1677
PREPARING FOR OPERATION…1677
SAFETY IS THINKING AHEAD…1677
WALK AROUND INSPECTION…1677
ENGINE START-UP…1682
AFTER ENGINE HAS STARTED…1683
EMERGENCY STEERING SYSTEM…1684
Operation…1684
Pre-Operation Testing…1684
Additional Guidelines…1685
MACHINE OPERATION SAFETY PRECAUTIONS…1685
LOADING…1686
HAULING…1686
PASSING…1687
DUMPING…1687
To Raise The Dump Body:…1687
To Lower The Dump Body: (When dumping over a berm or into a crusher):…1688
To Lower The Dump Body (When dumping on flat ground):…1688
SAFE PARKING PROCEDURES…1689
ENGINE SHUTDOWN PROCEDURE…1689
DELAYED ENGINE SHUTDOWN PROCEDURE…1690
SUDDEN LOSS OF POWER…1690
DISABLED TRUCK DUMPING PROCEDURE…1691
Hookup…1691
Raising the Body…1691
Lowering the Body…1691
TOWING…1692
OPERATOR CONTROLS…1693
STEERING WHEEL AND CONTROLS…1694
STEERING WHEEL…1694
HORN BUTTON…1694
TILT/TELESCOPE LEVER…1694
MULTI-FUNCTION TURN SIGNAL SWITCH…1694
Turn Signal Operation…1694
High Beam Headlight Operation…1694
Windshield Wiper Operation…1694
PEDALS…1695
SERVICE BRAKE PEDAL…1695
DYNAMIC RETARDER PEDAL…1695
Optional – Dual Function/Single Pedal…1695
THROTTLE PEDAL…1695
CAB CLIMATE CONTROL…1696
HEATER/AIR CONDITIONER VENTS…1696
HEATER/AIR CONDITIONER CONTROLS AND VENTS…1696
Defroster Vent Control Switch…1696
Heat Control Switch…1696
Temperature Control Knob…1696
Fan Control Knob…1697
Heater/Air Conditioner Selector Switch…1697
Heater/Air Conditioner Vents…1697
OVERHEAD PANEL CONTROLS AND COMPONENTS…1698
GRADE/SPEED WARNING CHART…1698
RADIO SPEAKERS…1698
WARNING ALARM BUZZER…1698
CAB RADIO…1698
WARNING LIGHTS DIMMER CONTROL…1698
WARNING/STATUS INDICATOR LIGHT PANEL…1698
AIR CLEANER VACUUM GAUGES…1698
WINDSHIELD WIPERS…1698
TRUCK CONTROLS…1699
F-N-R Selector Switch…1699
Hoist Control Lever…1700
CENTER CONSOLE…1699
CONSOLE SWITCHES AND CONTROLS…1700
Ashtray…1700
Cigarette Lighter…1700
Left-Hand Window Control Switch…1700
Right-Hand Window Control Switch…1700
Engine Shutdown Switch…1700
Override Switch…1700
Retard Speed Control (RSC) Switch…1701
Retard Speed Control (RSC) Dial…1701
Statex III Download Port…1702
Engine Diagnostic Port (CENSE)…1702
Modular Mining Port…1702
Modular mining port (15, Figure 32-7) is used if the optional modular mining system is installed on the truck…1702
Passenger Seat…1702
Engine Diagnostic Connectors…1702
Engine Diagnostics Connector…1702
Data Storage Button…1702
PAYLOAD METER…1702
Payload Meter Download Connector…1702
OPERATOR SEAT…1703
ADJUSTMENT…1703
INSTRUMENT PANEL…1704
CONTROL SYMBOLS…1704
CONTROL SWITCHES AND GAUGES…1705
Key Switch…1705
Engine Shutdown Switch With Timer Delay…1706
Fog Light Switch…1706
Ladder Light Switch…1706
Backup Light Switch…1706
Backup light switch (5, Figure 32-11) allows the backup lights to be turned ON providing added visibility and safety when the selector switch (see operator controls) is not in the REV position. When the switch is pressed toward the ON position, manua….1706
Panel Illumination Lights…1706
Cab Air Conditioner/Heater Vents…1706
Engine Cold Weather Starting Aid Switch…1706
Rotating Beacon Light Switch…1706
Heated Mirror Switch…1706
Wheel Brake Lock Switch…1707
Parking Brake Switch…1707
Digital Tachometer…1707
Right Turn Signal Indicator Light…1708
High Beam Headlight Indicator Light…1708
Left Turn Signal Indicator Light…1708
Digital Speedometer/Payload Meter Display…1708
Voltmeter Gauge…1708
Engine Oil Pressure Gauge…1708
Engine Water Temperature Gauge…1708
Fuel Gauge…1708
Engine Hourmeter…1708
Headlight Switch…1709
Panel Illumination Lights Dimmer Rheostat…1709
Payload Meter Switch…1709
OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL…1710
DESCRIPTION OF INDICATOR SYMBOLS…1710
INDICATOR LIGHT FUNCTIONS…1711
A1. High Hydraulic Oil Temperature…1711
B1. Low Steering Pressure…1711
C1. Low Accumulator Precharge Pressure…1712
D1. Electric System Fault…1712
E1. Low Brake Pressure…1712
A2. Low Hydraulic Tank Level…1712
B2. Automatic Lubrication System Pressure…1712
C2. Circuit Breaker Tripped…1712
D2. Hydraulic Oil Filter Monitor…1713
E2. Low Fuel…1713
A3. Parking Brake…1713
B3. Service Brake…1713
C3. Body Up…1713
D3. Dynamic Retarding…1713
E3. Stop Engine…1713
A4. Not Used…1714
B4. Manual Backup Lights…1714
C4. Engine Shutdown Timer…1714
D4. Retard Speed Control (RSC)…1714
E4. Check Engine…1714
A5. Service Engine Indicator (AEM)…1714
B5. High Wheel Motor Temperature…1714
C5. Blower Fault…1714
D5, E5, A6, B6, and C6. Not Used…1714
D6. Service Engine (CENSE)…1714
E6. Not Used…1714
Komatsu Engines with Centry™ Fuel Control…1715
Hazard Warning Light Switch…1715
Lamp Test Switch/Centry™ Diagnostic Test Switch…1715
CENTRY™ FUEL SYSTEM DIAGNOSTICS…1716
GENERAL OPERATION…1716
DETERMINING FAULT CODES…1716
EXITING THE DIAGNOSTICS MODE…1717
LUBRICATION AND SERVICE…1719
GENERAL INFORMATION…1719
HYDRAULIC TANK SERVICE…1719
Adding Oil…1719
COOLING SYSTEM SERVICE…1720
Radiator Filling Procedure…1720
RESERVE ENGINE OIL SYSTEM – (IF EQUIPPED)…1720
Reserve Oil Tank Filling Procedure (Remote Fill)…1720
LEFT-HAND FUEL RECEIVER – OPTIONAL (WIGGINS QUICK FILL)…1721
LUBRICATION CHART…1722
10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS…1723
10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS (Continued)…1724
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…1725
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…1725
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…1726
250 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)…1727
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…1728
500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)…1729
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…1730
1500 HOUR LUBRICATION AND MAINTENANCE CHECKS…1731
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS…1731
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS…1732
10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS…1733
AUTOMATIC LUBRICATION SYSTEM…1735
GENERAL DESCRIPTION…1735
SYSTEM COMPONENTS…1736
Filter Assembly…1736
Hydraulic Motor and Grease Pump…1736
Reservoir…1736
Fixed Pressure Reducing Valve…1736
Flow Control Valve…1736
Solenoid Valve…1738
Vent Valve…1738
Time Delay Module…1738
Pump Cutoff Pressure Switch…1738
Unloader Valve…1738
Pressure Switch…1738
Pressure Gauge…1738
Manual Override Button…1738
Injectors…1738
SYSTEM OPERATION…1740
Normal Operation…1740
Pressure Failure Detection Circuits…1741
GENERAL INSTRUCTIONS…1742
LUBRICANT REQUIRED FOR SYSTEM…1742
SYSTEM PRIMING…1742
LUBRICANT PUMP…1742
Pump Housing Oil Level…1742
Pump Pressure Control…1742
Filter And Reservoir…1743
Filter Assembly Element…1743
INJECTORS (SL-1 Series H)…1744
Injector Specifications…1744
Injector Adjustment…1744
INJECTOR OPERATION…1745
SYSTEM CHECKOUT…1746
Lubrication Cycle Timer Check…1746
Lubrication Cycle Timer Adjustment…1747
PREVENTIVE MAINTENANCE INSPECTION…1747
10 Hour Lubrication System Inspection…1747
250 Hour Inspection…1747
1000 Hour Inspection…1748
SYSTEM TROUBLESHOOTING CHART…1749
MAJOR COMPONENT DESCRIPTION…1751
SPECIFICATIONS…1753
PAYLOAD METER III…1755
PAYLOAD METER III…1759
Introduction…1759
Data Summary…1759
Data Gathering…1759
COMPONENT DESCRIPTION…1760
System Diagram…1760
Suspension Pressure Sensors…1760
Inclinometer…1760
Operator Display…1760
Payload Operator Switch…1761
Speed Input…1761
Body-Up Switch…1761
Brake Lock Switch…1761
Payload Meter…1761
Communications Ports…1761
Key Switch Input…1762
Payload Meter Power…1762
Load Lights…1762
Wiring and Termination…1763
TCI Outputs…1763
OPERATOR’S DISPLAY AND SWITCH…1764
Reading the Speedometer…1764
Reading the Load Display…1764
Using the Operator ID…1764
Using the Load and Ton Counter…1764
Total Ton Counter…1764
Total Load Counter…1765
Clearing the Counters…1765
Viewing Live Sensor Data…1765
Other Display Messages…1765
PAYLOAD OPERATION AND CALCULATION…1766
Description of Haul Cycle States…1766
Haul Cycle Description…1766
Load Calculation…1767
Carry Back…1767
Measurement Accuracy…1767
SOURCES FOR PAYLOAD ERROR…1767
Payload Error…1767
Loading Conditions…1768
Pressure Sensors…1768
Swingloads…1768
Speed and Distance…1768
HAUL CYCLE DATA…1768
Haul Cycle Data…1769
Haul Cycle Warning Flags…1770
M: Haul Cycle Too Long…1771
N: Sensor Input Error…1771
Frame Torque Data…1771
Sprung Weight Data…1771
Maximum Speed Data…1771
Alarm Records…1771
Fault Code Data…1772
PC SOFTWARE OVERVIEW…1773
PC Overview…1773
System Configuration…1773
Installing the PLM III Software…1773
DOWNLOADING DATA…1774
PLM III SYSTEM CONFIGURATION…1775
Starting Communications…1775
Displayed Payload Units…1775
Time Units…1775
Connection Menu…1775
Connecting to the Payload Meter…1776
Configure the Payload Meter…1776
Setting the Date and Time…1776
Setting the Truck Type…1777
Setting the Gauge Display Units…1777
Setting the Frame Serial Number…1777
Setting the Truck Number…1777
Setting the Komatsu Distributor…1777
Setting the Komatsu Customer…1777
Clean Truck Tare…1778
Inclinometer Calibration…1778
DATA ANALYSIS…1779
Creating a Query…1779
Sorting on Truck Unit Number…1779
Sorting on Truck Type…1779
Sorting on Date Range…1780
Sorting on Time Range…1780
Payload Detail Screen…1781
Creating Reports…1781
Summary – One Page Report…1782
Detailed – Multi-Page Report…1782
Creating Graphs…1783
Exporting Data…1783
CSV Export…1783
Compressed…1785
Importing Data…1785
Deleting Haul Cycle Records…1785
Viewing Alarms…1786
Deleting Alarm Records…1786
AM/FM RADIO / CD PLAYER…1787
GENERAL RADIO RECEIVER FUNCTIONS…1787
Turning On the Power…1787
One-Hour Timer…1787
Display…1788
Setting a Default Display…1788
Adjusting the Brightness of the Display…1788
Auxiliary Mode…1788
Adjusting the Receiver Settings…1788
USING THE CLOCK…1789
Setting the Clock…1789
USING THE ALARM…1789
Setting the Alarm…1789
Turning the Alarm Off…1789
Activating Snooze…1789
Setting Alarm Volume…1789
USING THE RADIO…1790
Finding a Station…1790
Setting the Presets…1790
USING THE WEATHERBAND…1791
USING THE COMPACT DISC PLAYER…1791
Playing a Compact Disc…1791
Button Functions…1791
PLAYING AN MP3 DISC…1792
MP3 Format Compatibility…1792
Root Directory…1792
Empty Directory or Folder…1792
No Folder…1792
File Name Display…1792
Pre-Programmed Playlists…1793
Playing MP3 Files…1793
Button Functions…1793
TROUBLESHOOTING…1794
CEAM020701 – Dump Truck 730E Trolley Operation & Maintenance Manual…1797
COVER…1797
INTRODUCTION…1801
FOREWORD…1801
TRUCK MODEL…1802
ABOUT THIS MANUAL…1803
ALERTS PAGE…1804
TABLE OF CONTENTS…1805
TORQUE TABLES AND CONVERSION CHARTS…1815
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…1816
STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts…1816
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws…1817
STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws…1818
GENERAL SAFETY…1825
PERSONAL SAFETY…1825
Safety Rules…1825
Truck Safety Features…1825
Clothing And Personal Items…1825
Unauthorized Modification…1825
Leaving The Operator’s Seat…1825
Mounting And Dismounting…1825
Fire Extinguishers And First Aid Kits…1826
Precautions For High Temperature Fluids…1826
Asbestos Dust Hazard Prevention…1826
Fire Prevention For Fuel And Oil…1826
ROPS Precautions…1827
Preventing Injury From Work Equipment…1827
Precautions For Optional Attachments…1827
Precautions When Starting The Machine…1827
PRECAUTIONS FOR TRUCK OPERATION…1828
Safety Is Thinking Ahead…1828
Safety At The Work Site…1828
Fire Prevention…1828
Preparing For Operation…1828
Ventilation For Enclosed Areas…1828
Mirrors, Windows, And Lights…1828
In The Operator’s Cab – Before Starting The Engine…1829
Seat Belts…1829
OPERATING THE MACHINE…1829
Starting The Engine…1829
Truck Operation – General…1829
Traveling In The Truck…1830
Precautions When Traveling In Reverse…1830
Traveling On Slopes…1830
Ensuring Good Visibility…1831
Operating On Snow…1831
Avoid Damage To The Dump Body…1831
Driving Near High-Voltage Cables…1831
When Loading The Truck…1831
When Dumping…1831
Working On Loose Ground…1831
Parking The Machine…1832
TOWING…1832
WORKING NEAR BATTERIES…1832
Battery Hazard Prevention…1832
Jump-Starting With Booster Cables…1833
Jump Starting With Receptacles…1833
PRECAUTIONS FOR MAINTENANCE…1834
BEFORE PERFORMING MAINTENANCE…1834
Stopping The Engine Before Service…1834
Warning Tag…1834
Proper Tools…1834
Securing The Dump Body…1834
DURING MAINTENANCE…1835
Personnel…1835
Attachments…1835
Working Under The Machine…1835
Keeping The Machine Clean…1835
Rules To Follow When Adding Fuel Or Oil…1835
Radiator Coolant Level…1835
Use Of Lighting…1835
Precautions With The Battery…1836
Handling High-Pressure Hoses…1836
Precautions With High-Pressure Oil…1836
Maintenance Near High Temperatures And High Pressures…1836
Rotating Fan And Belts…1836
Waste Materials…1836
Use of Safety Tie-Off Anchor During Maintenance and Repair…1836
TIRES…1837
Handling Tires…1837
Tire Maintenance…1838
Storing Tires After Removal…1838
ADDITIONAL JOB SITE RULES…1839
WHEN REPAIRS ARE NECESSARY…1840
WARNINGS AND CAUTIONS…1843
OPERATING INSTRUCTIONS…1851
PREPARING FOR OPERATION…1851
SAFETY IS THINKING talkAHEAD…1851
WALK AROUND INSPECTION…1851
ENGINE START-UP…1855
AFTER ENGINE HAS STARTED…1856
EMERGENCY STEERING SYSTEM…1857
Operation…1857
Pre-Operation Testing…1857
Additional Guidelines…1858
MACHINE OPERATION SAFETY PRECAUTIONS…1858
LOADING…1859
HAULING…1859
PASSING…1860
DUMPING…1860
To Raise The Dump Body:…1860
To Lower The Dump Body: (When dumping over a berm or into a crusher):…1861
To Lower The Dump Body (When dumping on flat ground):…1861
SAFE PARKING PROCEDURES…1862
ENGINE SHUTDOWN PROCEDURE…1862
DELAYED ENGINE SHUTDOWN PROCEDURE…1863
SUDDEN LOSS OF POWER…1863
DISABLED TRUCK OPERATION…1864
GENERAL…1864
STEERING AND BRAKE SYSTEM…1864
Components Required…1864
Hookup…1865
DISABLED TRUCK DUMPING PROCEDURE…1866
Hookup…1866
Raising the Body…1866
Lowering the Body…1866
TOWING…1867
TROLLEY OPERATING INSTRUCTIONS…1867
AFTER THE ENGINE HAS STARTED…1867
OPERATING IN DIESEL MODE…1868
OPERATING IN TROLLEY LINE MODE…1868
GETTING ON LINE…1869
Operating On Trolley…1870
GETTING OFF LINE…1872
LINE STATUS SIGNALS…1872
LINE STATUS SIGNAL MARKINGS…1873
TRAFFIC CONSIDERATION FOR TROLLEY LINE OPERATION…1873
APPROACHING SLOW MOVING VEHICLES IN A TROLLEY ASSISTED TRUCK…1873
OPERATING SLOW MOVING VEHICLES ON TROLLEY ASSIST RAMPS…1874
TRUCK FAILURE WHILE ON TROLLEY…1874
OPERATOR CONTROLS…1875
STEERING WHEEL AND CONTROLS…1876
STEERING WHEEL…1876
HORN BUTTON…1876
TILT/TELESCOPE LEVER…1876
MULTI-FUNCTION TURN SIGNAL SWITCH…1876
Turn Signal Operation…1876
High Beam Headlight Operation…1876
Windshield Wiper Operation…1876
PEDALS…1877
SERVICE BRAKE PEDAL…1877
DYNAMIC RETARDER PEDAL…1877
THROTTLE PEDAL…1877
OVERHEAD PANEL CONTROLS AND COMPONENTS…1878
GRADE/SPEED WARNING CHART…1878
RADIO SPEAKERS…1878
WINDSHIELD WIPERS…1878
WARNING ALARM BUZZER…1878
CAB RADIO…1878
WARNING LIGHTS DIMMER CONTROL…1878
AIR CLEANER VACUUM GAUGES…1878
CENTER CONSOLE…1879
TRUCK CONTROLS…1880
F-N-R Selector Switch…1880
Hoist Control Lever…1880
Trolley Master Control Lever…1880
CONSOLE SWITCHES AND CONTROLS…1880
Cigarette Lighter…1880
Window Control Switches…1880
Engine Shutdown Switch…1880
Override Switch…1881
Retard Speed Control (RSC) Switch…1881
Retard Speed Control (RSC) Dial…1881
Statex III Download Port…1882
Engine Diagnostic Port (CENSE)…1882
Engine Diagnostic Connectors…1882
Data Storage Button…1882
Passenger Seat…1882
PAYLOAD METER…1882
Payload Meter Download Connector…1882
CAB CLIMATE CONTROL…1883
HEATER/AIR CONDITIONER VENTS…1883
HEATER/AIR CONDITIONER CONTROLS AND VENTS…1883
Defroster Vent Control Switch…1883
Heat Control Switch…1883
Temperature Control Knob…1883
Fan Control Knob…1883
Heater/Air Conditioner Vents…1883
OPERATOR SEAT…1884
ADJUSTMENT…1884
INSTRUMENT PANELS…1885
GENERAL INFORMATION…1886
CONTROL SYMBOLS…1886
Key Switch…1887
Engine Shutdown Switch With Timer Delay…1887
Fog Light Switch…1887
Ladder Light Switch…1887
Backup Light Switch…1887
Panel Illumination Lights…1887
Cab Air Conditioner/Heater Vents…1888
Engine Cold Weather Starting Aid Switch…1888
Rotating Beacon Light Switch…1888
Heated Mirror Switch…1888
Wheel Brake Lock Switch…1888
Parking Brake Switch…1888
Digital Tachometer…1889
Right Turn Signal Indicator Light…1889
High Beam Headlight Indicator Light…1889
Left Turn Signal Indicator Light…1889
Digital Speedometer/Payload Meter Display…1889
Voltmeter Gauge…1889
Engine Oil Pressure Gauge…1889
Engine Water Temperature Gauge…1889
Fuel Gauge…1890
Engine Hourmeter…1890
Headlight Switch…1890
Panel Illumination Lights Dimmer Rheostat…1890
Payload Meter Switch…1890
OVERHEAD STATUS / WARNING INDICATOR LIGHT PANEL…1891
INDICATOR LIGHT FUNCTIONS…1892
High Hydraulic Oil Temperature…1892
Low Steering Pressure…1892
Low Accumulator Precharge Pressure Warning…1892
Electric System Fault Warning…1893
Low Brake Pressure Indicator…1893
Low Hydraulic Tank Level…1893
Low Automatic Lubrication System Pressure…1893
Circuit Breaker Tripped…1893
Hydraulic Oil Filter…1893
Low Fuel Indicator…1894
Parking Brake Indicator…1894
Service Brake Indicator…1894
Body Up Indicator…1894
Dynamic Retarding Indicator…1894
Stop Engine Warning…1894
Backup Indicator…1894
Engine Shutdown Timer Switch…1894
Retard Speed Control…1894
Check Engine…1895
Service Engine Indicator (AEM)…1895
High Wheel Motor Temperature Indicator…1895
Blower Fault Warning…1895
Service Engine Indicator (CENSE)…1895
Komatsu Engines w/Centry™ Fuel Control…1895
Hazard Warning Light Switch…1895
Lamp Test Switch/Centry™ Diagnostic Test Switch…1896
REAR AXLE LIGHT BAR…1899
Backup Lights…1899
Retard Lights…1899
Brake Light…1899
Backup Alarm…1899
CENTRY™ FUEL SYSTEM DIAGNOSTICS…1900
GENERAL OPERATION…1900
DETERMINING FAULT CODES…1900
EXITING THE DIAGNOSTICS MODE…1901
LUBRICATION AND SERVICE…1903
GENERAL INFORMATION…1903
HYDRAULIC TANK SERVICE…1903
Adding Oil…1903
COOLING SYSTEM SERVICE…1904
Radiator Filling Procedure…1904
Coolant Specifications…1904
Unacceptable Practices…1904
WHEEL MOTOR SERVICE…1904
RESERVE ENGINE OIL SYSTEM (IF EQUIPPED)…1905
Reserve Oil Tank Filling Procedure (Remote fill)…1905
Inline Screen…1905
QUICK FILL SERVICE CENTER…1906
LEFT-HAND FUEL RECEIVER – OPTIONAL (WIGGINS QUICK FILL)…1907
LUBRICATION CHART…1908
10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS…1909
10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS (Continued)…1910
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…1911
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…1911
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…1912
250 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)…1913
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…1914
500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)…1915
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…1916
1500 HOUR LUBRICATION AND MAINTENANCE CHECKS…1917
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS…1917
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS…1918
10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS…1919
AUTOMATIC LUBRICATION SYSTEM…1921
GENERAL DESCRIPTION…1921
SYSTEM COMPONENTS…1922
Filter Assembly…1922
Hydraulic Motor and Grease Pump…1922
Reservoir…1922
Fixed Pressure Reducing Valve…1922
Flow Control Valve…1922
Solenoid Valve…1924
Vent Valve…1924
Time Delay Module…1924
Pump Cutoff Pressure Switch…1924
Unloader Valve…1924
Pressure Switch…1924
Pressure Gauge…1924
Manual Override Button…1924
Injectors…1924
SYSTEM OPERATION…1926
Normal Operation…1926
Pressure Failure Detection Circuits…1927
GENERAL INSTRUCTIONS…1928
LUBRICANT REQUIRED FOR SYSTEM…1928
SYSTEM PRIMING…1928
LUBRICANT PUMP…1928
Pump Housing Oil Level…1928
Pump Pressure Control…1928
Filter And Reservoir…1929
Filter Assembly Element…1929
INJECTORS (SL-1 Series H)…1930
Injector Specifications…1930
Injector Adjustment…1930
INJECTOR OPERATION…1931
SYSTEM CHECKOUT…1932
Lubrication Cycle Timer Check…1932
Lubrication Cycle Timer Adjustment…1933
PREVENTIVE MAINTENANCE INSPECTION…1933
10 Hour Lubrication System Inspection…1933
250 Hour Inspection…1933
1000 Hour Inspection…1934
SYSTEM TROUBLESHOOTING CHART…1935
MAJOR COMPONENT DESCRIPTION…1937
SPECIFICATIONS…1939
PAYLOAD METER III…1941
PAYLOAD METER III…1945
Introduction…1945
Data Summary…1945
Data Gathering…1945
COMPONENT DESCRIPTION…1946
System Diagram…1946
Suspension Pressure Sensors…1946
Inclinometer…1946
Operator Display…1946
Payload Operator Switch…1947
Speed Input…1947
Body-Up Switch…1947
Brake Lock Switch…1947
Payload Meter…1947
Communications Ports…1947
Key Switch Input…1948
Payload Meter Power…1948
Load Lights…1948
Wiring and Termination…1949
TCI Outputs…1949
OPERATOR’S DISPLAY AND SWITCH…1950
Reading the Speedometer…1950
Reading the Load Display…1950
Using the Operator ID…1950
Using the Load and Ton Counter…1950
Total Ton Counter…1950
Total Load Counter…1951
Clearing the Counters…1951
Viewing Live Sensor Data…1951
Other Display Messages…1951
PAYLOAD OPERATION AND CALCULATION…1952
Description of Haul Cycle States…1952
Haul Cycle Description…1952
Load Calculation…1953
Carry Back…1953
Measurement Accuracy…1953
SOURCES FOR PAYLOAD ERROR…1953
Payload Error…1953
Loading Conditions…1954
Pressure Sensors…1954
Swingloads…1954
Speed and Distance…1954
HAUL CYCLE DATA…1954
Haul Cycle Data…1955
Haul Cycle Warning Flags…1956
M: Haul Cycle Too Long…1957
N: Sensor Input Error…1957
Frame Torque Data…1957
Sprung Weight Data…1957
Maximum Speed Data…1957
Alarm Records…1957
Fault Code Data…1958
PC SOFTWARE OVERVIEW…1959
PC Overview…1959
System Configuration…1959
Installing the PLM III Software…1959
DOWNLOADING DATA…1960
PLM III SYSTEM CONFIGURATION…1961
Starting Communications…1961
Displayed Payload Units…1961
Time Units…1961
Connection Menu…1961
Connecting to the Payload Meter…1962
Configure the Payload Meter…1962
Setting the Date and Time…1962
Setting the Truck Type…1963
Setting the Gauge Display Units…1963
Setting the Frame Serial Number…1963
Setting the Truck Number…1963
Setting the Komatsu Distributor…1963
Setting the Komatsu Customer…1963
Clean Truck Tare…1964
Inclinometer Calibration…1964
DATA ANALYSIS…1965
Creating a Query…1965
Sorting on Truck Unit Number…1965
Sorting on Truck Type…1965
Sorting on Date Range…1966
Sorting on Time Range…1966
Payload Detail Screen…1967
Creating Reports…1967
Summary – One Page Report…1968
Detailed – Multi-Page Report…1968
Creating Graphs…1969
Exporting Data…1969
CSV Export…1969
Compressed…1971
Importing Data…1971
Deleting Haul Cycle Records…1971
Viewing Alarms…1972
Deleting Alarm Records…1972
AM/FM RADIO / CD PLAYER…1973
GENERAL RADIO RECEIVER FUNCTIONS…1973
Turning On the Power…1973
One-Hour Timer…1973
Display…1974
Setting a Default Display…1974
Adjusting the Brightness of the Display…1974
Auxiliary Mode…1974
Adjusting the Receiver Settings…1974
USING THE CLOCK…1975
Setting the Clock…1975
USING THE ALARM…1975
Setting the Alarm…1975
Turning the Alarm Off…1975
Activating Snooze…1975
Setting Alarm Volume…1975
USING THE RADIO…1976
Finding a Station…1976
Setting the Presets…1976
USING THE WEATHERBAND…1977
USING THE COMPACT DISC PLAYER…1977
Playing a Compact Disc…1977
Button Functions…1977
PLAYING AN MP3 DISC…1978
MP3 Format Compatibility…1978
Root Directory…1978
Empty Directory or Folder…1978
No Folder…1978
File Name Display…1978
Pre-Programmed Playlists…1979
Playing MP3 Files…1979
Button Functions…1979
TROUBLESHOOTING…1980
CEAM020902 – Dump Truck 730E Operation & Maintenance Manual…1983
CEAM020902_Print.pdf…0
INTRODUCTION…1987
FOREWORD…1987
TRUCK MODEL ILLUSTRATION…1988
ABOUT THIS MANUAL…1989
ALERTS PAGE…1990
TABLE OF CONTENTS…1991
STANDARD CHARTS AND TABLES…2001
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…2001
STANDARD ASSEMBLY TORQUES For 12-Point, Grade 9 Cap screws (SAE)…2002
STANDARD ASSEMBLY TORQUES For Class 10.9 Cap screws & Class 10 Nuts…2002
GENERAL SAFETY…2007
PERSONAL SAFETY…2007
Safety Rules…2007
Truck Safety Features…2007
Clothing And Personal Items…2007
Unauthorized Modification…2007
Leaving The Operator’s Seat…2007
Mounting And Dismounting…2007
Fire Extinguishers And First Aid Kits…2008
Precautions For High Temperature Fluids…2008
Asbestos Dust Hazard Prevention…2008
Fire Prevention For Fuel And Oil…2008
ROPS Precautions…2009
Preventing Injury From Work Equipment…2009
Precautions For Optional Attachments…2009
Precautions When Starting The Machine…2009
PRECAUTIONS FOR TRUCK OPERATION…2010
Safety Is Thinking Ahead…2010
Safety At The Work Site…2010
Fire Prevention…2010
Preparing For Operation…2010
Ventilation For Enclosed Areas…2010
Mirrors, Windows, And Lights…2010
In The Operator’s Cab – Before Starting The Engine…2011
OPERATING THE MACHINE…2011
Starting The Engine…2011
Truck Operation – General…2011
Traveling In The Truck…2012
Precautions When Traveling In Reverse…2012
Traveling On Slopes…2012
Ensuring Good Visibility…2013
Operating On Snow…2013
Avoid Damage To The Dump Body…2013
Driving Near High-Voltage Cables…2013
When Loading The Truck…2013
When Dumping…2013
Working On Loose Ground…2013
Parking The Machine…2014
TOWING…2014
WORKING NEAR BATTERIES…2014
Battery Hazard Prevention…2014
Jump-Starting With Booster Cables…2015
Jump Starting With Receptacles…2015
PRECAUTIONS FOR MAINTENANCE…2016
BEFORE PERFORMING MAINTENANCE…2016
Stopping The Engine Before Service…2016
Warning Tag…2016
Proper Tools…2016
Securing The Dump Body…2016
DURING MAINTENANCE…2017
Personnel…2017
Attachments…2017
Working Under The Machine…2017
Keeping The Machine Clean…2017
Rules To Follow When Adding Fuel Or Oil…2017
Radiator Coolant Level…2017
Use Of Lighting…2017
Precautions With The Battery…2018
Handling High-Pressure Hoses…2018
Precautions With High-Pressure Oil…2018
Maintenance Near High Temperatures And High Pressures…2018
Rotating Fan And Belts…2018
Waste Materials…2018
TIRES…2019
Handling Tires…2019
Tire Maintenance…2020
Storing Tires After Removal…2020
ADDITIONAL JOB SITE RULES…2021
WHEN REPAIRS ARE NECESSARY…2022
WARNINGS AND CAUTIONS…2025
OPERATING INSTRUCTIONS…2033
PREPARING FOR OPERATION…2033
SAFETY IS THINKING AHEAD…2033
WALK AROUND INSPECTION…2033
ENGINE START-UP…2038
AFTER ENGINE HAS STARTED…2039
EMERGENCY STEERING SYSTEM…2040
Operation…2040
Pre-Operation Testing…2040
Additional Guidelines…2041
MACHINE OPERATION SAFETY PRECAUTIONS…2041
LOADING…2042
HAULING…2042
PASSING…2043
DUMPING…2043
To Raise The Dump Body:…2043
To Lower The Dump Body: (When dumping over a berm or into a crusher):…2044
To Lower The Dump Body (When dumping on flat ground):…2044
SAFE PARKING PROCEDURES…2045
ENGINE SHUTDOWN PROCEDURE…2045
DELAYED ENGINE SHUTDOWN PROCEDURE…2046
SUDDEN LOSS OF POWER…2046
DISABLED TRUCK DUMPING PROCEDURE…2047
Hookup…2047
Raising the Body…2047
Lowering the Body…2047
TOWING…2048
OPERATOR CAB AND CONTROLS…2049
STEERING WHEEL AND CONTROLS…2050
STEERING WHEEL…2050
HORN BUTTON…2050
TILT/TELESCOPE LEVER…2050
MULTI-FUNCTION TURN SIGNAL SWITCH…2050
Turn Signal Operation…2050
High Beam Headlight Operation…2050
Windshield Wiper Operation…2050
PEDALS…2051
SERVICE BRAKE PEDAL…2051
DYNAMIC RETARDER PEDAL…2051
THROTTLE PEDAL…2051
OVERHEAD PANEL CONTROLS AND COMPONENTS…2052
GRADE/SPEED WARNING CHART…2052
RADIO SPEAKERS…2052
WARNING ALARM BUZZER…2052
CAB RADIO…2052
WARNING LIGHTS DIMMER CONTROL…2052
WARNING/STATUS INDICATOR LIGHT PANEL…2052
AIR CLEANER VACUUM GAUGES…2052
WINDSHIELD WIPERS…2052
TRUCK CONTROLS…2053
F-N-R Selector Switch…2053
Hoist Control Lever…2053
CONSOLE SWITCHES AND CONTROLS…2054
Cigarette Lighter…2054
Left-Hand Window Control Switch…2054
Right-Hand Window Control Switch…2054
Engine Shutdown Switch…2054
Override Switch…2054
Retard Speed Control (RSC) Switch…2055
Retard Speed Control (RSC) Dial…2055
Statex III Download Port…2056
Engine Diagnostic Port (CENSE)…2056
Engine Diagnostic Connectors…2056
Passenger Seat…2056
PAYLOAD METER…2056
Payload Meter Download Connector…2056
CAB CLIMATE CONTROL…2057
HEATER / AIR CONDITIONER CONTROLS…2057
Fan Speed Control Knob…2057
Temperature Control Knob…2057
Air Flow Directional Knob…2057
Heater/Air Conditioner Vents…2057
OPERATOR SEAT…2058
ADJUSTMENT…2058
INSTRUMENT PANEL…2059
GENERAL INFORMATION…2060
CONTROL SYMBOLS…2060
Key Switch…2061
Engine Shutdown Switch With Timer Delay…2061
Fog Light Switch…2061
Ladder Light Switch…2061
Backup Light Switch…2061
Panel Illumination Lights…2061
Cab Air Conditioner/Heater Vents…2062
Engine Cold Weather Starting Aid Switch…2062
Rotating Beacon Light Switch…2062
Heated Mirror Switch…2062
Wheel Brake Lock Switch…2062
Parking Brake Switch…2062
Digital Tachometer…2063
Right Turn Signal Indicator Light…2063
High Beam Headlight Indicator Light…2063
Left Turn Signal Indicator Light…2063
Digital Speedometer/Payload Meter Display…2063
Voltmeter Gauge…2063
Engine Oil Pressure Gauge…2063
Engine Water Temperature Gauge…2063
Fuel Gauge…2063
Engine Hourmeter…2063
Headlight Switch…2064
Panel Illumination Lights Dimmer Rheostat…2064
Payload Meter Switch…2064
OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL…2065
DESCRIPTION OF INDICATOR SYMBOLS…2065
INDICATOR LIGHT FUNCTIONS…2066
A1. High Hydraulic Oil Temperature…2066
B1. Low Steering Pressure…2066
C1. Low Accumulator Precharge Pressure…2067
D1. Electric System Fault…2067
E1. Low Brake Pressure…2067
A2. Low Hydraulic Tank Level…2067
B2. Automatic Lubrication System Pressure…2067
C2. Circuit Breaker Tripped…2067
D2. Hydraulic Oil Filter Monitor…2068
E2. Low Fuel…2068
A3. Parking Brake…2068
B3. Service Brake…2068
C3. Body Up…2068
D3. Dynamic Retarding…2068
E3. Stop Engine…2068
A4. Not Used…2069
B4. Manual Backup Lights…2069
C4. Engine Shutdown Timer…2069
D4. Retard Speed Control (RSC)…2069
E4. Check Engine…2069
A5. Service Engine Indicator (AEM)…2069
B5. High Wheel Motor Temperature…2069
C5. Blower Fault…2069
D5, E5, A6, B6, and C6. Not Used…2069
D6. Service Engine (CENSE)…2069
E6. Not Used…2069
Komatsu Engines w/Centry™ Fuel Control…2070
Hazard Warning Light Switch…2070
Lamp Test Switch/Centry™ Diagnostic Test Switch…2070
VEHICLE HEALTH MONITORING SYSTEM (VHMS)…2070
BASIC PRECAUTIONS…2070
OPERATION…2070
INTERFACE MODULE…2072
CENTRY™ FUEL SYSTEM DIAGNOSTICS…2073
GENERAL OPERATION…2073
DETERMINING FAULT CODES…2073
EXITING THE DIAGNOSTICS MODE…2074
LUBRICATION AND SERVICE…2075
GENERAL INFORMATION…2075
HYDRAULIC TANK SERVICE…2075
Adding Oil…2075
COOLING SYSTEM SERVICE…2076
Radiator Filling Procedure…2076
RESERVE ENGINE OIL SYSTEM – (IF EQUIPPED)…2076
Reserve Oil Tank Filling Procedure (Remote Fill)…2076
LEFT-HAND FUEL RECEIVER – OPTIONAL (WIGGINS QUICK FILL)…2077
LUBRICATION CHART…2078
10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS…2079
10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS (Continued)…2080
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…2081
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…2081
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…2082
250 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)…2083
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…2084
500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)…2085
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…2086
1500 HOUR LUBRICATION AND MAINTENANCE CHECKS…2087
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS…2087
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS…2088
10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS…2089
AUTOMATIC LUBRICATION SYSTEM…2091
GENERAL DESCRIPTION…2091
SYSTEM COMPONENTS…2092
Filter Assembly…2092
Hydraulic Motor and Grease Pump…2092
Reservoir…2092
Fixed Pressure Reducing Valve…2092
Flow Control Valve…2092
Solenoid Valve…2094
Vent Valve…2094
Time Delay Module…2094
Pump Cutoff Pressure Switch…2094
Unloader Valve…2094
Pressure Switch…2094
Pressure Gauge…2094
Manual Override Button…2094
Injectors…2094
SYSTEM OPERATION…2096
Normal Operation…2096
Pressure Failure Detection Circuits…2097
GENERAL INSTRUCTIONS…2098
LUBRICANT REQUIRED FOR SYSTEM…2098
SYSTEM PRIMING…2098
LUBRICANT PUMP…2098
Pump Housing Oil Level…2098
Pump Pressure Control…2098
FILTER AND RESERVOIR…2099
Filter Assembly Element…2099
INJECTORS (SL-1 Series H)…2100
Injector Specifications…2100
Injector Adjustment…2100
INJECTOR OPERATION…2101
SYSTEM CHECKOUT…2102
Lubrication Cycle Timer Check…2102
Lubrication Cycle Timer Adjustment…2103
PREVENTIVE MAINTENANCE INSPECTION…2103
10 Hour Lubrication System Inspection…2103
250 Hour Inspection…2103
1000 Hour Inspection…2104
SYSTEM TROUBLESHOOTING CHART…2105
730E MAJOR COMPONENTS…2108
MAJOR COMPONENT DESCRIPTION…2107
SPECIFICATIONS…2109
PAYLOAD METER III™…2111
INDEX…2111
Introduction…2113
Data Summary…2113
Data Gathering…2113
COMPONENT DESCRIPTION…2114
System Diagram…2114
Suspension Pressure Sensors…2114
Inclinometer…2114
Operator Display…2114
Operator Switch…2115
Speed Input…2115
Body-Up Switch…2115
Brake Lock Switch…2115
Payload Meter…2115
Communications Ports…2115
Key Switch Input…2116
Payload Meter Power…2116
Load Lights…2116
Wiring and Termination…2117
TCI Outputs…2117
OPERATOR’S DISPLAY AND SWITCH…2118
Reading the Speedometer…2118
Reading the Load Display…2118
Using the Operator ID…2118
Using the Load and Ton Counter…2118
Total Ton Counter…2118
Total Load Counter…2119
Clearing the Counters…2119
Viewing Live Sensor Data…2119
Other Display Messages…2119
PAYLOAD OPERATION & CALCULATION…2120
Haul Cycle States…2120
Haul Cycle Description…2120
Load Calculation…2121
Carry Back…2121
Measurement Accuracy…2121
SOURCES FOR PAYLOAD ERROR…2121
Payload Error…2121
Loading Conditions…2122
Pressure Sensors…2122
Swingloads…2122
Speed and Distance…2122
HAUL CYCLE DATA…2122
Haul Cycle Data…2123
Haul Cycle Warning Flags…2124
Frame Torque Data…2125
Sprung Weight Data…2125
Maximum Speed Data…2125
Alarm Records…2125
Fault Code Data…2126
PC SOFTWARE OVERVIEW…2127
PC Overview…2127
System Configuration…2127
Installing the PLMIII Software…2127
DOWNLOADING DATA…2128
PLM III SYSTEM CONFIGURATION…2129
Starting Communications…2129
Displayed Payload Units…2129
Time Units…2129
Connection Menu…2129
Connecting to the Payload Meter…2130
Configure the Payload Meter…2130
Setting the Date and Time…2130
Setting the Truck Type…2131
Setting the Gauge Display Units…2131
Setting the Frame Serial Number…2131
Setting the Truck Number…2131
Setting the Komatsu Distributor…2131
Setting the Komatsu Customer…2131
Clean Truck Tare…2132
Inclinometer Calibration…2132
DATA ANALYSIS…2133
Creating a Query…2133
Sorting on Truck Unit Number…2133
Sorting on Truck Type…2133
Sorting on Date Range…2134
Sorting on Time Range…2134
Payload Detail Screen…2135
Creating Reports…2135
Summary – one page report…2136
Detailed – multi-page report…2136
Creating Graphs…2137
Exporting Data…2137
CSV Export…2137
Compressed…2138
Importing Data…2139
Deleting Haul Cycle Records…2139
Viewing Alarms…2140
Deleting Alarm Records…2140
AM/FM RADIO / CD PLAYER…2143
OPERATING INSTRUCTIONS…2143
GENERAL RADIO RECEIVER FUNCTIONS…2143
Turning On the Power…2143
One-Hour Timer…2143
Display…2144
Setting a Default Display…2144
Adjusting the Brightness of the Display…2144
Auxiliary Mode…2144
Adjusting the Receiver Settings…2144
USING THE CLOCK…2145
Setting the Clock…2145
USING THE ALARM…2145
Setting the Alarm…2145
Turning the Alarm Off…2145
Activating Snooze…2145
Setting Alarm Volume…2145
USING THE RADIO…2146
Finding a Station…2146
Setting the Presets…2147
SATELLITE RADIO SERVICE (Optional)…2147
Activating Satellite Radio (Optional)…2147
USING THE WEATHERBAND…2148
USING THE COMPACT DISC PLAYER…2148
Playing a Compact Disc…2148
Button Functions…2148
PLAYING AN MP3 DISC…2149
MP3 Format Compatibility…2149
Root Directory…2149
Empty Directory or Folder…2149
No Folder…2149
File Name Display…2149
Pre-Programmed Playlists…2150
Playing MP3 Files…2150
Button Functions…2150
TROUBLESHOOTING…2151
CEAM022201 – Dump Truck 730E Operation & Maintenance Manual…2155
INTRODUCTION…2159
FOREWORD…2159
TRUCK MODEL ILLUSTRATION…2160
ABOUT THIS MANUAL…2161
ALERTS PAGE…2162
TABLE OF CONTENTS…2163
STANDARD CHARTS AND TABLES…2173
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…2173
STANDARD ASSEMBLY TORQUES For 12-Point, Grade 9 Cap screws (SAE)…2174
STANDARD ASSEMBLY TORQUES For Class 10.9 Cap screws & Class 10 Nuts…2174
GENERAL SAFETY…2179
PERSONAL SAFETY…2179
Safety Rules…2179
Truck Safety Features…2179
Clothing And Personal Items…2179
Unauthorized Modification…2179
Leaving The Operator’s Seat…2179
Mounting And Dismounting…2179
Fire Extinguishers And First Aid Kits…2180
Precautions For High Temperature Fluids…2180
Asbestos Dust Hazard Prevention…2180
Fire Prevention For Fuel And Oil…2180
ROPS Precautions…2181
Preventing Injury From Work Equipment…2181
Precautions For Optional Attachments…2181
Precautions When Starting The Machine…2181
PRECAUTIONS FOR TRUCK OPERATION…2182
Safety Is Thinking Ahead…2182
Safety At The Work Site…2182
Fire Prevention…2182
Preparing For Operation…2182
Ventilation For Enclosed Areas…2182
Mirrors, Windows, And Lights…2182
In The Operator’s Cab – Before Starting The Engine…2183
Seat Belts…2183
OPERATING THE MACHINE…2183
Starting The Engine…2183
Truck Operation – General…2183
Traveling In The Truck…2184
Precautions When Traveling In Reverse…2184
Traveling On Slopes…2184
Ensuring Good Visibility…2185
Operating On Snow…2185
Avoid Damage To The Dump Body…2185
Driving Near High-Voltage Cables…2185
When Loading The Truck…2185
When Dumping…2185
Working On Loose Ground…2185
Parking The Machine…2186
TOWING…2186
WORKING NEAR BATTERIES…2186
Battery Hazard Prevention…2186
Jump-Starting With Booster Cables…2187
Jump Starting With Receptacles…2187
PRECAUTIONS FOR MAINTENANCE…2188
BEFORE PERFORMING MAINTENANCE…2188
Stopping The Engine Before Service…2188
Warning Tag…2188
Proper Tools…2188
Securing The Dump Body…2188
DURING MAINTENANCE…2189
Personnel…2189
Attachments…2189
Working Under The Machine…2189
Keeping The Machine Clean…2189
Rules To Follow When Adding Fuel Or Oil…2189
Radiator Coolant Level…2189
Use Of Lighting…2189
Precautions With The Battery…2190
Handling High-Pressure Hoses…2190
Precautions With High-Pressure Oil…2190
Maintenance Near High Temperatures And High Pressures…2190
Rotating Fan And Belts…2190
Waste Materials…2190
TIRES…2191
Handling Tires…2191
Tire Maintenance…2192
Storing Tires After Removal…2192
ADDITIONAL JOB SITE RULES…2193
WHEN REPAIRS ARE NECESSARY…2194
WARNINGS AND CAUTIONS…2197
OPERATING INSTRUCTIONS…2205
PREPARING FOR OPERATION…2205
SAFETY IS THINKING AHEAD…2205
WALK AROUND INSPECTION…2205
ENGINE START-UP…2210
AFTER ENGINE HAS STARTED…2211
EMERGENCY STEERING SYSTEM…2212
Operation…2212
Pre-Operation Testing…2212
Additional Guidelines…2213
MACHINE OPERATION SAFETY PRECAUTIONS…2213
LOADING…2214
HAULING…2214
PASSING…2215
DUMPING…2215
To Raise The Dump Body:…2215
To Lower The Dump Body: (When dumping over a berm or into a crusher):…2216
To Lower The Dump Body (When dumping on flat ground):…2216
SAFE PARKING PROCEDURES…2217
ENGINE SHUTDOWN PROCEDURE…2217
DELAYED ENGINE SHUTDOWN PROCEDURE…2218
SUDDEN LOSS OF POWER…2218
DISABLED TRUCK DUMPING PROCEDURE…2219
Hookup…2219
Raising the Body…2219
Lowering the Body…2219
TOWING…2220
OPERATOR CAB AND CONTROLS…2221
STEERING WHEEL AND CONTROLS…2222
STEERING WHEEL…2222
HORN BUTTON…2222
TILT/TELESCOPE LEVER…2222
MULTI-FUNCTION TURN SIGNAL SWITCH…2222
Turn Signal Operation…2222
High Beam Headlight Operation…2222
Windshield Wiper Operation…2222
PEDALS…2223
SERVICE BRAKE PEDAL…2223
DYNAMIC RETARDER PEDAL…2223
THROTTLE PEDAL…2223
OVERHEAD PANEL CONTROLS AND COMPONENTS…2224
GRADE/SPEED WARNING CHART…2224
RADIO SPEAKERS…2224
WARNING ALARM BUZZER…2224
CAB RADIO…2224
WARNING LIGHTS DIMMER CONTROL…2224
WARNING/STATUS INDICATOR LIGHT PANEL…2224
AIR CLEANER VACUUM GAUGES…2224
WINDSHIELD WIPERS…2224
TRUCK CONTROLS…2225
F-N-R Selector Switch…2225
Hoist Control Lever…2225
CONSOLE SWITCHES AND CONTROLS…2226
Cigarette Lighter…2226
Left-Hand Window Control Switch…2226
Right-Hand Window Control Switch…2226
Engine Shutdown Switch…2226
Override Switch…2226
Retard Speed Control (RSC) Switch…2227
Retard Speed Control (RSC) Dial…2227
Statex III Download Port…2228
Engine Diagnostic Port (CENSE)…2228
Engine Diagnostic Connectors…2228
Passenger Seat…2228
PAYLOAD METER…2228
Payload Meter Download Connector…2228
CAB CLIMATE CONTROL…2229
HEATER / AIR CONDITIONER CONTROLS…2229
Fan Speed Control Knob…2229
Temperature Control Knob…2229
Air Flow Directional Knob…2229
Heater/Air Conditioner Vents…2229
OPERATOR SEAT…2230
Seat Belts…2230
ADJUSTMENT…2230
INSTRUMENT PANEL…2231
GENERAL INFORMATION…2232
CONTROL SYMBOLS…2232
Key Switch…2233
Engine Shutdown Switch With Timer Delay…2233
Fog Light Switch…2233
Ladder Light Switch…2233
Backup Light Switch…2233
Panel Illumination Lights…2233
Cab Air Conditioner/Heater Vents…2234
Engine Cold Weather Starting Aid Switch…2234
Rotating Beacon Light Switch…2234
Heated Mirror Switch…2234
Wheel Brake Lock Switch…2234
Parking Brake Switch…2234
Digital Tachometer…2235
Right Turn Signal Indicator Light…2235
High Beam Headlight Indicator Light…2235
Left Turn Signal Indicator Light…2235
Digital Speedometer/Payload Meter Display…2235
Voltmeter Gauge…2235
Engine Oil Pressure Gauge…2235
Engine Water Temperature Gauge…2235
Fuel Gauge…2235
Engine Hourmeter…2235
Headlight Switch…2236
Panel Illumination Lights Dimmer Rheostat…2236
Payload Meter Switch…2236
OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL…2237
DESCRIPTION OF INDICATOR SYMBOLS…2237
INDICATOR LIGHT FUNCTIONS…2238
A1. High Hydraulic Oil Temperature…2238
B1. Low Steering Pressure…2238
C1. Low Accumulator Precharge Pressure…2239
D1. Electric System Fault…2239
E1. Low Brake Pressure…2239
A2. Low Hydraulic Tank Level…2239
B2. Automatic Lubrication System Pressure…2239
C2. Circuit Breaker Tripped…2239
D2. Hydraulic Oil Filter Monitor…2240
E2. Low Fuel…2240
A3. Parking Brake…2240
B3. Service Brake…2240
C3. Body Up…2240
D3. Dynamic Retarding…2240
E3. Stop Engine…2240
A4. Not Used…2241
B4. Manual Backup Lights…2241
C4. Engine Shutdown Timer…2241
D4. Retard Speed Control (RSC)…2241
E4. Check Engine…2241
A5. Service Engine Indicator (AEM)…2241
B5. High Wheel Motor Temperature…2241
C5. Blower Fault…2241
D5, E5, A6, B6, and C6. Not Used…2241
D6. Service Engine (CENSE)…2241
E6. Not Used…2241
Komatsu Engines w/Centry™ Fuel Control…2242
Hazard Warning Light Switch…2242
Lamp Test Switch/Centry™ Diagnostic Test Switch…2242
VEHICLE HEALTH MONITORING SYSTEM (VHMS)…2242
BASIC PRECAUTIONS…2242
OPERATION…2242
INTERFACE MODULE…2244
CENTRY™ FUEL SYSTEM DIAGNOSTICS…2245
GENERAL OPERATION…2245
DETERMINING FAULT CODES…2245
EXITING THE DIAGNOSTICS MODE…2246
LUBRICATION AND SERVICE…2247
GENERAL INFORMATION…2247
HYDRAULIC TANK SERVICE…2247
Adding Oil…2247
COOLING SYSTEM SERVICE…2248
Radiator Filling Procedure…2248
RESERVE ENGINE OIL SYSTEM – (IF EQUIPPED)…2248
Reserve Oil Tank Filling Procedure (Remote Fill)…2248
LEFT-HAND FUEL RECEIVER – OPTIONAL (WIGGINS QUICK FILL)…2249
LUBRICATION CHART…2250
10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS…2251
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…2253
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…2253
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…2254
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…2256
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…2258
1500 HOUR LUBRICATION AND MAINTENANCE CHECKS…2259
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS…2259
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS…2260
10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS…2261
AUTOMATIC LUBRICATION SYSTEM…2263
GENERAL DESCRIPTION…2263
SYSTEM COMPONENTS…2264
Filter Assembly…2264
Hydraulic Motor and Grease Pump…2264
Reservoir…2264
Fixed Pressure Reducing Valve…2264
Flow Control Valve…2264
Solenoid Valve…2266
Vent Valve…2266
Time Delay Module…2266
Pump Cutoff Pressure Switch…2266
Unloader Valve…2266
Pressure Switch…2266
Pressure Gauge…2266
Manual Override Button…2266
Injectors…2266
SYSTEM OPERATION…2268
Normal Operation…2268
Pressure Failure Detection Circuits…2269
GENERAL INSTRUCTIONS…2270
LUBRICANT REQUIRED FOR SYSTEM…2270
SYSTEM PRIMING…2270
LUBRICANT PUMP…2270
Pump Housing Oil Level…2270
Pump Pressure Control…2270
FILTER AND RESERVOIR…2271
Filter Assembly Element…2271
INJECTORS (SL-1 Series H)…2272
Injector Specifications…2272
Injector Adjustment…2272
INJECTOR OPERATION…2273
SYSTEM CHECKOUT…2274
Lubrication Cycle Timer Check…2274
Lubrication Cycle Timer Adjustment…2275
PREVENTIVE MAINTENANCE INSPECTION…2275
10 Hour Lubrication System Inspection…2275
250 Hour Inspection…2275
1000 Hour Inspection…2276
SYSTEM TROUBLESHOOTING CHART…2277
730E MAJOR COMPONENTS…2280
MAJOR COMPONENT DESCRIPTION…2279
SPECIFICATIONS…2281
PAYLOAD METER III™…2283
INDEX…2283
Introduction…2285
Data Summary…2285
Data Gathering…2285
COMPONENT DESCRIPTION…2286
System Diagram…2286
Suspension Pressure Sensors…2286
Inclinometer…2286
Operator Display…2286
Operator Switch…2287
Speed Input…2287
Body-Up Switch…2287
Brake Lock Switch…2287
Payload Meter…2287
Communications Ports…2287
Key Switch Input…2288
Payload Meter Power…2288
Load Lights…2288
Wiring and Termination…2289
TCI Outputs…2289
OPERATOR’S DISPLAY AND SWITCH…2290
Reading the Speedometer…2290
Reading the Load Display…2290
Using the Operator ID…2290
Using the Load and Ton Counter…2290
Total Ton Counter…2290
Total Load Counter…2291
Clearing the Counters…2291
Viewing Live Sensor Data…2291
Other Display Messages…2291
PAYLOAD OPERATION & CALCULATION…2292
Haul Cycle States…2292
Haul Cycle Description…2292
Load Calculation…2293
Carry Back…2293
Measurement Accuracy…2293
SOURCES FOR PAYLOAD ERROR…2293
Payload Error…2293
Loading Conditions…2294
Pressure Sensors…2294
Swingloads…2294
Speed and Distance…2294
HAUL CYCLE DATA…2294
Haul Cycle Data…2295
Haul Cycle Warning Flags…2296
Frame Torque Data…2297
Sprung Weight Data…2297
Maximum Speed Data…2297
Alarm Records…2297
Fault Code Data…2298
PC SOFTWARE OVERVIEW…2299
PC Overview…2299
System Configuration…2299
Installing the PLMIII Software…2299
DOWNLOADING DATA…2300
PLM III SYSTEM CONFIGURATION…2301
Starting Communications…2301
Displayed Payload Units…2301
Time Units…2301
Connection Menu…2301
Connecting to the Payload Meter…2302
Configure the Payload Meter…2302
Setting the Date and Time…2302
Setting the Truck Type…2303
Setting the Gauge Display Units…2303
Setting the Frame Serial Number…2303
Setting the Truck Number…2303
Setting the Komatsu Distributor…2303
Setting the Komatsu Customer…2303
Clean Truck Tare…2304
Inclinometer Calibration…2304
DATA ANALYSIS…2305
Creating a Query…2305
Sorting on Truck Unit Number…2305
Sorting on Truck Type…2305
Sorting on Date Range…2306
Sorting on Time Range…2306
Payload Detail Screen…2307
Creating Reports…2307
Summary – one page report…2308
Detailed – multi-page report…2308
Creating Graphs…2309
Exporting Data…2309
CSV Export…2309
Compressed…2310
Importing Data…2311
Deleting Haul Cycle Records…2311
Viewing Alarms…2312
Deleting Alarm Records…2312
AM/FM RADIO / CD / MP3 / USB / iPOD™ / AUX PLAYER…2315
OPERATING INSTRUCTIONS…2315
GENERAL RADIO RECEIVER FUNCTIONS…2315
Turning On the Power…2315
One-Hour Timer…2315
Adjusting the Volume…2316
Display…2316
Radio Mode Displays…2316
CD Mode Displays…2316
MP3/USB/iPod Mode Displays…2316
AUX Input Displays…2317
CLOCK/ALARM Button…2317
Front Auxiliary Mode…2317
Rear Auxiliary Mode…2317
Adjusting the Receiver Audio Settings…2317
Adjusting the Receiver Menu Settings…2318
USING THE RADIO…2319
Finding a Station…2319
Setting the Presets…2319
USING THE CLOCK…2320
Setting the Clock…2320
USING THE ALARM…2320
Setting the Alarm…2320
Turning the Alarm Off…2321
Activating Snooze…2321
USING THE WEATHERBAND (USA Only)…2321
USING THE COMPACT DISC PLAYER/USB…2322
Playing A Compact Disc…2322
Button Functions…2322
PLAYING AN MP3 DISC/USB…2323
Root Directory…2323
Empty Directory or Folder…2323
No Folder…2323
File Name Display…2323
PLAYING MP3 FILES…2323
Button Functions…2323
USING AN iPOD®…2324
Playing an iPod…2324
Button Functions…2324
OPERATING TIPS…2325
Tips About The Audio System…2325
Understanding Radio Reception…2325
Care of The Compact Discs…2325
TROUBLESHOOTING…2326
CEAM024000 – Dump Truck 730E Trolley Operation & Maintenance Manual…2329
INTRODUCTION…2333
FOREWORD…2333
TRUCK MODEL ILLUSTRATION…2334
ABOUT THIS MANUAL…2335
ALERTS PAGE…2336
TABLE OF CONTENTS…2337
STANDARD CHARTS AND TABLES…2347
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…2347
STANDARD ASSEMBLY TORQUES For 12-Point, Grade 9 Cap screws (SAE)…2348
STANDARD ASSEMBLY TORQUES For Class 10.9 Cap screws & Class 10 Nuts…2348
GENERAL SAFETY…2353
PERSONAL SAFETY…2353
Safety Rules…2353
Truck Safety Features…2353
Clothing And Personal Items…2353
Unauthorized Modification…2353
Leaving The Operator’s Seat…2353
Mounting And Dismounting…2353
Fire Extinguishers And First Aid Kits…2354
Precautions For High Temperature Fluids…2354
Asbestos Dust Hazard Prevention…2354
Fire Prevention For Fuel And Oil…2354
ROPS Precautions…2355
Preventing Injury From Work Equipment…2355
Precautions For Optional Attachments…2355
Precautions When Starting The Machine…2355
PRECAUTIONS FOR TRUCK OPERATION…2356
Safety Is Thinking Ahead…2356
Safety At The Work Site…2356
Fire Prevention…2356
Preparing For Operation…2356
Ventilation For Enclosed Areas…2356
Mirrors, Windows, And Lights…2356
In The Operator’s Cab – Before Starting The Engine…2357
Seat Belts…2357
OPERATING THE MACHINE…2357
Starting The Engine…2357
Truck Operation – General…2357
Traveling In The Truck…2358
Precautions When Traveling In Reverse…2358
Traveling On Slopes…2358
Ensuring Good Visibility…2359
Operating On Snow…2359
Avoid Damage To The Dump Body…2359
Driving Near High-Voltage Cables…2359
When Loading The Truck…2359
When Dumping…2359
Working On Loose Ground…2359
Parking The Machine…2360
TOWING…2360
WORKING NEAR BATTERIES…2360
Battery Hazard Prevention…2360
Jump-Starting With Booster Cables…2361
Jump Starting With Receptacles…2361
PRECAUTIONS FOR MAINTENANCE…2362
BEFORE PERFORMING MAINTENANCE…2362
Stopping The Engine Before Service…2362
Warning Tag…2362
Proper Tools…2362
Securing The Dump Body…2362
DURING MAINTENANCE…2363
Personnel…2363
Attachments…2363
Working Under The Machine…2363
Keeping The Machine Clean…2363
Rules To Follow When Adding Fuel Or Oil…2363
Radiator Coolant Level…2363
Use Of Lighting…2363
Precautions With The Battery…2364
Handling High-Pressure Hoses…2364
Precautions With High-Pressure Oil…2364
Maintenance Near High Temperatures And High Pressures…2364
Rotating Fan And Belts…2364
Waste Materials…2364
TIRES…2365
Handling Tires…2365
Tire Maintenance…2366
Storing Tires After Removal…2366
ADDITIONAL JOB SITE RULES…2367
WHEN REPAIRS ARE NECESSARY…2368
WARNINGS AND CAUTIONS…2371
OPERATING INSTRUCTIONS…2379
PREPARING FOR OPERATION…2379
SAFETY IS THINKING AHEAD…2379
WALK AROUND INSPECTION…2379
ENGINE START-UP…2383
AFTER ENGINE HAS STARTED…2384
EMERGENCY STEERING SYSTEM…2385
Operation…2385
Pre-Operation Testing…2385
Additional Guidelines…2386
MACHINE OPERATION SAFETY PRECAUTIONS…2386
LOADING…2387
HAULING…2387
PASSING…2388
DUMPING…2388
To Raise The Dump Body:…2388
To Lower The Dump Body: (When dumping over a berm or into a crusher):…2389
To Lower The Dump Body (When dumping on flat ground):…2389
SAFE PARKING PROCEDURES…2390
ENGINE SHUTDOWN PROCEDURE…2390
DELAYED ENGINE SHUTDOWN PROCEDURE…2391
SUDDEN LOSS OF POWER…2391
DISABLED TRUCK DUMPING PROCEDURE…2392
Hookup…2392
Raising the Body…2392
Lowering the Body…2392
TOWING…2393
TROLLEY OPERATING INSTRUCTIONS…2393
AFTER THE ENGINE HAS STARTED…2393
OPERATING IN DIESEL MODE…2394
OPERATING IN TROLLEY LINE MODE…2394
GETTING ON LINE…2395
Operating On Trolley…2396
GETTING OFF LINE…2398
LINE STATUS SIGNALS…2398
LINE STATUS SIGNAL MARKINGS…2399
TRAFFIC CONSIDERATION FOR TROLLEY LINE OPERATION…2399
APPROACHING SLOW MOVING VEHICLES IN A TROLLEY ASSISTED TRUCK…2399
OPERATING SLOW MOVING VEHICLES ON TROLLEY ASSIST RAMPS…2400
TRUCK FAILURE WHILE ON TROLLEY…2400
OPERATOR CAB AND CONTROLS…2401
STEERING WHEEL AND CONTROLS…2402
STEERING WHEEL…2402
HORN BUTTON…2402
TILT/TELESCOPE LEVER…2402
MULTI-FUNCTION TURN SIGNAL SWITCH…2402
Turn Signal Operation…2402
High Beam Headlight Operation…2402
Windshield Wiper Operation…2402
PEDALS…2403
SERVICE BRAKE PEDAL…2403
DYNAMIC RETARDER PEDAL…2403
THROTTLE PEDAL…2403
OVERHEAD PANEL CONTROLS AND COMPONENTS…2404
GRADE/SPEED WARNING CHART…2404
RADIO SPEAKERS…2404
WARNING ALARM BUZZER…2404
CAB RADIO…2404
WARNING LIGHTS DIMMER CONTROL…2404
WARNING/STATUS INDICATOR LIGHT PANEL…2404
AIR CLEANER VACUUM GAUGES…2404
WINDSHIELD WIPERS…2404
TRUCK CONTROLS…2405
F-N-R Selector Switch…2405
Hoist Control Lever…2405
CONSOLE SWITCHES AND CONTROLS…2406
Cigarette Lighter…2406
Left-Hand Window Control Switch…2406
Right-Hand Window Control Switch…2406
Engine Shutdown Switch…2406
Override Switch…2406
Retard Speed Control (RSC) Switch…2407
Retard Speed Control (RSC) Dial…2407
Statex III Download Port…2408
Engine Diagnostic Port (CENSE)…2408
Engine Diagnostic Connectors…2408
Passenger Seat…2408
PAYLOAD METER…2408
Payload Meter Download Connector…2408
CAB CLIMATE CONTROL…2409
HEATER / AIR CONDITIONER CONTROLS…2409
Fan Speed Control Knob…2409
Temperature Control Knob…2409
Air Flow Directional Knob…2409
Heater/Air Conditioner Vents…2409
OPERATOR SEAT…2410
Seat Belts…2410
ADJUSTMENT…2410
INSTRUMENT PANEL…2411
GENERAL INFORMATION…2412
CONTROL SYMBOLS…2412
Key Switch…2413
Engine Shutdown Switch With Timer Delay…2413
Fog Light Switch…2413
Ladder Light Switch…2413
Backup Light Switch…2413
Panel Illumination Lights…2413
Cab Air Conditioner/Heater Vents…2414
Engine Cold Weather Starting Aid Switch…2414
Rotating Beacon Light Switch…2414
Heated Mirror Switch…2414
Wheel Brake Lock Switch…2414
Parking Brake Switch…2414
Digital Tachometer…2415
Right Turn Signal Indicator Light…2415
High Beam Headlight Indicator Light…2415
Left Turn Signal Indicator Light…2415
Digital Speedometer/Payload Meter Display…2415
Voltmeter Gauge…2415
Engine Oil Pressure Gauge…2415
Engine Water Temperature Gauge…2415
Fuel Gauge…2415
Engine Hourmeter…2415
Headlight Switch…2416
Panel Illumination Lights Dimmer Rheostat…2416
Payload Meter Switch…2416
OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL…2417
INDICATOR LIGHT FUNCTIONS…2418
A1. High Hydraulic Oil Temperature…2418
B1. Low Steering Pressure…2418
C1. Low Accumulator Precharge Pressure…2419
D1. Electric System Fault…2419
E1. Low Brake Pressure…2419
A2. Low Hydraulic Tank Level…2419
B2. Automatic Lubrication System Pressure…2419
C2. Circuit Breaker Tripped…2419
D2. Hydraulic Oil Filter Monitor…2420
E2. Low Fuel…2420
A3. Parking Brake…2420
B3. Service Brake…2420
C3. Body Up…2420
D3. Dynamic Retarding…2420
E3. Stop Engine…2420
A4. Not Used…2421
B4. Manual Backup Lights…2421
C4. Engine Shutdown Timer…2421
D4. Retard Speed Control (RSC)…2421
E4. Check Engine…2421
A5. Service Engine Indicator (AEM)…2421
B5. High Wheel Motor Temperature…2421
C5. Blower Fault…2421
D5, E5, A6, B6, and C6. Not Used…2421
D6. Service Engine (CENSE)…2421
E6. Not Used…2421
Komatsu Engines w/Centry™ Fuel Control…2422
Hazard Warning Light Switch…2422
Lamp Test Switch/Centry™ Diagnostic Test Switch…2422
TROLLEY INDICATOR LIGHTS…2422
Diesel Power Indicator…2422
Ready For Trolley Indicator…2422
On Trolley Indicator…2422
Trolley Fault Indicator…2423
Left Limit Indicator (Optional)…2423
Max Speed Indicator…2423
High Speed Indicator…2423
Med Speed Indicator…2424
Low Speed Indicator…2424
Right Limit Indicator (Optional)…2424
CENTRY™ FUEL SYSTEM DIAGNOSTICS…2425
GENERAL OPERATION…2425
DETERMINING FAULT CODES…2425
EXITING THE DIAGNOSTICS MODE…2426
LUBRICATION AND SERVICE…2427
GENERAL INFORMATION…2427
HYDRAULIC TANK SERVICE…2427
Adding Oil…2427
COOLING SYSTEM SERVICE…2428
Radiator Filling Procedure…2428
RESERVE ENGINE OIL SYSTEM – (IF EQUIPPED)…2428
Reserve Oil Tank Filling Procedure (Remote Fill)…2428
LEFT-HAND FUEL RECEIVER – OPTIONAL (WIGGINS QUICK FILL)…2429
LUBRICATION CHART…2430
10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS…2431
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…2433
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…2433
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…2434
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…2436
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…2438
1500 HOUR LUBRICATION AND MAINTENANCE CHECKS…2439
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS…2439
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS…2440
10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS…2441
AUTOMATIC LUBRICATION SYSTEM…2443
GENERAL DESCRIPTION…2443
SYSTEM COMPONENTS…2444
Filter Assembly…2444
Hydraulic Motor and Grease Pump…2444
Reservoir…2444
Fixed Pressure Reducing Valve…2444
Flow Control Valve…2444
Solenoid Valve…2446
Vent Valve…2446
Time Delay Module…2446
Pump Cutoff Pressure Switch…2446
Unloader Valve…2446
Pressure Switch…2446
Pressure Gauge…2446
Manual Override Button…2446
Injectors…2446
SYSTEM OPERATION…2448
Normal Operation…2448
Pressure Failure Detection Circuits…2449
GENERAL INSTRUCTIONS…2450
LUBRICANT REQUIRED FOR SYSTEM…2450
SYSTEM PRIMING…2450
LUBRICANT PUMP…2450
Pump Housing Oil Level…2450
Pump Pressure Control…2450
FILTER AND RESERVOIR…2451
Filter Assembly Element…2451
INJECTORS (SL-1 Series H)…2452
Injector Specifications…2452
Injector Adjustment…2452
INJECTOR OPERATION…2453
SYSTEM CHECKOUT…2454
Lubrication Cycle Timer Check…2454
Lubrication Cycle Timer Adjustment…2455
PREVENTIVE MAINTENANCE INSPECTION…2455
10 Hour Lubrication System Inspection…2455
250 Hour Inspection…2455
1000 Hour Inspection…2456
SYSTEM TROUBLESHOOTING CHART…2457
MAJOR COMPONENT DESCRIPTION…2459
SPECIFICATIONS…2461
PAYLOAD METER III™…2463
INDEX…2463
Introduction…2465
Data Summary…2465
Data Gathering…2465
COMPONENT DESCRIPTION…2466
System Diagram…2466
Suspension Pressure Sensors…2466
Inclinometer…2466
Operator Display…2466
Operator Switch…2467
Speed Input…2467
Body-Up Switch…2467
Brake Lock Switch…2467
Payload Meter…2467
Communications Ports…2467
Key Switch Input…2468
Payload Meter Power…2468
Load Lights…2468
Wiring and Termination…2469
TCI Outputs…2469
OPERATOR’S DISPLAY AND SWITCH…2470
Reading the Speedometer…2470
Reading the Load Display…2470
Using the Operator ID…2470
Using the Load and Ton Counter…2470
Total Ton Counter…2470
Total Load Counter…2471
Clearing the Counters…2471
Viewing Live Sensor Data…2471
Other Display Messages…2471
PAYLOAD OPERATION & CALCULATION…2472
Haul Cycle States…2472
Haul Cycle Description…2472
Load Calculation…2473
Carry Back…2473
Measurement Accuracy…2473
SOURCES FOR PAYLOAD ERROR…2473
Payload Error…2473
Loading Conditions…2474
Pressure Sensors…2474
Swingloads…2474
Speed and Distance…2474
HAUL CYCLE DATA…2474
Haul Cycle Data…2475
Haul Cycle Warning Flags…2476
Frame Torque Data…2477
Sprung Weight Data…2477
Maximum Speed Data…2477
Alarm Records…2477
Fault Code Data…2478
PC SOFTWARE OVERVIEW…2479
PC Overview…2479
System Configuration…2479
Installing the PLMIII Software…2479
DOWNLOADING DATA…2480
PLM III SYSTEM CONFIGURATION…2481
Starting Communications…2481
Displayed Payload Units…2481
Time Units…2481
Connection Menu…2481
Connecting to the Payload Meter…2482
Configure the Payload Meter…2482
Setting the Date and Time…2482
Setting the Truck Type…2483
Setting the Gauge Display Units…2483
Setting the Frame Serial Number…2483
Setting the Truck Number…2483
Setting the Komatsu Distributor…2483
Setting the Komatsu Customer…2483
Clean Truck Tare…2484
Inclinometer Calibration…2484
DATA ANALYSIS…2485
Creating a Query…2485
Sorting on Truck Unit Number…2485
Sorting on Truck Type…2485
Sorting on Date Range…2486
Sorting on Time Range…2486
Payload Detail Screen…2487
Creating Reports…2487
Summary – one page report…2488
Detailed – multi-page report…2488
Creating Graphs…2489
Exporting Data…2489
CSV Export…2489
Compressed…2490
Importing Data…2491
Deleting Haul Cycle Records…2491
Viewing Alarms…2492
Deleting Alarm Records…2492
AM/FM RADIO / CD / MP3 / USB / iPOD™ / AUX PLAYER…2495
OPERATING INSTRUCTIONS…2495
GENERAL RADIO RECEIVER FUNCTIONS…2495
Turning On the Power…2495
One-Hour Timer…2495
Adjusting the Volume…2496
Display…2496
Radio Mode Displays…2496
CD Mode Displays…2496
MP3/USB/iPod Mode Displays…2496
AUX Input Displays…2497
CLOCK/ALARM Button…2497
Front Auxiliary Mode…2497
Rear Auxiliary Mode…2497
Adjusting the Receiver Audio Settings…2497
Adjusting the Receiver Menu Settings…2498
USING THE RADIO…2499
Finding a Station…2499
Setting the Presets…2499
USING THE CLOCK…2500
Setting the Clock…2500
USING THE ALARM…2500
Setting the Alarm…2500
Turning the Alarm Off…2501
Activating Snooze…2501
USING THE WEATHERBAND (USA Only)…2501
USING THE COMPACT DISC PLAYER/USB…2502
Playing A Compact Disc…2502
Button Functions…2502
PLAYING AN MP3 DISC/USB…2503
Root Directory…2503
Empty Directory or Folder…2503
No Folder…2503
File Name Display…2503
PLAYING MP3 FILES…2503
Button Functions…2503
USING AN iPOD®…2504
Playing an iPod…2504
Button Functions…2504
OPERATING TIPS…2505
Tips About The Audio System…2505
Understanding Radio Reception…2505
Care of The Compact Discs…2505
TROUBLESHOOTING…2506
CEAM024802 – Dump Truck 730E Operation & Maintenance Manual…2509
1 INTRODUCTION…2522
FOREWORD…2522
ABOUT THIS MANUAL…2523
ALERTS…2524
TRUCK MODEL ILLUSTRATION…2525
NON-OEM PARTS IN CRITICAL SYSTEMS…2526
2 STANDARD CHARTS AND TABLES…2528
GENERAL INFORMATION…2528
EFFECT OF SPECIAL LUBRICANTS…2528
SUGGESTED SOURCES FOR RUST PREVENTIVE GREASE…2528
STANDARD TIGHTENING TORQUES…2529
CLASS 10.9 CAP SCREWS & CLASS 10 NUTS…2529
SAE GRADE 5 AND GRADE 8 CAP SCREWS…2530
SAE GRADE 9 CAP SCREWS…2531
T-BOLT CLAMPS…2531
SPLIT FLANGE CLAMPS…2532
FLARED TUBE AND HOSE FITTINGS…2532
JIC 37° SWIVEL NUTS…2533
PIPE THREAD FITTINGS…2534
O-RING BOSS FITTINGS…2535
O-RING FACE SEAL FITTINGS…2536
CONVERSION MULTIPLIERS…2537
METRIC TO ENGLISH…2537
ENGLISH TO METRIC…2538
TEMPERATURE CONVERSIONS…2539
3 GENERAL SAFETY…2542
GENERAL SAFETY…2542
Safety Rules…2542
Truck Safety Features…2542
Clothing And Personal Items…2542
Unauthorized Modification…2542
Leaving The Operator’S Seat…2542
Mounting And Dismounting…2543
Fire Extinguishers And First Aid Kits…2543
Precautions For High Temperature Fluids…2543
Asbestos Dust Hazard Prevention…2543
Fire Prevention…2543
Rops Precautions…2544
Preventing Injury From Work Equipment…2544
Precautions For Optional Attachments…2544
Precautions When Starting The Machine…2544
PRECAUTIONS FOR TRUCK OPERATION…2545
Safety Is Thinking Ahead…2545
Safety At The Worksite…2545
Preparing For Operation…2545
Ventilation For Enclosed Areas…2545
Mirrors, Windows, And Lights…2545
Before Starting The Engine…2545
Seat Belts…2546
Emergency Egress Ladders…2546
OPERATING THE MACHINE…2547
General Information…2547
Starting The Engine…2547
Traveling In The Machine…2547
Traveling In Reverse…2548
Traveling On Slopes…2548
Traveling On Snow…2548
Traveling Near High Voltage Cables…2548
Traveling On Loose Ground…2548
Ensuring Good Visibility…2549
Avoid Damage To The Dump Body…2549
Safe Parking Of The Machine…2549
Loading The Machine…2549
Dumping The Machine…2549
Towing The Machine…2549
EXTERIOR LIGHTING…2550
Fog Lights…2550
Headlights…2550
Brake Light…2550
Retard Light…2551
Clearance/Turn Signal Lights…2551
Backup Lights…2551
Retard Lights…2551
Brake Lights…2551
Backup Alarm…2552
PRECAUTIONS FOR MAINTENANCE…2553
BEFORE PERFORMING MAINTENANCE…2553
Securing The Dump Body…2553
DURING MAINTENANCE…2554
Warning Tag…2554
Proper Tools…2554
Attachments…2554
Working Under The Machine…2554
Keeping The Machine Clean…2554
Adding Fuel Or Oil To The Machine…2555
Radiator Coolant Level…2555
Use Of Lighting…2555
Handling High Pressure Hoses…2555
Precautions With High Pressure Oil…2555
Maintenance Near High Temperatures and High Pressures…2555
Rotating Fan And Belts…2556
Waste Materials…2556
Use of Tie-Off Anchor During Maintenance…2556
Handling Tires…2556
Tire Maintenance…2557
Storing Tires After Removal…2557
Battery Hazard Prevention…2557
Jump Starting With Booster Cables…2558
Jump Starting With Receptacles…2558
WHEN REPAIRS ARE NECESSARY…2560
Observe The Following Precautions…2560
SPECIAL PRECAUTIONS…2561
Preliminary Procedures Before Welding or Performing Maintenance…2561
Engine Shutdown Procedure Before Welding or Performing Maintenan…2561
4 WARNING AND CAUTIONS…2564
GENERAL INFORMATION…2564
PIN PLATE…2564
GRADE SPEED CHART…2565
MACHINE SAFETY…2565
KEY SWITCH…2568
OIL FILL AND CHECK…2569
HIGH PRESSURES…2570
BATTERY AND ISOLATION BOX…2572
HIGH VOLTAGE…2573
WELDING…2574
LIFTING POINTS…2574
AUTOMATIC LUBRICATION FILL…2575
ROPS/FOPS…2576
LUBRICATION CHART…2576
5 OPERATING INSTRUCTIONS…2578
PREPARING FOR OPERATION…2578
Safety Is Thinking Ahead…2578
Walk Around Inspection…2578
TRUCK OPERATION…2583
ENGINE START-UP SAFETY…2583
After Engine Has Started…2583
MACHINE OPERATION SAFETY PRECAUTIONS…2584
Machine Operation On The Haul Road…2585
Starting On A Grade With A Loaded Truck…2585
Retarding On A Grade…2585
Passing…2586
Loading…2586
Dumping…2587
Lowering The Dump Body (When Dumping On Flat Ground)…2588
Lowering The Dump Body (When Dumping Over A Berm Or Into A Crush…2588
SUDDEN LOSS OF ENGINE POWER…2588
EMERGENCY STEERING SYSTEM…2589
Operation…2589
Pre-Operation Testing…2589
Additional Guidelines…2590
SAFE PARKING PROCEDURES…2590
NORMAL ENGINE SHUTDOWN PROCEDURE…2590
DISABLED TRUCK CONNECTORS…2592
GENERAL INFORMATION…2592
STEERING AND BRAKE SYSTEM…2592
Components Required…2592
Hookup…2592
HOIST SYSTEM…2593
Hookup…2593
Dumping Procedure…2594
TOWING…2595
Towing Procedure…2595
PAYLOAD METER III SYSTEM…2596
GENERAL INFORMATION…2596
Data Summary…2596
Data Gathering…2596
COMPONENT DESCRIPTION…2596
Operator Display…2596
Operator Switch…2596
Brake Lock Switch…2597
Payload Meter Module…2597
Communications Ports…2597
Load Lights…2597
OPERATORS DISPLAY AND SWITCH…2597
Reading the Load Display…2597
Setting the Operator ID…2598
Load and Ton Counter…2598
Viewing Live Sensor Data…2598
Other Display Messages…2599
HAUL CYCLE WARNING FLAGS…2599
Haul Cycle Data…2599
Haul Cycle Warning Flags…2601
PC SOFTWARE OVERVIEW…2602
SYSTEM CONFIGURATION…2603
Connecting to the Payload Meter…2603
Displayed Payload Units…2603
Connection Menu…2603
Configure the Payload Meter…2604
Setting the Date and Time…2604
Setting the Truck Type and Serial Number…2605
Setting the Gauge Display Units…2605
Setting the Carryback Alarm Threshold…2605
Setting the Truck Number…2606
Setting the Komatsu Distributor…2606
Setting the Komatsu Customer…2606
Clean Truck Tare Calibration…2606
Inclinometer Calibration…2607
DOWNLOADING PAYLOAD DATA…2607
UPLOADING DATA…2608
DATA ANALYSIS…2609
Creating a Query…2609
Payload Detail Screen…2610
Creating Reports…2610
Creating Graphs…2610
Exporting Data…2611
Importing Data…2612
Deleting Haul Cycle Records…2612
Viewing Alarms…2612
Deleting Alarm Records…2612
Patent Acknowledment…2612
AUTOMATIC LUBRICATION SYSTEM…2613
GENERAL INFORMATION…2613
COMPONENT DESCRIPTION…2613
Filter…2614
Vent Valve…2615
Flow Control Valve…2615
Grease Reservoir…2615
Pressure Reducing Valve…2615
Hydraulic Motor and Pump…2615
Solenoid Valve…2615
Pressure Cut Off Switch…2615
Injectors…2616
Grease Pressure Failure Switch…2617
Relief Valve (unloader valve)…2617
Lubrication Cycle Timer…2617
SYSTEM OPERATION…2617
Filling The Reservoir…2617
Priming The Automatic Lubrication System…2618
PREVENTIVE MAINTENANCE PROCEDURES…2619
Daily Lubrication System Inspection…2619
250 Hour Inspection…2619
1000 Hour Inspection…2620
SYSTEM CHECKOUT…2620
General Checks…2620
Lubrication Controller Components…2620
RESERVE ENGINE OIL SYSTEM (Optional)…2622
Operation…2622
Changing Oil…2622
6 OPERATOR CAB AND CONTROLS…2626
CAB INTERIOR…2626
STEERING WHEEL AND CONTROLS…2627
Horn Button…2627
Tilt / Telescope Lever…2627
Multi-Function Turn Signal Switch…2627
Turn Signal Operation…2627
High Beam Headlight Operation…2627
Windshield Wiper Operation…2628
PEDALS…2629
SERVICE BRAKE PEDAL…2629
DYNAMIC RETARD PEDAL…2629
Dynamic Retarding…2629
ACCELERATOR PEDAL…2629
OVERHEAD PANEL AND DISPLAYS…2631
RADIO SPEAKERS…2631
WARNING ALARM BUZZER…2631
CAB RADIO…2631
WARNING LIGHT DIMMER CONTROL…2631
STATUS/WARNING INDICATOR LIGHT PANEL…2631
AIR CLEANER VACUUM GAUGES…2631
WINDSHIELD WIPERS…2631
CENTER CONSOLE…2632
FNR CONTROL LEVER…2632
Lowering The Dump Body…2633
WINDOW CONTROL SWITCHES…2633
ENGINE STOP SWITCH…2633
OVERRIDE/FAULT RESET SWITCH…2633
RETARD SPEED CONTROL (RSC) SWITCH…2633
RETARD SPEED CONTROL (RSC) ADJUST DIAL…2633
DATA STORE BUTTON…2634
DIAGNOSTIC PORTS…2635
ENGINE (CENTRY)…2635
ENGINE (CENSE)…2635
STATEX III…2635
KOMTRAX Plus AND PAYLOAD METER…2635
INTERFACE MODULE …2636
OPERATOR’S SEAT (Standard)…2637
SEAT BELTS…2637
ADJUSTMENT…2637
HEATER / AIR CONDITIONER CONTROLS…2639
Fan Speed Control Knob…2639
Temperature Control Knob…2639
Air Flow Directional Knob…2639
Heater/Air Conditioner Vents…2639
INSTRUMENT PANEL …2640
CONTROL SYMBOLS…2640
Key Switch…2641
Engine Shutdown Switch…2642
Fog Light Swich…2642
Ladder Light Switch…2642
Backup Light Switch…2642
Panel Illumination Lights…2642
Cab Air Conditioner/Heater Vents…2642
Engine Cold Weather Starting Aid Switch…2642
Rotating Beacon Light Switch (Optional)…2642
Heated Mirror Switch (Optional)…2642
Leakage Test Switch (Trolley Only)…2643
Wheel Brake Lock Control Switch…2643
Parking Brake Switch…2643
Tachometer…2643
Right Turn Signal Indicator…2643
High Beam Indicator…2644
Left Turn Signal Indicator…2644
Speedometer/Payload Meter Display…2644
Voltmeter Gauge…2644
Engine Oil Pressure Gauge…2644
Water Temperature Gauge…2644
Fuel Level Gauge…2644
Hourmeter…2644
Headlight Switch…2645
Panel Light Dimmer…2645
Payload Meter Switch…2645
OVERHEAD STATUS/WARNING INDICATOR…2646
STATUS / WARNING INDICATOR LIGHT SYMBOLS…2647
High Hydraulic Oil Temperature…2647
Low Steering Pressure…2647
Low Accumulator Precharge Pressure…2648
No Power…2649
Low Brake Pressure…2649
Low Hydraulic Tank Level…2649
Automatic Lubrication System Pressure…2649
Circuit Breaker Tripped…2649
Hydraulic Oil Filter Monitor…2649
Low Fuel…2650
Parking Brake…2650
Service Brake…2650
Body Up…2650
Dynamic Retarding…2650
Stop Engine…2650
Manual Backup Lights…2651
Engine Shutdown Timer…2651
Retard Speed Control (RSC) Indicator…2651
Check Engine…2651
Service Engine Indicator (AEM)…2651
Propulsion System Temperature…2651
Blower Fault…2652
Service Engine Indicator (CENSE)…2652
Hazard Light Switch…2652
Lamp Test Switch…2652
KOMTRAX Plus…2653
KOMTRAX Plus OPERATION…2653
Basic Precautions…2653
Interface Module…2655
DOWNLOADING KOMTRAX Plus DATA…2655
GENERAL INFORMATION…2655
KOMTRAX Plus DOWNLOADING PROCEDURE…2655
Location of Downloaded Files…2656
UPLOADING KOMTRAX Plus DATA…2657
ORBCOMM…2658
CENTRYTM FUEL SYSTEM DIAGNOSTICS…2660
GENERAL OPERATION…2660
DETERMINING FAULT CODES…2660
EXITING THE DIAGNOSTICS MODE…2661
7 LUBRICATION AND SERVICE…2664
GENERAL INFORMATION…2664
HYDRAULIC SYSTEM SERVICE…2664
Hydraulic Tank…2664
Hydraulic Filters…2665
Hydraulic Pump Drive Shaft…2665
WHEEL MOTOR SERVICE…2665
COOLANT LEVEL SERVICE…2665
Radiator Filling Procedure…2665
Coolant Specifications…2666
Unacceptable Practices…2666
RESERVE ENGINE OIL SERVICE (If Equipped)…2666
Reserve Oil Tank Filling Procedure (Remote Fill)…2666
CAB AIR FILTER SERVICE…2667
FUEL SYSTEM SERVICE…2667
Fuel Tank Cleaning…2667
Fuel Filter Service…2668
INTAKE AIR CLEANER SERVICE…2668
FRONT WHEEL SERVICE…2670
Oil Sampling…2670
FRONT ENGINE MOUNT TRUNION SERVICE…2670
QUICK FILL SERVICE CENTER…2670
LUBRICATION CHART…2672
EVERY 10 HOUR (DAILY) MAINTENANCE…2673
INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION…2675
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION…2676
EVERY 250 HOUR LUBRICATION AND MAINTENANCE…2677
EVERY 500 HOUR LUBRICATION AND MAINTENANCE…2679
EVERY 1000 HOURS LUBRICATION AND MAINTENANCE…2681
EVERY 2500 HOUR MAINTENANCE…2682
EVERY 5000 HOUR MAINTENANCE…2683
EVERY 10,000 HOUR MAINTENANCE…2684
8 SPECIFICATIONS…2686
MAJOR COMPONENT DESCRIPTION…2686
Truck And Engine…2686
Alternator (GTA-22)…2686
Wheel Motors (GE 788)…2686
Blower…2686
Suspension…2686
Operator's Cab…2686
Power Steering…2686
Dynamic Retarding Gird…2686
Brake System…2686
SPECIFICATIONS…2687
Engine…2687
Electric Drive System…2687
Dynamic Retarding…2687
Battery Electric System…2687
Service Capacities…2687
Hydraulic Systems…2687
Service Brakes…2687
Steering…2687
Standard Dump Body Capacities And Dimensions…2688
Tires…2688
Weight Distribution…2688
Overall Truck Dimensions…2688
9 RADIO…2692
RADIO OPERATION…2692
GENERAL RADIO RECEIVER FUNCTIONS…2692
Turning On the Power…2692
One-Hour Timer…2693
Finding a Station…2693
Setting the Presets…2693
Adjusting the Receiver Audio Settings…2694
Display…2694
Adjusting the Receiver Menu Settings…2694
Front Auxiliary Mode…2695
Rear Auxiliary Mode…2695
CLOCK…2696
Clock/Alarm Button…2696
Setting the Clock…2696
Setting the Alarm…2696
Turning the Alarm Off…2697
Activating Snooze…2697
CD PLAYER…2698
Playing A Compact Disc…2698
Playing an MP3 DISC…2698
CD Mode Displays…2698
Button Functions…2698
MP3 PLAYER…2700
Playing MP3 Files…2700
MP3 Mode Displays…2700
Button Functions…2701
iPod®…2702
Playing an iPod®…2702
iPod® Mode Displays…2702
Button Functions…2702
WEATHERBAND (USA Only)…2704
TROUBLESHOOTING…2705
Tips About The Audio System…2705
Understanding Radio Reception…2705
Care of The Compact Discs…2705
CEAM024900 – Dump Truck 730E Trolley Operation & Maintenance Manual…2706
COVER…2706
INTRODUCTION…2710
FOREWORD…2710
ABOUT THIS MANUAL…2712
ALERTS PAGE…2713
TABLE OF CONTENTS…2714
TORQUE TABLES AND CONVERSION CHARTS…2724
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…2725
STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts…2725
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws…2726
STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws…2727
GENERAL SAFETY…2734
PERSONAL SAFETY…2734
Safety Rules…2734
Truck Safety Features…2734
Clothing And Personal Items…2734
Unauthorized Modification…2734
Leaving The Operator’s Seat…2734
Mounting And Dismounting…2734
Fire Extinguishers And First Aid Kits…2735
Precautions For High Temperature Fluids…2735
Asbestos Dust Hazard Prevention…2735
Fire Prevention For Fuel And Oil…2735
ROPS Precautions…2736
Preventing Injury From Work Equipment…2736
Precautions For Optional Attachments…2736
Precautions When Starting The Machine…2736
PRECAUTIONS FOR TRUCK OPERATION…2737
Safety Is Thinking Ahead…2737
Safety At The Work Site…2737
Fire Prevention…2737
Preparing For Operation…2737
Ventilation For Enclosed Areas…2737
Mirrors, Windows, And Lights…2737
In The Operator’s Cab – Before Starting The Engine…2738
Seat Belts…2738
OPERATING THE MACHINE…2738
Starting The Engine…2738
Truck Operation – General…2738
Traveling In The Truck…2739
Precautions When Traveling In Reverse…2739
Traveling On Slopes…2739
Ensuring Good Visibility…2740
Operating On Snow…2740
Avoid Damage To The Dump Body…2740
Driving Near High-Voltage Cables…2740
When Loading The Truck…2740
When Dumping…2740
Working On Loose Ground…2740
Parking The Machine…2741
TOWING…2741
WORKING NEAR BATTERIES…2741
Battery Hazard Prevention…2741
Jump-Starting With Booster Cables…2742
Jump Starting With Receptacles…2742
PRECAUTIONS FOR MAINTENANCE…2743
BEFORE PERFORMING MAINTENANCE…2743
Stopping The Engine Before Service…2743
Warning Tag…2743
Proper Tools…2743
Securing The Dump Body…2743
DURING MAINTENANCE…2744
Personnel…2744
Attachments…2744
Working Under The Machine…2744
Keeping The Machine Clean…2744
Rules To Follow When Adding Fuel Or Oil…2744
Radiator Coolant Level…2744
Use Of Lighting…2744
Precautions With The Battery…2745
Handling High-Pressure Hoses…2745
Precautions With High-Pressure Oil…2745
Maintenance Near High Temperatures And High Pressures…2745
Rotating Fan And Belts…2745
Waste Materials…2745
Use of Tie-Off Anchor During Maintenance and Repair…2745
TIRES…2746
Handling Tires…2746
Tire Maintenance…2747
Storing Tires After Removal…2747
ADDITIONAL JOB SITE RULES…2748
WHEN REPAIRS ARE NECESSARY…2749
WARNINGS AND CAUTIONS…2752
OPERATING INSTRUCTIONS…2760
PREPARING FOR OPERATION…2760
SAFETY IS THINKING talkAHEAD…2760
WALK AROUND INSPECTION…2760
ENGINE START-UP…2764
AFTER ENGINE HAS STARTED…2765
EMERGENCY STEERING SYSTEM…2766
Operation…2766
Pre-Operation Testing…2766
Additional Guidelines…2767
MACHINE OPERATION SAFETY PRECAUTIONS…2767
LOADING…2768
HAULING…2768
PASSING…2769
DUMPING…2769
To Raise The Dump Body:…2769
To Lower The Dump Body: (When dumping over a berm or into a crusher):…2770
To Lower The Dump Body (When dumping on flat ground):…2770
SAFE PARKING PROCEDURES…2771
ENGINE SHUTDOWN PROCEDURE…2771
DELAYED ENGINE SHUTDOWN PROCEDURE…2772
SUDDEN LOSS OF POWER…2772
DISABLED TRUCK OPERATION…2773
GENERAL…2773
STEERING AND BRAKE SYSTEM…2773
Components Required…2773
Hookup…2774
DISABLED TRUCK DUMPING PROCEDURE…2775
Hookup…2775
Raising the Body…2775
Lowering the Body…2775
TOWING…2776
TROLLEY OPERATING INSTRUCTIONS…2776
AFTER THE ENGINE HAS STARTED…2776
OPERATING IN DIESEL MODE…2777
OPERATING IN TROLLEY LINE MODE…2777
GETTING ON LINE…2778
Operating On Trolley…2779
GETTING OFF LINE…2781
LINE STATUS SIGNALS…2781
LINE STATUS SIGNAL MARKINGS…2782
TRAFFIC CONSIDERATION FOR TROLLEY LINE OPERATION…2782
APPROACHING SLOW MOVING VEHICLES IN A TROLLEY ASSISTED TRUCK…2782
OPERATING SLOW MOVING VEHICLES ON TROLLEY ASSIST RAMPS…2783
TRUCK FAILURE WHILE ON TROLLEY…2783
OPERATOR CAB AND CONTROLS…2784
STEERING WHEEL AND CONTROLS…2785
Horn Button…2785
Multi-Function Turn Signal Switch…2785
SERVICE BRAKE PEDAL…2786
DYNAMIC RETARDER PEDAL…2786
Optional – Dual Function / Single Pedal…2786
THROTTLE PEDAL…2786
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS…2787
HEATER / AIR CONDITIONER VENTS…2786
Defroster Vent Control Switch…2787
Heat Control Switch…2787
Temperature Control Knob…2787
Fan Control Knob…2787
Heater / Air Conditioner Selector Switch…2787
Heater / Air Conditioner Vents…2787
INSTRUMENT PANEL…2788
GRADE / SPEED WARNING CHART…2788
RADIO SPEAKERS…2788
WARNING ALARM BUZZER…2788
CAB RADIO…2788
WARNING LIGHTS DIMMER CONTROL…2788
WARNING INDICATOR LIGHT PANEL…2788
AIR CLEANER VACUUM GAUGES…2788
WINDSHIELD WIPERS…2788
CENTER CONSOLE…2789
Data Storage Button…2789
Data storage button (1, Figure 32-7) is for use by qualified maintenance personnel to record in memory a “snap-shot” of the Statex III drive system…2789
Trolley Master Control Lever…2789
F-N-R Selector Switch…2789
Hoist Control Lever…2790
Retard Speed Control (RSC) Adjust Dial…2790
Retard Speed Control (RSC) Off / On Switch…2791
Override Switch…2791
Engine Shutdown Switch…2791
Window Control Switches…2791
Ash Tray…2791
Lighter…2791
Passenger Seat…2791
Download Ports and Connectors…2792
Engine Diagnostics Port…2792
Engine diagnostics port (12) is used by qualified personnel to access engine diagnostic information…2792
Komatsu Engine CENSE Connector…2792
CENSE Connector (13) is a three-pin connector is for use by qualified personnel to access engine diagnostic information for the CENSE system. Refer to the engine manufacturer’s service publications for troubleshooting information…2792
Statex III Downlad Port…2792
Modular Mining Port (Optional)…2792
Modular mining port location is used if the optional Modular Mining System is installed on the truck…2792
Centry™ Fuel Control…2792
Diagnostics Download Port (Optional)…2792
Payload Meter…2792
Payload Meter Download Connector…2792
OPERATOR SEAT…2793
INSTRUMENT PANEL AND INDICATOR LIGHTS…2794
CONTROL SYMBOLS…2794
INSTRUMENT PANEL…2794
PANEL GAUGES, INDICATORS, AND CONTROLS…2795
Key Switch…2795
Engine Shut down Switch with Timer Delay…2796
Fog Lights (Optional)…2796
Ladder Light Switch…2796
Manual Backup Switch…2796
Manual backup switch (5) allows the backup lights to be turned on providing added visibility and safety when the selector switch is not in the REV position. When the switch is pressed toward the on position, the manual backup light indicator (B4, Ove….2796
Panel Illumination Lights…2796
Cab Air Conditioner / Heater Vents…2796
Engine Cold Weather Starting Aid (Optional)…2797
Rotating Beacon Light Switch (Optional)…2797
Heated Mirror Switch (Optional)…2797
Leakage Test Switch (Trolley Option Only)…2797
Wheel Brake Lock Control…2797
Parking Brake Control…2797
Tachometer…2798
Right Turn Signal Indicator…2798
High Beam Indicator…2798
Left Turn Signal Indicator…2798
Speedometer / Payload Meter Display…2798
Voltmeter…2798
Engine Oil Pressure Gauge…2798
Water Temperature Gauge…2798
Fuel Gauge…2798
Blank (Not Used)…2798
Hourmeter…2798
Blank (Not Used)…2798
Blank (Not Used)…2798
Light Switch…2799
Panel Light Dimmer…2799
Payload Meter Switch…2799
OVERHEAD STATUS / WARNING INDICATOR LIGHT PANEL…2800
INDICATOR LIGHT SYMBOLS…2801
TROLLEY INDICATOR LIGHTS…2805
Hazard Warning Light Switch…2807
Lamp Test Switch / Centry™ Diagnostic Test Switch…2807
CENTRY™ FUEL SYSTEM DIAGNOSTICS…2808
DETERMINING FAULT CODES…2808
EXITING THE DIAGNOSTICS MODE…2809
LUBRICATION AND SERVICE…2810
GENERAL INFORMATION…2810
HYDRAULIC TANK SERVICE…2810
Adding Oil…2810
COOLING SYSTEM SERVICE…2811
Radiator Filling Procedure…2811
Coolant Specifications…2811
Unacceptable Practices…2811
WHEEL MOTOR SERVICE…2811
RESERVE ENGINE OIL SYSTEM (IF EQUIPPED)…2812
Reserve Oil Tank Filling Procedure (Remote fill)…2812
Inline Screen…2812
QUICK FILL SERVICE CENTER…2813
LEFT-HAND FUEL RECEIVER – OPTIONAL (WIGGINS QUICK FILL)…2814
LUBRICATION CHART…2815
10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS…2816
10 HOUR (DAILY) LUBE AND MAINTENANCE CHECKS (Continued)…2817
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…2818
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…2818
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…2819
250 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)…2820
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…2821
500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)…2822
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…2823
1500 HOUR LUBRICATION AND MAINTENANCE CHECKS…2824
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS…2824
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS…2825
10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS…2826
AUTOMATIC LUBRICATION SYSTEM…2828
GENERAL DESCRIPTION…2828
SYSTEM COMPONENTS…2829
Filter Assembly…2829
Hydraulic Motor and Grease Pump…2829
Reservoir…2829
Fixed Pressure Reducing Valve…2829
Flow Control Valve…2829
Solenoid Valve…2831
Vent Valve…2831
Time Delay Module…2831
Pump Cutoff Pressure Switch…2831
Unloader Valve…2831
Pressure Switch…2831
Pressure Gauge…2831
Manual Override Button…2831
Injectors…2831
SYSTEM OPERATION…2833
Normal Operation…2833
Pressure Failure Detection Circuits…2834
GENERAL INSTRUCTIONS…2835
LUBRICANT REQUIRED FOR SYSTEM…2835
SYSTEM PRIMING…2835
LUBRICANT PUMP…2835
Pump Housing Oil Level…2835
Pump Pressure Control…2835
Filter And Reservoir…2836
Filter Assembly Element…2836
INJECTORS (SL-1 Series H)…2837
Injector Specifications…2837
Injector Adjustment…2837
INJECTOR OPERATION…2838
SYSTEM CHECKOUT…2839
Lubrication Cycle Timer Check…2839
Lubrication Cycle Timer Adjustment…2840
PREVENTIVE MAINTENANCE INSPECTION…2840
10 Hour Lubrication System Inspection…2840
250 Hour Inspection…2840
1000 Hour Inspection…2841
SYSTEM TROUBLESHOOTING CHART…2842
MAJOR COMPONENT DESCRIPTION…2844
SPECIFICATIONS…2846
PAYLOAD METER III™…2848
Introduction…2848
Data Summary…2848
Data Gathering…2848
COMPONENT DESCRIPTION…2849
System Diagram…2849
Suspension Pressure Sensors…2849
Inclinometer…2849
Speedometer/Load Display…2849
Operator Switches…2850
Speed Input…2850
Body-Up Switch…2850
Brake Lock Switch…2850
Payload Meter…2850
Communications Ports…2850
Key Switch Input…2851
Payload Meter Power…2851
Load Lights…2851
Wiring and Termination…2852
TCI Outputs…2852
LOAD DISPLAY AND OPERATOR SWITCHES…2853
Setting the Operator ID…2853
Total Ton and Total Load Counters…2853
Viewing Live Sensor Data…2853
PAYLOAD OPERATION & CALCULATION…2854
Description of Haul Cycles…2854
Load Calculation…2855
Carry Back…2855
Measurement Accuracy…2855
SOURCES FOR PAYLOAD ERROR…2855
Suspensions…2855
Loading Conditions…2856
Pressure Sensors…2856
Swingloads…2856
Speed and Distance…2856
HAUL CYCLE DATA…2856
Haul Cycle Warning Flags…2856
Frame Torque Data…2859
Sprung Weight Data…2859
Maximum Speed Data…2859
Alarm Records…2860
PDM SOFTWARE OVERVIEW…2861
System Configuration…2861
Installing the PDM Software…2861
DOWNLOADING DATA…2861
PLM III SYSTEM CONFIGURATION…2862
Starting Communications…2862
Connection Menu…2862
Connecting to the Payload Meter…2863
Configuring the Payload Meter…2863
Setting the Date and Time…2863
Setting the Truck Type…2864
Setting the Display Units…2864
Setting the Frame Serial Number…2864
Setting the Truck Number…2864
Setting the Komatsu Distributor…2864
Setting the Komatsu Customer…2864
Clean Truck Tare…2865
Inclinometer Calibration…2865
DATA ANALYSIS…2866
Creating a Query…2866
Sorting on Truck Unit Number…2866
Sorting on Truck Type…2866
Sorting on Date Range…2867
Sorting on Time Range…2867
Payload Detail Screen…2868
Creating Reports…2869
Creating Graphs…2870
Exporting Data…2870
Importing Data…2872
Deleting Haul Cycle Records…2872
Viewing Alarms…2872
Deleting Alarm Records…2872
AM/FM RADIO / CD / MP3 / USB / iPOD™ / AUX PLAYER…2874
OPERATING INSTRUCTIONS…2874
GENERAL RADIO RECEIVER FUNCTIONS…2874
Turning On the Power…2874
One-Hour Timer…2874
Adjusting the Volume…2875
Display…2875
Radio Mode Displays…2875
CD Mode Displays…2875
MP3/USB/iPod Mode Displays…2875
AUX Input Displays…2876
CLOCK/ALARM Button…2876
Front Auxiliary Mode…2876
Rear Auxiliary Mode…2876
Adjusting the Receiver Audio Settings…2876
Adjusting the Receiver Menu Settings…2877
USING THE RADIO…2878
Finding a Station…2878
Setting the Presets…2878
USING THE CLOCK…2879
Setting the Clock…2879
USING THE ALARM…2879
Setting the Alarm…2879
Turning the Alarm Off…2880
Activating Snooze…2880
USING THE WEATHERBAND (USA Only)…2880
USING THE COMPACT DISC PLAYER/USB…2881
Playing A Compact Disc…2881
Button Functions…2881
PLAYING AN MP3 DISC/USB…2882
Root Directory…2882
Empty Directory or Folder…2882
No Folder…2882
File Name Display…2882
PLAYING MP3 FILES…2882
Button Functions…2882
USING AN iPOD®…2883
Playing an iPod…2883
Button Functions…2883
OPERATING TIPS…2884
Tips About The Audio System…2884
Understanding Radio Reception…2884
Care of The Compact Discs…2884
TROUBLESHOOTING…2885
CEAM025201 – Dump Truck 730E Trolley Operation & Maintenance Manual…2888
1 INTRODUCTION…2901
FOREWORD…2901
ABOUT THIS MANUAL…2902
ALERTS…2903
TRUCK MODEL ILLUSTRATION…2904
NON-OEM PARTS IN CRITICAL SYSTEMS…2905
2 STANDARD CHARTS AND TABLES…2907
GENERAL INFORMATION…2907
EFFECT OF SPECIAL LUBRICANTS…2907
SUGGESTED SOURCES FOR RUST PREVENTIVE GREASE…2907
STANDARD TIGHTENING TORQUES…2908
CLASS 10.9 CAP SCREWS & CLASS 10 NUTS…2908
SAE GRADE 5 AND GRADE 8 CAP SCREWS…2909
SAE GRADE 9 CAP SCREWS…2910
T-BOLT CLAMPS…2910
SPLIT FLANGE CLAMPS…2911
FLARED TUBE AND HOSE FITTINGS…2911
JIC 37° SWIVEL NUTS…2912
PIPE THREAD FITTINGS…2913
O-RING BOSS FITTINGS…2914
O-RING FACE SEAL FITTINGS…2915
CONVERSION MULTIPLIERS…2916
METRIC TO ENGLISH…2916
ENGLISH TO METRIC…2917
TEMPERATURE CONVERSIONS…2918
3 GENERAL SAFETY…2921
GENERAL SAFETY…2921
Safety Rules…2921
Truck Safety Features…2921
Clothing And Personal Items…2921
Unauthorized Modification…2921
Leaving The Operator’S Seat…2921
Mounting And Dismounting…2922
Fire Extinguishers And First Aid Kits…2922
Precautions For High Temperature Fluids…2922
Asbestos Dust Hazard Prevention…2922
Fire Prevention…2922
Rops Precautions…2923
Preventing Injury From Work Equipment…2923
Precautions For Optional Attachments…2923
Precautions When Starting The Machine…2923
PRECAUTIONS FOR TRUCK OPERATION…2924
Safety Is Thinking Ahead…2924
Safety At The Worksite…2924
Preparing For Operation…2924
Ventilation For Enclosed Areas…2924
Mirrors, Windows, And Lights…2924
Before Starting The Engine…2924
Seat Belts…2925
Emergency Egress Ladders…2925
OPERATING THE MACHINE…2926
General Information…2926
Starting The Engine…2926
Traveling In The Machine…2926
Traveling In Reverse…2927
Traveling On Slopes…2927
Traveling On Snow…2927
Traveling Near High Voltage Cables…2927
Traveling On Loose Ground…2927
Ensuring Good Visibility…2928
Avoid Damage To The Dump Body…2928
Safe Parking Of The Machine…2928
Loading The Machine…2928
Dumping The Machine…2928
Towing The Machine…2928
EXTERIOR LIGHTING…2929
Fog Lights…2929
Headlights…2929
Brake Light…2929
Retard Light…2930
Clearance/Turn Signal Lights…2930
Backup Lights…2930
Retard Lights…2930
Brake Lights…2930
Backup Alarm…2931
PRECAUTIONS FOR MAINTENANCE…2932
BEFORE PERFORMING MAINTENANCE…2932
Securing The Dump Body…2932
DURING MAINTENANCE…2933
Warning Tag…2933
Proper Tools…2933
Attachments…2933
Working Under The Machine…2933
Keeping The Machine Clean…2933
Adding Fuel Or Oil To The Machine…2934
Radiator Coolant Level…2934
Use Of Lighting…2934
Handling High Pressure Hoses…2934
Precautions With High Pressure Oil…2934
Maintenance Near High Temperatures and High Pressures…2934
Rotating Fan And Belts…2935
Waste Materials…2935
Use of Tie-Off Anchor During Maintenance…2935
Handling Tires…2935
Tire Maintenance…2936
Storing Tires After Removal…2936
Battery Hazard Prevention…2936
Jump Starting With Booster Cables…2937
Jump Starting With Receptacles…2937
WHEN REPAIRS ARE NECESSARY…2939
Observe The Following Precautions…2939
SPECIAL PRECAUTIONS…2940
Preliminary Procedures Before Welding or Performing Maintenance…2940
Engine Shutdown Procedure Before Welding or Performing Maintenan…2940
4 WARNING AND CAUTIONS…2943
GENERAL INFORMATION…2943
PIN PLATE…2943
GRADE SPEED CHART…2944
MACHINE SAFETY…2944
KEY SWITCH…2947
OIL FILL AND CHECK…2948
HIGH PRESSURES…2949
BATTERY AND ISOLATION BOX…2951
HIGH VOLTAGE…2952
WELDING…2953
LIFTING POINTS…2953
AUTOMATIC LUBRICATION FILL…2954
ROPS/FOPS…2955
LUBRICATION CHART…2955
5 OPERATING INSTRUCTIONS…2957
PREPARING FOR OPERATION…2957
Safety Is Thinking Ahead…2957
Walk Around Inspection…2957
TRUCK OPERATION…2962
ENGINE START-UP SAFETY…2962
After Engine Has Started…2962
MACHINE OPERATION SAFETY PRECAUTIONS…2963
Machine Operation On The Haul Road…2964
Starting On A Grade With A Loaded Truck…2964
Retarding On A Grade…2964
Passing…2965
Loading…2965
Dumping…2966
Lowering The Dump Body (When Dumping On Flat Ground)…2967
Lowering The Dump Body (When Dumping Over A Berm Or Into A Crush…2967
SUDDEN LOSS OF ENGINE POWER…2967
EMERGENCY STEERING SYSTEM…2968
Operation…2968
Pre-Operation Testing…2968
Additional Guidelines…2969
SAFE PARKING PROCEDURES…2969
NORMAL ENGINE SHUTDOWN PROCEDURE…2969
DISABLED TRUCK CONNECTORS…2971
GENERAL INFORMATION…2971
STEERING AND BRAKE SYSTEM…2971
Components Required…2971
Hookup…2971
HOIST SYSTEM…2972
Hookup…2972
Dumping Procedure…2973
TOWING…2974
Towing Procedure…2974
TROLLEY OPERATING INSTRUCTIONS…2975
AFTER THE ENGINE HAS STARTED…2975
OPERATING IN DIESEL MODE…2975
OPERATING IN TROLLEY LINE MODE…2975
GETTING ON LINE…2976
OPERATION ON TROLLEY…2977
GETTING OFF LINE…2978
LINE STATUS SIGNALS…2978
LINE STATUS SIGNAL MARKINGS…2978
TRAFFIC CONSIDERATION FOR TROLLEY LINE OPERATION…2979
APPROACHING SLOW MOVING VEHICLES IN A TROLLEY ASSISTED TRUCK…2979
OPERATING SLOW MOVING VEHICLES ON TROLLEY ASSIST RAMPS…2979
TRUCK FAILURE WHILE ON TROLLEY…2979
PAYLOAD METER III SYSTEM…2981
GENERAL INFORMATION…2981
Data Summary…2981
Data Gathering…2981
COMPONENT DESCRIPTION…2981
Operator Display…2981
Operator Switch…2981
Brake Lock Switch…2982
Payload Meter Module…2982
Communications Ports…2982
Load Lights…2982
OPERATORS DISPLAY AND SWITCH…2982
Reading the Load Display…2982
Setting the Operator ID…2983
Load and Ton Counter…2983
Viewing Live Sensor Data…2983
Other Display Messages…2984
HAUL CYCLE WARNING FLAGS…2984
Haul Cycle Data…2984
Haul Cycle Warning Flags…2986
PC SOFTWARE OVERVIEW…2987
SYSTEM CONFIGURATION…2988
Connecting to the Payload Meter…2988
Displayed Payload Units…2988
Connection Menu…2988
Configure the Payload Meter…2989
Setting the Date and Time…2989
Setting the Truck Type and Serial Number…2990
Setting the Gauge Display Units…2990
Setting the Carryback Alarm Threshold…2990
Setting the Truck Number…2991
Setting the Komatsu Distributor…2991
Setting the Komatsu Customer…2991
Clean Truck Tare Calibration…2991
Inclinometer Calibration…2992
DOWNLOADING PAYLOAD DATA…2992
UPLOADING DATA…2993
DATA ANALYSIS…2994
Creating a Query…2994
Payload Detail Screen…2995
Creating Reports…2995
Creating Graphs…2995
Exporting Data…2996
Importing Data…2997
Deleting Haul Cycle Records…2997
Viewing Alarms…2997
Deleting Alarm Records…2997
Patent Acknowledment…2997
AUTOMATIC LUBRICATION SYSTEM…2998
GENERAL INFORMATION…2998
COMPONENT DESCRIPTION…2998
Filter…2999
Vent Valve…3000
Flow Control Valve…3000
Grease Reservoir…3000
Pressure Reducing Valve…3000
Hydraulic Motor and Pump…3000
Solenoid Valve…3000
Pressure Cut Off Switch…3000
Injectors…3001
Grease Pressure Failure Switch…3002
Relief Valve (unloader valve)…3002
Lubrication Cycle Timer…3002
SYSTEM OPERATION…3002
Filling The Reservoir…3002
Priming The Automatic Lubrication System…3003
PREVENTIVE MAINTENANCE PROCEDURES…3004
Daily Lubrication System Inspection…3004
250 Hour Inspection…3004
1000 Hour Inspection…3005
SYSTEM CHECKOUT…3005
General Checks…3005
Lubrication Controller Components…3005
RESERVE ENGINE OIL SYSTEM (Optional)…3007
Operation…3007
Changing Oil…3007
6 OPERATOR CAB AND CONTROLS…3011
CAB INTERIOR…3011
STEERING WHEEL AND CONTROLS…3012
Horn Button…3012
Tilt / Telescope Lever…3012
Multi-Function Turn Signal Switch…3012
Turn Signal Operation…3012
High Beam Headlight Operation…3012
Windshield Wiper Operation…3013
PEDALS…3014
SERVICE BRAKE PEDAL…3014
DYNAMIC RETARD PEDAL…3014
Dynamic Retarding…3014
ACCELERATOR PEDAL…3014
OVERHEAD PANEL AND DISPLAYS…3016
RADIO SPEAKERS…3016
WARNING ALARM BUZZER…3016
CAB RADIO…3016
WARNING LIGHT DIMMER CONTROL…3016
STATUS/WARNING INDICATOR LIGHT PANEL…3016
AIR CLEANER VACUUM GAUGES…3016
WINDSHIELD WIPERS…3016
CENTER CONSOLE…3017
FNR CONTROL LEVER…3017
Lowering The Dump Body…3018
WINDOW CONTROL SWITCHES…3018
ENGINE STOP SWITCH…3018
OVERRIDE/FAULT RESET SWITCH…3018
RETARD SPEED CONTROL (RSC) SWITCH…3018
RETARD SPEED CONTROL (RSC) ADJUST DIAL…3018
DATA STORE BUTTON…3019
DIAGNOSTIC PORTS…3020
ENGINE (CENTRY)…3020
ENGINE (CENSE)…3020
STATEX III…3020
KOMTRAX Plus AND PAYLOAD METER…3020
INTERFACE MODULE …3021
OPERATOR’S SEAT (Standard)…3022
SEAT BELTS…3022
ADJUSTMENT…3022
HEATER / AIR CONDITIONER CONTROLS…3024
Fan Speed Control Knob…3024
Temperature Control Knob…3024
Air Flow Directional Knob…3024
Heater/Air Conditioner Vents…3024
INSTRUMENT PANEL …3025
CONTROL SYMBOLS…3025
Key Switch…3026
Engine Shutdown Switch…3027
Fog Light Swich…3027
Ladder Light Switch…3027
Backup Light Switch…3027
Panel Illumination Lights…3027
Cab Air Conditioner/Heater Vents…3027
Engine Cold Weather Starting Aid Switch…3027
Rotating Beacon Light Switch (Optional)…3027
Heated Mirror Switch (Optional)…3027
Leakage Test Switch (Trolley Only)…3028
Wheel Brake Lock Control Switch…3028
Parking Brake Switch…3028
Tachometer…3028
Right Turn Signal Indicator…3028
High Beam Indicator…3029
Left Turn Signal Indicator…3029
Speedometer/Payload Meter Display…3029
Voltmeter Gauge…3029
Engine Oil Pressure Gauge…3029
Water Temperature Gauge…3029
Fuel Level Gauge…3029
Hourmeter…3029
Headlight Switch…3030
Panel Light Dimmer…3030
Payload Meter Switch…3030
OVERHEAD STATUS/WARNING INDICATOR…3031
STATUS / WARNING INDICATOR LIGHT SYMBOLS…3032
High Hydraulic Oil Temperature…3032
Low Steering Pressure…3032
Low Accumulator Precharge Pressure…3033
No Power…3033
Low Brake Pressure…3034
Low Hydraulic Tank Level…3034
Automatic Lubrication System Pressure…3034
Circuit Breaker Tripped…3034
Hydraulic Oil Filter Monitor…3034
Low Fuel…3034
Parking Brake…3035
Service Brake…3035
Body Up…3035
Dynamic Retarding…3035
Stop Engine…3035
Manual Backup Lights…3036
Engine Shutdown Timer…3036
Retard Speed Control (RSC) Indicator…3036
Check Engine…3036
Service Engine Indicator (AEM)…3036
Propulsion System Temperature…3036
Blower Fault…3036
Service Engine Indicator (CENSE)…3037
Hazard Light Switch…3037
Lamp Test Switch…3037
TROLLEY INDICATOR LIGHT SYMBOLS…3037
Diesel Power Indicator…3037
Ready For Trolley Indicator…3037
On Trolley Indicator…3037
Trolley Fault Indicator…3038
Left Limit Indicator (Optional)…3038
Max Speed Indicator…3038
High Speed Indicator…3038
Med. Speed Indicator…3038
Low Speed Indicator…3039
Right Limit Indicator (Optional)…3039
CENTRYTM FUEL SYSTEM DIAGNOSTICS…3040
GENERAL OPERATION…3040
DETERMINING FAULT CODES…3040
EXITING THE DIAGNOSTICS MODE…3041
7 LUBRICATION AND SERVICE…3043
GENERAL INFORMATION…3043
HYDRAULIC SYSTEM SERVICE…3043
Hydraulic Tank…3043
Hydraulic Filters…3044
Hydraulic Pump Drive Shaft…3044
WHEEL MOTOR SERVICE…3044
COOLANT LEVEL SERVICE…3044
Radiator Filling Procedure…3044
Coolant Specifications…3045
Unacceptable Practices…3045
RESERVE ENGINE OIL SERVICE (If Equipped)…3045
Reserve Oil Tank Filling Procedure (Remote Fill)…3045
CAB AIR FILTER SERVICE…3046
FUEL SYSTEM SERVICE…3046
Fuel Tank Cleaning…3046
Fuel Filter Service…3047
INTAKE AIR CLEANER SERVICE…3047
FRONT WHEEL SERVICE…3049
Oil Sampling…3049
FRONT ENGINE MOUNT TRUNION SERVICE…3049
QUICK FILL SERVICE CENTER…3049
LUBRICATION CHART…3051
EVERY 10 HOUR (DAILY) MAINTENANCE…3052
INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION…3054
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION…3055
EVERY 250 HOUR LUBRICATION AND MAINTENANCE…3056
EVERY 500 HOUR LUBRICATION AND MAINTENANCE…3058
EVERY 1000 HOURS LUBRICATION AND MAINTENANCE…3060
EVERY 2500 HOUR MAINTENANCE…3061
EVERY 5000 HOUR MAINTENANCE…3062
EVERY 10,000 HOUR MAINTENANCE…3063
8 SPECIFICATIONS…3065
MAJOR COMPONENT DESCRIPTION…3065
Truck And Engine…3065
Alternator (GTA-22)…3065
Wheel Motors (GE 788)…3065
Blower…3065
Suspension…3065
Operator's Cab…3065
Power Steering…3065
Dynamic Retarding Gird…3065
Brake System…3065
SPECIFICATIONS…3066
Engine…3066
Electric Drive System…3066
Dynamic Retarding…3066
Battery Electric System…3066
Service Capacities…3066
Hydraulic Systems…3066
Service Brakes…3066
Steering…3066
Standard Dump Body Capacities And Dimensions…3067
Tires…3067
Weight Distribution…3067
Overall Truck Dimensions…3067
9 RADIO…3071
RADIO OPERATION…3071
GENERAL RADIO RECEIVER FUNCTIONS…3071
Turning On the Power…3071
One-Hour Timer…3072
Finding a Station…3072
Setting the Presets…3072
Adjusting the Receiver Audio Settings…3073
Display…3073
Adjusting the Receiver Menu Settings…3073
Front Auxiliary Mode…3074
Rear Auxiliary Mode…3074
CLOCK…3075
Clock/Alarm Button…3075
Setting the Clock…3075
Setting the Alarm…3075
Turning the Alarm Off…3076
Activating Snooze…3076
CD PLAYER…3077
Playing A Compact Disc…3077
Playing an MP3 DISC…3077
CD Mode Displays…3077
Button Functions…3077
MP3 PLAYER…3079
Playing MP3 Files…3079
MP3 Mode Displays…3079
Button Functions…3080
iPod®…3081
Playing an iPod®…3081
iPod® Mode Displays…3081
Button Functions…3081
WEATHERBAND (USA Only)…3083
TROUBLESHOOTING…3084
Tips About The Audio System…3084
Understanding Radio Reception…3084
Care of The Compact Discs…3084
CEAM025901 – Dump Truck 730E Operation & Maintenance Manual…3085
1 INTRODUCTION…3100
FOREWORD…3100
ABOUT THIS MANUAL…3101
ALERTS…3102
TRUCK MODEL ILLUSTRATION…3103
NON-OEM PARTS IN CRITICAL SYSTEMS…3104
2 STANDARD CHARTS AND TABLES…3106
GENERAL INFORMATION…3106
EFFECT OF SPECIAL LUBRICANTS…3106
SUGGESTED SOURCES FOR RUST PREVENTIVE GREASE…3106
STANDARD TIGHTENING TORQUES…3107
CLASS 10.9 CAP SCREWS & CLASS 10 NUTS…3107
SAE GRADE 5 AND GRADE 8 CAP SCREWS…3108
SAE GRADE 9 CAP SCREWS…3109
T-BOLT CLAMPS…3109
SPLIT FLANGE CLAMPS…3110
FLARED TUBE AND HOSE FITTINGS…3110
JIC 37° SWIVEL NUTS…3111
PIPE THREAD FITTINGS…3112
O-RING BOSS FITTINGS…3113
O-RING FACE SEAL FITTINGS…3114
CONVERSION MULTIPLIERS…3115
METRIC TO ENGLISH…3115
ENGLISH TO METRIC…3116
TEMPERATURE CONVERSIONS…3117
3 GENERAL SAFETY…3120
GENERAL SAFETY…3120
Safety Rules…3120
Truck Safety Features…3120
Clothing And Personal Items…3120
Unauthorized Modification…3120
Leaving The Operator’S Seat…3120
Mounting And Dismounting…3121
Fire Extinguishers And First Aid Kits…3121
Precautions For High Temperature Fluids…3121
Asbestos Dust Hazard Prevention…3121
Fire Prevention…3121
Rops Precautions…3122
Preventing Injury From Work Equipment…3122
Precautions For Optional Attachments…3122
Precautions When Starting The Machine…3122
PRECAUTIONS FOR TRUCK OPERATION…3123
Safety Is Thinking Ahead…3123
Safety At The Worksite…3123
Preparing For Operation…3123
Ventilation For Enclosed Areas…3123
Mirrors, Windows, And Lights…3123
Before Starting The Engine…3123
Seat Belts…3124
Emergency Egress Ladders…3124
OPERATING THE MACHINE…3125
General Information…3125
Starting The Engine…3125
Traveling In The Machine…3125
Traveling In Reverse…3126
Traveling On Slopes…3126
Traveling On Snow…3126
Traveling Near High Voltage Cables…3126
Traveling On Loose Ground…3126
Ensuring Good Visibility…3127
Avoid Damage To The Dump Body…3127
Safe Parking Of The Machine…3127
Loading The Machine…3127
Dumping The Machine…3127
Towing The Machine…3127
EXTERIOR LIGHTING…3128
Fog Lights…3128
Headlights…3128
Brake Light…3128
Retard Light…3129
Clearance/Turn Signal Lights…3129
Backup Lights…3129
Retard Lights…3129
Brake Lights…3129
Backup Alarm…3130
PRECAUTIONS FOR MAINTENANCE…3131
BEFORE PERFORMING MAINTENANCE…3131
Securing The Dump Body…3131
DURING MAINTENANCE…3132
Warning Tag…3132
Proper Tools…3132
Attachments…3132
Working Under The Machine…3132
Keeping The Machine Clean…3132
Adding Fuel Or Oil To The Machine…3133
Radiator Coolant Level…3133
Use Of Lighting…3133
Handling High Pressure Hoses…3133
Precautions With High Pressure Oil…3133
Maintenance Near High Temperatures and High Pressures…3133
Rotating Fan And Belts…3134
Waste Materials…3134
Use of Tie-Off Anchor During Maintenance…3134
Handling Tires…3134
Tire Maintenance…3135
Storing Tires After Removal…3135
Battery Hazard Prevention…3135
Jump Starting With Booster Cables…3136
Jump Starting With Receptacles…3136
WHEN REPAIRS ARE NECESSARY…3138
Observe The Following Precautions…3138
SPECIAL PRECAUTIONS…3139
Preliminary Procedures Before Welding or Performing Maintenance…3139
Engine Shutdown Procedure Before Welding or Performing Maintenan…3139
4 WARNING AND CAUTIONS…3142
GENERAL INFORMATION…3142
PIN PLATE…3142
GRADE SPEED CHART…3143
MACHINE SAFETY…3143
KEY SWITCH…3146
OIL FILL AND CHECK…3147
HIGH PRESSURES…3148
BATTERY AND ISOLATION BOX…3150
HIGH VOLTAGE…3151
WELDING…3152
LIFTING POINTS…3152
AUTOMATIC LUBRICATION FILL…3153
ROPS/FOPS…3154
LUBRICATION CHART…3154
5 OPERATING INSTRUCTIONS…3156
PREPARING FOR OPERATION…3156
Safety Is Thinking Ahead…3156
Walk Around Inspection…3156
TRUCK OPERATION…3161
ENGINE START-UP SAFETY…3161
After Engine Has Started…3161
MACHINE OPERATION SAFETY PRECAUTIONS…3162
Machine Operation On The Haul Road…3163
Starting On A Grade With A Loaded Truck…3163
Retarding On A Grade…3163
Passing…3164
Loading…3164
Dumping…3165
Lowering The Dump Body (When Dumping On Flat Ground)…3166
Lowering The Dump Body (When Dumping Over A Berm Or Into A Crush…3166
SUDDEN LOSS OF ENGINE POWER…3166
EMERGENCY STEERING SYSTEM…3167
Operation…3167
Pre-Operation Testing…3167
Additional Guidelines…3168
SAFE PARKING PROCEDURES…3168
NORMAL ENGINE SHUTDOWN PROCEDURE…3168
DISABLED TRUCK CONNECTORS…3170
GENERAL INFORMATION…3170
STEERING AND BRAKE SYSTEM…3170
Components Required…3170
Hookup…3170
HOIST SYSTEM…3171
Hookup…3171
Dumping Procedure…3172
TOWING…3173
Towing Procedure…3173
PAYLOAD METER III SYSTEM…3174
GENERAL INFORMATION…3174
Data Summary…3174
Data Gathering…3174
COMPONENT DESCRIPTION…3174
Operator Display…3174
Operator Switch…3174
Brake Lock Switch…3175
Payload Meter Module…3175
Communications Ports…3175
Load Lights…3175
OPERATORS DISPLAY AND SWITCH…3175
Reading the Load Display…3175
Setting the Operator ID…3176
Load and Ton Counter…3176
Viewing Live Sensor Data…3176
Other Display Messages…3177
HAUL CYCLE WARNING FLAGS…3177
Haul Cycle Data…3177
Haul Cycle Warning Flags…3179
PC SOFTWARE OVERVIEW…3180
SYSTEM CONFIGURATION…3181
Connecting to the Payload Meter…3181
Displayed Payload Units…3181
Connection Menu…3181
Configure the Payload Meter…3182
Setting the Date and Time…3182
Setting the Truck Type and Serial Number…3183
Setting the Gauge Display Units…3183
Setting the Carryback Alarm Threshold…3183
Setting the Truck Number…3184
Setting the Komatsu Distributor…3184
Setting the Komatsu Customer…3184
Clean Truck Tare Calibration…3184
Inclinometer Calibration…3185
DOWNLOADING PAYLOAD DATA…3185
UPLOADING DATA…3186
DATA ANALYSIS…3187
Creating a Query…3187
Payload Detail Screen…3188
Creating Reports…3188
Creating Graphs…3188
Exporting Data…3189
Importing Data…3190
Deleting Haul Cycle Records…3190
Viewing Alarms…3190
Deleting Alarm Records…3190
Patent Acknowledment…3190
AUTOMATIC LUBRICATION SYSTEM…3191
GENERAL INFORMATION…3191
COMPONENT DESCRIPTION…3191
Filter…3192
Vent Valve…3193
Flow Control Valve…3193
Grease Reservoir…3193
Pressure Reducing Valve…3193
Hydraulic Motor and Pump…3193
Solenoid Valve…3193
Pressure Cut Off Switch…3193
Injectors…3194
Grease Pressure Failure Switch…3195
Relief Valve (unloader valve)…3195
Lubrication Cycle Timer…3195
SYSTEM OPERATION…3195
Filling The Reservoir…3195
Priming The Automatic Lubrication System…3196
PREVENTIVE MAINTENANCE PROCEDURES…3197
Daily Lubrication System Inspection…3197
250 Hour Inspection…3197
1000 Hour Inspection…3198
SYSTEM CHECKOUT…3198
General Checks…3198
Lubrication Controller Components…3198
RESERVE ENGINE OIL SYSTEM (Optional)…3200
Operation…3200
Changing Oil…3200
6 OPERATOR CAB AND CONTROLS…3204
CAB INTERIOR…3204
STEERING WHEEL AND CONTROLS…3205
Horn Button…3205
Tilt / Telescope Lever…3205
Multi-Function Turn Signal Switch…3205
Turn Signal Operation…3205
High Beam Headlight Operation…3205
Windshield Wiper Operation…3206
PEDALS…3207
SERVICE BRAKE PEDAL…3207
DYNAMIC RETARD PEDAL…3207
Dynamic Retarding…3207
ACCELERATOR PEDAL…3207
OVERHEAD PANEL AND DISPLAYS…3209
RADIO SPEAKERS…3209
WARNING ALARM BUZZER…3209
CAB RADIO…3209
WARNING LIGHT DIMMER CONTROL…3209
STATUS/WARNING INDICATOR LIGHT PANEL…3209
AIR CLEANER VACUUM GAUGES…3209
WINDSHIELD WIPERS…3209
CENTER CONSOLE…3210
FNR CONTROL LEVER…3210
Lowering The Dump Body…3211
WINDOW CONTROL SWITCHES…3211
ENGINE STOP SWITCH…3211
OVERRIDE/FAULT RESET SWITCH…3211
RETARD SPEED CONTROL (RSC) SWITCH…3211
RETARD SPEED CONTROL (RSC) ADJUST DIAL…3211
DATA STORE BUTTON…3212
DIAGNOSTIC PORTS…3213
ENGINE (CENTRY)…3213
ENGINE (CENSE)…3213
STATEX III…3213
KOMTRAX Plus AND PAYLOAD METER…3213
INTERFACE MODULE …3214
OPERATOR’S SEAT (Standard)…3215
SEAT BELTS…3215
ADJUSTMENT…3215
HEATER / AIR CONDITIONER CONTROLS…3217
Fan Speed Control Knob…3217
Temperature Control Knob…3217
Air Flow Directional Knob…3217
Heater/Air Conditioner Vents…3217
INSTRUMENT PANEL …3218
CONTROL SYMBOLS…3218
Key Switch…3219
Engine Shutdown Switch…3220
Fog Light Swich…3220
Ladder Light Switch…3220
Backup Light Switch…3220
Panel Illumination Lights…3220
Cab Air Conditioner/Heater Vents…3220
Engine Cold Weather Starting Aid Switch…3220
Rotating Beacon Light Switch (Optional)…3220
Heated Mirror Switch (Optional)…3220
Leakage Test Switch (Trolley Only)…3221
Wheel Brake Lock Control Switch…3221
Parking Brake Switch…3221
Tachometer…3221
Right Turn Signal Indicator…3221
High Beam Indicator…3222
Left Turn Signal Indicator…3222
Speedometer/Payload Meter Display…3222
Voltmeter Gauge…3222
Engine Oil Pressure Gauge…3222
Water Temperature Gauge…3222
Fuel Level Gauge…3222
Hourmeter…3222
Headlight Switch…3223
Panel Light Dimmer…3223
Payload Meter Switch…3223
OVERHEAD STATUS/WARNING INDICATOR…3224
STATUS / WARNING INDICATOR LIGHT SYMBOLS…3225
High Hydraulic Oil Temperature…3225
Low Steering Pressure…3225
Low Accumulator Precharge Pressure…3226
No Power…3227
Low Brake Pressure…3227
Low Hydraulic Tank Level…3227
Automatic Lubrication System Pressure…3227
Circuit Breaker Tripped…3227
Hydraulic Oil Filter Monitor…3227
Low Fuel…3228
Parking Brake…3228
Service Brake…3228
Body Up…3228
Dynamic Retarding…3228
Stop Engine…3228
Manual Backup Lights…3229
Engine Shutdown Timer…3229
Retard Speed Control (RSC) Indicator…3229
Check Engine…3229
Service Engine Indicator (AEM)…3229
Propulsion System Temperature…3229
Blower Fault…3230
Service Engine Indicator (CENSE)…3230
Hazard Light Switch…3230
Lamp Test Switch…3230
KOMTRAX Plus…3231
KOMTRAX Plus OPERATION…3231
Basic Precautions…3231
Interface Module…3233
DOWNLOADING KOMTRAX Plus DATA…3233
GENERAL INFORMATION…3233
KOMTRAX Plus DOWNLOADING PROCEDURE…3233
Location of Downloaded Files…3234
UPLOADING KOMTRAX Plus DATA…3235
ORBCOMM…3236
CENTRYTM FUEL SYSTEM DIAGNOSTICS…3238
GENERAL OPERATION…3238
DETERMINING FAULT CODES…3238
EXITING THE DIAGNOSTICS MODE…3239
7 LUBRICATION AND SERVICE…3242
GENERAL INFORMATION…3242
HYDRAULIC SYSTEM SERVICE…3242
Hydraulic Tank…3242
Hydraulic Filters…3243
Hydraulic Pump Drive Shaft…3243
WHEEL MOTOR SERVICE…3243
COOLANT LEVEL SERVICE…3243
Radiator Filling Procedure…3243
Coolant Specifications…3244
Unacceptable Practices…3244
RESERVE ENGINE OIL SERVICE (If Equipped)…3244
Reserve Oil Tank Filling Procedure (Remote Fill)…3244
CAB AIR FILTER SERVICE…3245
FUEL SYSTEM SERVICE…3245
Fuel Tank Cleaning…3245
Fuel Filter Service…3246
INTAKE AIR CLEANER SERVICE…3246
FRONT WHEEL SERVICE…3248
Oil Sampling…3248
FRONT ENGINE MOUNT TRUNION SERVICE…3248
QUICK FILL SERVICE CENTER…3248
LUBRICATION CHART…3250
EVERY 10 HOUR (DAILY) MAINTENANCE…3251
INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION…3253
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION…3254
EVERY 250 HOUR LUBRICATION AND MAINTENANCE…3255
EVERY 500 HOUR LUBRICATION AND MAINTENANCE…3257
EVERY 1000 HOURS LUBRICATION AND MAINTENANCE…3259
EVERY 2500 HOUR MAINTENANCE…3260
EVERY 5000 HOUR MAINTENANCE…3261
EVERY 10,000 HOUR MAINTENANCE…3262
8 SPECIFICATIONS…3264
MAJOR COMPONENT DESCRIPTION…3264
Truck And Engine…3264
Alternator (GTA-22)…3264
Wheel Motors (GE 788)…3264
Blower…3264
Suspension…3264
Operator's Cab…3264
Power Steering…3264
Dynamic Retarding Gird…3264
Brake System…3264
SPECIFICATIONS…3265
Engine…3265
Electric Drive System…3265
Dynamic Retarding…3265
Battery Electric System…3265
Service Capacities…3265
Hydraulic Systems…3265
Service Brakes…3265
Steering…3265
Standard Dump Body Capacities And Dimensions…3266
Tires…3266
Weight Distribution…3266
Overall Truck Dimensions…3266
9 RADIO…3270
RADIO OPERATION…3270
GENERAL RADIO RECEIVER FUNCTIONS…3270
Turning On the Power…3270
One-Hour Timer…3271
Finding a Station…3271
Setting the Presets…3271
Adjusting the Receiver Audio Settings…3272
Display…3272
Adjusting the Receiver Menu Settings…3272
Front Auxiliary Mode…3273
Rear Auxiliary Mode…3273
CLOCK…3274
Clock/Alarm Button…3274
Setting the Clock…3274
Setting the Alarm…3274
Turning the Alarm Off…3275
Activating Snooze…3275
CD PLAYER…3276
Playing A Compact Disc…3276
Playing an MP3 DISC…3276
CD Mode Displays…3276
Button Functions…3276
MP3 PLAYER…3278
Playing MP3 Files…3278
MP3 Mode Displays…3278
Button Functions…3279
iPod®…3280
Playing an iPod®…3280
iPod® Mode Displays…3280
Button Functions…3280
WEATHERBAND (USA Only)…3282
TROUBLESHOOTING…3283
Tips About The Audio System…3283
Understanding Radio Reception…3283
Care of The Compact Discs…3283
CEAM026301 – Dump Truck 730E Trolley Operation & Maintenance Manual…3284
1 INTRODUCTION…3297
FOREWORD…3297
ABOUT THIS MANUAL…3298
ALERTS…3299
TRUCK MODEL ILLUSTRATION…3300
NON-OEM PARTS IN CRITICAL SYSTEMS…3301
2 STANDARD CHARTS AND TABLES…3303
GENERAL INFORMATION…3303
EFFECT OF SPECIAL LUBRICANTS…3303
SUGGESTED SOURCES FOR RUST PREVENTIVE GREASE…3303
STANDARD TIGHTENING TORQUES…3304
CLASS 10.9 CAP SCREWS & CLASS 10 NUTS…3304
SAE GRADE 5 AND GRADE 8 CAP SCREWS…3305
SAE GRADE 9 CAP SCREWS…3306
T-BOLT CLAMPS…3306
SPLIT FLANGE CLAMPS…3307
FLARED TUBE AND HOSE FITTINGS…3307
JIC 37° SWIVEL NUTS…3308
PIPE THREAD FITTINGS…3309
O-RING BOSS FITTINGS…3310
O-RING FACE SEAL FITTINGS…3311
CONVERSION MULTIPLIERS…3312
METRIC TO ENGLISH…3312
ENGLISH TO METRIC…3313
TEMPERATURE CONVERSIONS…3314
3 GENERAL SAFETY…3317
GENERAL SAFETY…3317
Safety Rules…3317
Truck Safety Features…3317
Clothing And Personal Items…3317
Unauthorized Modification…3317
Leaving The Operator’S Seat…3317
Mounting And Dismounting…3318
Fire Extinguishers And First Aid Kits…3318
Precautions For High Temperature Fluids…3318
Asbestos Dust Hazard Prevention…3318
Fire Prevention…3318
Rops Precautions…3319
Preventing Injury From Work Equipment…3319
Precautions For Optional Attachments…3319
Precautions When Starting The Machine…3319
PRECAUTIONS FOR TRUCK OPERATION…3320
Safety Is Thinking Ahead…3320
Safety At The Worksite…3320
Preparing For Operation…3320
Ventilation For Enclosed Areas…3320
Mirrors, Windows, And Lights…3320
Before Starting The Engine…3320
Seat Belts…3321
Emergency Egress Ladders…3321
OPERATING THE MACHINE…3322
General Information…3322
Starting The Engine…3322
Traveling In The Machine…3322
Traveling In Reverse…3323
Traveling On Slopes…3323
Traveling On Snow…3323
Traveling Near High Voltage Cables…3323
Traveling On Loose Ground…3323
Ensuring Good Visibility…3324
Avoid Damage To The Dump Body…3324
Safe Parking Of The Machine…3324
Loading The Machine…3324
Dumping The Machine…3324
Towing The Machine…3324
EXTERIOR LIGHTING…3325
Fog Lights…3325
Headlights…3325
Brake Light…3325
Retard Light…3326
Clearance/Turn Signal Lights…3326
Backup Lights…3326
Retard Lights…3326
Brake Lights…3326
Backup Alarm…3327
PRECAUTIONS FOR MAINTENANCE…3328
BEFORE PERFORMING MAINTENANCE…3328
Securing The Dump Body…3328
DURING MAINTENANCE…3329
Warning Tag…3329
Proper Tools…3329
Attachments…3329
Working Under The Machine…3329
Keeping The Machine Clean…3329
Adding Fuel Or Oil To The Machine…3330
Radiator Coolant Level…3330
Use Of Lighting…3330
Handling High Pressure Hoses…3330
Precautions With High Pressure Oil…3330
Maintenance Near High Temperatures and High Pressures…3330
Rotating Fan And Belts…3331
Waste Materials…3331
Use of Tie-Off Anchor During Maintenance…3331
Handling Tires…3331
Tire Maintenance…3332
Storing Tires After Removal…3332
Battery Hazard Prevention…3332
Jump Starting With Booster Cables…3333
Jump Starting With Receptacles…3333
WHEN REPAIRS ARE NECESSARY…3335
Observe The Following Precautions…3335
SPECIAL PRECAUTIONS…3336
Preliminary Procedures Before Welding or Performing Maintenance…3336
Engine Shutdown Procedure Before Welding or Performing Maintenan…3336
4 WARNING AND CAUTIONS…3339
GENERAL INFORMATION…3339
PIN PLATE…3339
GRADE SPEED CHART…3340
MACHINE SAFETY…3340
KEY SWITCH…3343
OIL FILL AND CHECK…3344
HIGH PRESSURES…3345
BATTERY AND ISOLATION BOX…3347
HIGH VOLTAGE…3348
WELDING…3349
LIFTING POINTS…3349
AUTOMATIC LUBRICATION FILL…3350
ROPS/FOPS…3351
LUBRICATION CHART…3351
5 OPERATING INSTRUCTIONS…3353
PREPARING FOR OPERATION…3353
Safety Is Thinking Ahead…3353
Walk Around Inspection…3353
TRUCK OPERATION…3358
ENGINE START-UP SAFETY…3358
After Engine Has Started…3358
MACHINE OPERATION SAFETY PRECAUTIONS…3359
Machine Operation On The Haul Road…3360
Starting On A Grade With A Loaded Truck…3360
Retarding On A Grade…3360
Passing…3361
Loading…3361
Dumping…3362
Lowering The Dump Body (When Dumping On Flat Ground)…3363
Lowering The Dump Body (When Dumping Over A Berm Or Into A Crush…3363
SUDDEN LOSS OF ENGINE POWER…3363
EMERGENCY STEERING SYSTEM…3364
Operation…3364
Pre-Operation Testing…3364
Additional Guidelines…3365
SAFE PARKING PROCEDURES…3365
NORMAL ENGINE SHUTDOWN PROCEDURE…3365
DISABLED TRUCK CONNECTORS…3367
GENERAL INFORMATION…3367
STEERING AND BRAKE SYSTEM…3367
Components Required…3367
Hookup…3367
HOIST SYSTEM…3368
Hookup…3368
Dumping Procedure…3369
TOWING…3370
Towing Procedure…3370
TROLLEY OPERATING INSTRUCTIONS…3371
AFTER THE ENGINE HAS STARTED…3371
OPERATING IN DIESEL MODE…3371
OPERATING IN TROLLEY LINE MODE…3371
GETTING ON LINE…3372
OPERATION ON TROLLEY…3373
GETTING OFF LINE…3374
LINE STATUS SIGNALS…3374
LINE STATUS SIGNAL MARKINGS…3374
TRAFFIC CONSIDERATION FOR TROLLEY LINE OPERATION…3375
APPROACHING SLOW MOVING VEHICLES IN A TROLLEY ASSISTED TRUCK…3375
OPERATING SLOW MOVING VEHICLES ON TROLLEY ASSIST RAMPS…3375
TRUCK FAILURE WHILE ON TROLLEY…3375
PAYLOAD METER III SYSTEM…3377
GENERAL INFORMATION…3377
Data Summary…3377
Data Gathering…3377
COMPONENT DESCRIPTION…3377
Operator Display…3377
Operator Switch…3377
Brake Lock Switch…3378
Payload Meter Module…3378
Communications Ports…3378
Load Lights…3378
OPERATORS DISPLAY AND SWITCH…3378
Reading the Load Display…3378
Setting the Operator ID…3379
Load and Ton Counter…3379
Viewing Live Sensor Data…3379
Other Display Messages…3380
HAUL CYCLE WARNING FLAGS…3380
Haul Cycle Data…3380
Haul Cycle Warning Flags…3382
PC SOFTWARE OVERVIEW…3383
SYSTEM CONFIGURATION…3384
Connecting to the Payload Meter…3384
Displayed Payload Units…3384
Connection Menu…3384
Configure the Payload Meter…3385
Setting the Date and Time…3385
Setting the Truck Type and Serial Number…3386
Setting the Gauge Display Units…3386
Setting the Carryback Alarm Threshold…3386
Setting the Truck Number…3387
Setting the Komatsu Distributor…3387
Setting the Komatsu Customer…3387
Clean Truck Tare Calibration…3387
Inclinometer Calibration…3388
DOWNLOADING PAYLOAD DATA…3388
UPLOADING DATA…3389
DATA ANALYSIS…3390
Creating a Query…3390
Payload Detail Screen…3391
Creating Reports…3391
Creating Graphs…3391
Exporting Data…3392
Importing Data…3393
Deleting Haul Cycle Records…3393
Viewing Alarms…3393
Deleting Alarm Records…3393
Patent Acknowledment…3393
AUTOMATIC LUBRICATION SYSTEM…3394
GENERAL INFORMATION…3394
COMPONENT DESCRIPTION…3394
Filter…3395
Vent Valve…3396
Flow Control Valve…3396
Grease Reservoir…3396
Pressure Reducing Valve…3396
Hydraulic Motor and Pump…3396
Solenoid Valve…3396
Pressure Cut Off Switch…3396
Injectors…3397
Grease Pressure Failure Switch…3398
Relief Valve (unloader valve)…3398
Lubrication Cycle Timer…3398
SYSTEM OPERATION…3398
Filling The Reservoir…3398
Priming The Automatic Lubrication System…3399
PREVENTIVE MAINTENANCE PROCEDURES…3400
Daily Lubrication System Inspection…3400
250 Hour Inspection…3400
1000 Hour Inspection…3401
SYSTEM CHECKOUT…3401
General Checks…3401
Lubrication Controller Components…3401
RESERVE ENGINE OIL SYSTEM (Optional)…3403
Operation…3403
Changing Oil…3403
6 OPERATOR CAB AND CONTROLS…3407
CAB INTERIOR…3407
STEERING WHEEL AND CONTROLS…3408
Horn Button…3408
Tilt / Telescope Lever…3408
Multi-Function Turn Signal Switch…3408
Turn Signal Operation…3408
High Beam Headlight Operation…3408
Windshield Wiper Operation…3409
PEDALS…3410
SERVICE BRAKE PEDAL…3410
DYNAMIC RETARD PEDAL…3410
Dynamic Retarding…3410
ACCELERATOR PEDAL…3410
OVERHEAD PANEL AND DISPLAYS…3412
RADIO SPEAKERS…3412
WARNING ALARM BUZZER…3412
CAB RADIO…3412
WARNING LIGHT DIMMER CONTROL…3412
STATUS/WARNING INDICATOR LIGHT PANEL…3412
AIR CLEANER VACUUM GAUGES…3412
WINDSHIELD WIPERS…3412
CENTER CONSOLE…3413
FNR CONTROL LEVER…3413
Lowering The Dump Body…3414
WINDOW CONTROL SWITCHES…3414
ENGINE STOP SWITCH…3414
OVERRIDE/FAULT RESET SWITCH…3414
RETARD SPEED CONTROL (RSC) SWITCH…3414
RETARD SPEED CONTROL (RSC) ADJUST DIAL…3414
DATA STORE BUTTON…3415
DIAGNOSTIC PORTS…3416
ENGINE (CENTRY)…3416
ENGINE (CENSE)…3416
STATEX III…3416
KOMTRAX Plus AND PAYLOAD METER…3416
INTERFACE MODULE …3417
OPERATOR’S SEAT (Standard)…3418
SEAT BELTS…3418
ADJUSTMENT…3418
HEATER / AIR CONDITIONER CONTROLS…3420
Fan Speed Control Knob…3420
Temperature Control Knob…3420
Air Flow Directional Knob…3420
Heater/Air Conditioner Vents…3420
INSTRUMENT PANEL …3421
CONTROL SYMBOLS…3421
Key Switch…3422
Engine Shutdown Switch…3423
Fog Light Swich…3423
Ladder Light Switch…3423
Backup Light Switch…3423
Panel Illumination Lights…3423
Cab Air Conditioner/Heater Vents…3423
Engine Cold Weather Starting Aid Switch…3423
Rotating Beacon Light Switch (Optional)…3423
Heated Mirror Switch (Optional)…3423
Leakage Test Switch (Trolley Only)…3424
Wheel Brake Lock Control Switch…3424
Parking Brake Switch…3424
Tachometer…3424
Right Turn Signal Indicator…3424
High Beam Indicator…3425
Left Turn Signal Indicator…3425
Speedometer/Payload Meter Display…3425
Voltmeter Gauge…3425
Engine Oil Pressure Gauge…3425
Water Temperature Gauge…3425
Fuel Level Gauge…3425
Hourmeter…3425
Headlight Switch…3426
Panel Light Dimmer…3426
Payload Meter Switch…3426
OVERHEAD STATUS/WARNING INDICATOR…3427
STATUS / WARNING INDICATOR LIGHT SYMBOLS…3428
High Hydraulic Oil Temperature…3428
Low Steering Pressure…3428
Low Accumulator Precharge Pressure…3429
No Power…3429
Low Brake Pressure…3430
Low Hydraulic Tank Level…3430
Automatic Lubrication System Pressure…3430
Circuit Breaker Tripped…3430
Hydraulic Oil Filter Monitor…3430
Low Fuel…3430
Parking Brake…3431
Service Brake…3431
Body Up…3431
Dynamic Retarding…3431
Stop Engine…3431
Manual Backup Lights…3432
Engine Shutdown Timer…3432
Retard Speed Control (RSC) Indicator…3432
Check Engine…3432
Service Engine Indicator (AEM)…3432
Propulsion System Temperature…3432
Blower Fault…3432
Service Engine Indicator (CENSE)…3433
Hazard Light Switch…3433
Lamp Test Switch…3433
TROLLEY INDICATOR LIGHT SYMBOLS…3433
Diesel Power Indicator…3433
Ready For Trolley Indicator…3433
On Trolley Indicator…3433
Trolley Fault Indicator…3434
Left Limit Indicator (Optional)…3434
Max Speed Indicator…3434
High Speed Indicator…3434
Med. Speed Indicator…3434
Low Speed Indicator…3435
Right Limit Indicator (Optional)…3435
CENTRYTM FUEL SYSTEM DIAGNOSTICS…3436
GENERAL OPERATION…3436
DETERMINING FAULT CODES…3436
EXITING THE DIAGNOSTICS MODE…3437
7 LUBRICATION AND SERVICE…3439
GENERAL INFORMATION…3439
HYDRAULIC SYSTEM SERVICE…3439
Hydraulic Tank…3439
Hydraulic Filters…3440
Hydraulic Pump Drive Shaft…3440
WHEEL MOTOR SERVICE…3440
COOLANT LEVEL SERVICE…3440
Radiator Filling Procedure…3440
Coolant Specifications…3441
Unacceptable Practices…3441
RESERVE ENGINE OIL SERVICE (If Equipped)…3441
Reserve Oil Tank Filling Procedure (Remote Fill)…3441
CAB AIR FILTER SERVICE…3442
FUEL SYSTEM SERVICE…3442
Fuel Tank Cleaning…3442
Fuel Filter Service…3443
INTAKE AIR CLEANER SERVICE…3443
FRONT WHEEL SERVICE…3445
Oil Sampling…3445
FRONT ENGINE MOUNT TRUNION SERVICE…3445
QUICK FILL SERVICE CENTER…3445
LUBRICATION CHART…3447
EVERY 10 HOUR (DAILY) MAINTENANCE…3448
INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION…3450
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION…3451
EVERY 250 HOUR LUBRICATION AND MAINTENANCE…3452
EVERY 500 HOUR LUBRICATION AND MAINTENANCE…3454
EVERY 1000 HOURS LUBRICATION AND MAINTENANCE…3456
EVERY 2500 HOUR MAINTENANCE…3457
EVERY 5000 HOUR MAINTENANCE…3458
EVERY 10,000 HOUR MAINTENANCE…3459
8 SPECIFICATIONS…3461
MAJOR COMPONENT DESCRIPTION…3461
Truck And Engine…3461
Alternator (GTA-22)…3461
Wheel Motors (GE 788)…3461
Blower…3461
Suspension…3461
Operator's Cab…3461
Power Steering…3461
Dynamic Retarding Gird…3461
Brake System…3461
SPECIFICATIONS…3462
Engine…3462
Electric Drive System…3462
Dynamic Retarding…3462
Battery Electric System…3462
Service Capacities…3462
Hydraulic Systems…3462
Service Brakes…3462
Steering…3462
Standard Dump Body Capacities And Dimensions…3463
Tires…3463
Weight Distribution…3463
Overall Truck Dimensions…3463
9 RADIO…3467
RADIO OPERATION…3467
GENERAL RADIO RECEIVER FUNCTIONS…3467
Turning On the Power…3467
One-Hour Timer…3468
Finding a Station…3468
Setting the Presets…3468
Adjusting the Receiver Audio Settings…3469
Display…3469
Adjusting the Receiver Menu Settings…3469
Front Auxiliary Mode…3470
Rear Auxiliary Mode…3470
CLOCK…3471
Clock/Alarm Button…3471
Setting the Clock…3471
Setting the Alarm…3471
Turning the Alarm Off…3472
Activating Snooze…3472
CD PLAYER…3473
Playing A Compact Disc…3473
Playing an MP3 DISC…3473
CD Mode Displays…3473
Button Functions…3473
MP3 PLAYER…3475
Playing MP3 Files…3475
MP3 Mode Displays…3475
Button Functions…3476
iPod®…3477
Playing an iPod®…3477
iPod® Mode Displays…3477
Button Functions…3477
WEATHERBAND (USA Only)…3479
TROUBLESHOOTING…3480
Tips About The Audio System…3480
Understanding Radio Reception…3480
Care of The Compact Discs…3480
CEAM027700 – Dump Truck 730E Operation & Maintenance Manual…3481
1 INTRODUCTION…3494
FOREWORD…3494
ABOUT THIS MANUAL…3495
ALERTS…3496
TRUCK MODEL ILLUSTRATION…3497
WARNINGS…3498
CALIFORNIA PROPOSITION 65 WARNINGS…3498
NON-OEM PARTS IN CRITICAL SYSTEMS…3499
2 STANDARD CHARTS AND TABLES…3502
GENERAL INFORMATION…3502
EFFECT OF SPECIAL LUBRICANTS…3502
SUGGESTED SOURCES FOR RUST PREVENTIVE GREASE…3502
STANDARD TIGHTENING TORQUES…3503
CLASS 10.9 CAP SCREWS & CLASS 10 NUTS…3503
SAE GRADE 5 AND GRADE 8 CAP SCREWS…3504
SAE GRADE 9 CAP SCREWS…3505
T-BOLT CLAMPS…3505
SPLIT FLANGE CLAMPS…3506
FLARED TUBE AND HOSE FITTINGS…3506
JIC 37° SWIVEL NUTS…3507
PIPE THREAD FITTINGS…3508
O-RING BOSS FITTINGS…3509
O-RING FACE SEAL FITTINGS…3510
CONVERSION MULTIPLIERS…3511
METRIC TO ENGLISH…3511
ENGLISH TO METRIC…3512
TEMPERATURE CONVERSIONS…3513
3 GENERAL SAFETY…3516
GENERAL SAFETY…3516
Safety Rules…3516
Truck Safety Features…3516
Clothing And Personal Items…3516
Unauthorized Modification…3516
Leaving The Operator’s Seat…3516
Mounting And Dismounting…3516
Fire Extinguishers And First Aid Kits…3517
Precautions For High Temperature Fluids…3517
Asbestos Dust Hazard Prevention…3517
Fire Prevention…3517
ROPS Precautions…3517
Preventing Injury From Work Equipment…3518
Precautions For Optional Attachments…3518
Precautions When Starting The Machine…3518
PRECAUTIONS FOR TRUCK OPERATION…3519
Safety Is Thinking Ahead…3519
Safety At The Worksite…3519
Preparing For Operation…3519
Ventilation For Enclosed Areas…3519
Mirrors, Windows, And Lights…3519
Before Starting The Engine…3519
Seat Belts…3519
Emergency Egress Ladders…3520
OPERATING THE MACHINE…3521
General Information…3521
Starting The Engine…3521
Traveling In Reverse…3521
Traveling On Slopes…3522
Traveling On Snow…3522
Traveling Near High Voltage Cables…3522
Traveling On Loose Ground…3522
Ensuring Good Visibility…3522
Avoid Damage To The Dump Body…3522
Safe Parking Of The Machine…3522
Loading The Machine…3523
Dumping The Machine…3523
Towing The Machine…3523
EXTERIOR LIGHTING…3523
Fog Lights…3524
Headlights…3524
Brake Light…3524
Retard Light…3524
Clearance/Turn Signal Lights…3524
Brake Lights…3524
Retard Lights…3524
Backup Lights…3524
Backup Alarm…3524
PRECAUTIONS FOR MAINTENANCE…3525
BEFORE PERFORMING MAINTENANCE…3525
Electrical System Isolation…3525
Securing The Dump Body…3526
DURING MAINTENANCE…3526
Warning Tag…3526
Proper Tools…3527
Attachments…3527
Working Under The Machine…3527
Keeping The Machine Clean…3527
Adding Fuel Or Oil To The Machine…3527
Radiator Coolant Level…3527
Use of Lighting…3527
Handling High Pressure Hoses…3528
Precautions With High Pressure Oil…3528
Maintenance Near High Temperatures and High Pressures…3528
Rotating Fan and Belts…3528
Waste Materials…3528
Use of Tie-Off Anchor During Maintenance…3528
Handling Tires…3528
Tire Maintenance…3529
Storing Tires After Removal…3529
BATTERY HAZARD PREVENTION…3529
Jump Starting With Booster Cables…3530
Jump Starting With Receptacles…3531
WHEN REPAIRS ARE NECESSARY…3532
Observe The Following Precautions…3532
SPECIAL PRECAUTIONS…3533
Preliminary Procedures Before Welding or Performing Maintenance…3533
Engine Shutdown Procedure Before Welding or Performing Maintenan…3533
Before welding on the machine, obey the following guidelines:…3533
Discharging Control Cabinet Capacitors…3534
4 WARNING AND CAUTIONS…3536
GENERAL INFORMATION…3536
PIN PLATE…3536
GRADE SPEED CHART…3537
MACHINE SAFETY…3537
KEY SWITCH…3540
OIL FILL AND CHECK…3541
HIGH PRESSURES…3542
BATTERY AND ISOLATION BOX…3544
HIGH VOLTAGE…3547
WELDING…3549
LIFTING POINTS…3550
EMERGENCY DUMPING…3550
AUTOMATIC LUBRICATION FILL…3551
ROPS/FOPS…3551
TOWING…3551
LUBRICATION CHART…3551
5 OPERATING INSTRUCTIONS…3554
PREPARING FOR OPERATION…3554
Safety Is Thinking Ahead…3554
Walk Around Inspection…3554
RETRACTABLE LADDER SYSTEM (If Equipped)…3559
GENERAL INFORMATION…3559
LADDER SYSTEM DESCRIPTION…3559
LADDER SYSTEM OPERATION…3559
Retractable Ladder Switch…3559
Ground Level Ladder Down Switch…3560
Emergency Down Valve…3560
PRE-SHIFT BRAKE TEST…3561
OPERATION…3561
Service Brake Test…3562
Parking Brake Test…3562
Retard System Test…3563
Brake Test Exit Criteria…3563
TRUCK OPERATION…3564
ENGINE START-UP SAFETY…3564
After Engine Has Started…3564
MACHINE OPERATION SAFETY PRECAUTIONS…3565
Machine Operation on the Haul Road…3566
Starting on a Grade With a Loaded Truck…3566
Retarding on a Grade…3566
Passing…3567
Loading…3567
Overload Speed Limit Function…3567
Dumping…3568
Lowering the Dump Body (When Dumping on Flat Ground)…3568
Lowering the Dump Body (When Dumping Over a Berm Or Into a Crush…3569
SUDDEN LOSS OF ENGINE POWER…3569
EMERGENCY STEERING SYSTEM…3570
Operation…3570
Pre-Operation Testing…3570
Additional Guidelines…3571
SAFE PARKING PROCEDURES…3571
NORMAL ENGINE SHUTDOWN PROCEDURE…3571
DISABLED TRUCK CONNECTORS…3573
GENERAL INFORMATION…3573
STEERING AND BRAKE SYSTEM…3573
Hookup…3573
HOIST SYSTEM…3573
Hookup…3574
Dumping Procedure…3574
TOWING…3575
SPECIAL WIRING HARNESS…3575
PAYLOAD METER III SYSTEM…3578
GENERAL INFORMATION…3578
Data Summary…3578
Data Gathering…3578
COMPONENT DESCRIPTION…3578
Operator Display…3578
Operator Switch…3578
Brake Lock Switch…3578
Payload Meter Module…3578
Communications Ports…3579
Load Lights…3579
OPERATOR’S DISPLAY AND SWITCH…3579
Reading the Load Display…3579
Setting the Operator ID…3579
Load and Ton Counter…3579
Viewing Live Sensor Data…3580
Other Display Messages…3580
HAUL CYCLE WARNING FLAGS…3580
Haul Cycle Data…3580
Haul Cycle Warning Flags…3582
PC SOFTWARE OVERVIEW…3583
SYSTEM CONFIGURATION…3584
Connecting to the Payload Meter…3584
Displayed Payload Units…3584
Connection Menu…3585
Configure the Payload Meter…3585
Setting the Date and Time…3585
Setting the Truck Type and Serial Number…3586
Setting the Gauge Display Units…3586
Setting the Carryback Alarm Threshold…3586
Setting the Truck Number…3586
Setting the Komatsu Distributor…3587
Setting the Komatsu Customer…3587
Clean Truck Tare Calibration…3587
Inclinometer Calibration…3588
DOWNLOADING PAYLOAD DATA…3588
UPLOADING DATA…3589
DATA ANALYSIS…3590
Creating a Query…3590
Payload Detail Screen…3590
Creating Reports…3591
Creating Graphs…3591
Exporting Data…3592
Importing Data…3592
Deleting Haul Cycle Records…3592
Viewing Alarms…3593
Deleting Alarm Records…3593
Patent Acknowledgment…3593
AUTOMATIC LUBRICATION SYSTEM…3594
GENERAL INFORMATION…3594
COMPONENT DESCRIPTION…3594
Filter…3595
Hydraulic Motor and Pump…3595
Grease Reservoir…3595
Pressure Reducing Valve…3595
Flow Control Valve…3595
Solenoid Valve…3596
Vent Valve…3596
Lubrication Cycle Timer…3596
Pressure Cut Off Switch…3596
Injectors…3596
Grease Pressure Failure Switch…3597
Relief Valve (unloader valve)…3597
SYSTEM OPERATION…3597
Filling The Reservoir…3597
Priming The Automatic Lubrication System…3598
PREVENTIVE MAINTENANCE PROCEDURES…3598
Daily Lubrication System Inspection…3598
250 Hour Inspection…3599
1000 Hour Inspection…3599
SYSTEM CHECKOUT…3599
General Checks…3599
Lubrication Cycle Operation…3600
6 OPERATOR CAB AND CONTROLS…3602
CAB INTERIOR…3602
STEERING WHEEL AND CONTROLS…3603
Horn Button…3603
Tilt / Telescope Lever…3603
Multi-Function Turn Signal Switch…3603
Speed Control Lever…3603
Turn Signal Operation…3603
High Beam Headlight Operation…3604
Windshield Wiper Operation…3604
PEDALS…3605
SERVICE BRAKE PEDAL…3605
DYNAMIC RETARD PEDAL…3605
Dynamic Retarding…3605
ACCELERATOR PEDAL…3605
OVERHEAD PANEL AND DISPLAYS…3606
RADIO SPEAKERS…3606
WARNING ALARM BUZZER…3606
CAB RADIO…3606
AIR CLEANER VACUUM GAUGES…3606
CENTER CONSOLE…3607
DIRECTIONAL CONTROL LEVER…3607
ENGINE STOP SWITCH…3607
OVERRIDE/FAULT RESET SWITCH…3607
HOIST CONTROL LEVER…3607
Raising The Dump Body…3608
Lowering The Dump Body…3608
WINDOW CONTROL SWITCHES…3608
DATA STORE BUTTON…3608
FIRE SUPPRESSION CONTROL OUTLET…3608
COMMUNICATION RADIO OUTLET…3608
12V AUXILIARY POWER OUTLETS…3608
DIAGNOSTIC PORTS…3609
ENGINE…3609
DRIVE SYSTEM…3609
PAYLOAD METER…3609
KOMTRAX Plus …3609
INTERFACE MODULE (IM)…3609
ALTERNATE DRIVE SYSTEM (USB)…3609
ALTERNATE DRIVE SYSTEM (ETHERNET)…3609
OPERATOR SEAT (Standard)…3610
SEAT BELTS…3610
ADJUSTMENT…3610
PASSENGER SEAT (Standard)…3612
SEAT BELTS…3612
ADJUSTMENT…3612
OPERATOR SEAT (Optional)…3613
SEAT BELTS…3613
ADJUSTMENT…3613
PASSENGER SEAT (Optional)…3614
SEAT BELTS…3614
ADJUSTMENT…3614
HEATER / AIR CONDITIONER CONTROLS…3615
Fan Speed Control Knob…3615
Temperature Control Knob…3615
Air Flow Directional Knob…3615
Heater/Air Conditioner Vents…3615
INSTRUMENT PANEL …3616
CONTROL SYMBOLS…3616
Cab/Air Conditioner Vents…3617
Status Indicator Light Panel…3617
Hydraulic Oil Temperature Gauge…3617
Coolant Temperature Gauge…3617
Speedometer/Digital Display…3617
Fuel Level Gauge…3617
Drive System Temperature Gauge…3617
Hazard Warning Light Switch…3618
Pre-Shift Brake Test Switch…3618
Wheel Brake Lock Control Switch…3618
Rest Switch…3618
Engine Warm Up…3619
Key Switch…3619
Warning Light…3619
Digital Display Contrast Buttons…3619
Turn Signal Indicators…3619
Panel Light Dimmer…3619
Mode Switches…3619
Fog Light Swich…3620
Backup Light Switch…3620
Ladder Light Switch…3620
Headlight/Panel Illumination Light Switch…3620
STATUS INDICATOR LIGHT PANEL…3621
STATUS INDICATOR LIGHT SYMBOLS…3621
Body Up…3621
Parking Brake…3621
Propel System Not Ready…3621
No Propel…3621
Engine Warm Up…3622
Engine Shutdown Delay…3622
Retarding Grid Drier…3622
Wheel Brake Lock…3622
Traction Control…3622
Repair Monitor…3622
Retractable Ladder Down…3622
Snapshot In Progress…3622
Pantograph Energized…3622
Pantograph Up…3622
Service Brake…3622
Dynamic Retarding…3622
No DC Link Voltage…3622
DIGITAL DISPLAY OPERATION…3623
Toggling Through Main Level Screens…3623
Toggling Through Warning Screens…3624
Entering Payload Meter Data…3625
KOMTRAX Plus…3626
KOMTRAX Plus OPERATION…3626
Basic Precautions…3626
Interface Module…3627
DOWNLOADING KOMTRAX Plus DATA…3628
GENERAL INFORMATION…3628
KOMTRAX Plus DOWNLOADING PROCEDURE…3628
Location of Downloaded Files…3628
UPLOADING KOMTRAX Plus DATA…3629
ORBCOMM…3630
KOMATSU WIRELESS BRIDGE (Optional)…3631
General Information…3631
Communication Setup…3631
Switching to the KWB_SETUP Network…3631
Setting the Computer Subnet Mask and IP Address…3632
Setting Up the KWB…3632
Adding Encryption…3633
Final Computer Settings…3633
Downloading Data…3633
Resetting the KWB…3634
FUSES AND CIRCUIT BREAKERS…3635
FUSE BLOCK #1…3635
FUSE BLOCK #2…3636
FUSE BLOCK #3…3637
FUSE BLOCK #4…3637
CIRCUIT BREAKERS…3637
7 LUBRICATION AND SERVICE…3640
GENERAL INFORMATION…3640
HYDRAULIC SYSTEM SERVICE…3640
Hydraulic Tank…3640
Hydraulic Filters…3641
Hydraulic Pump Drive Shaft…3641
WHEEL MOTOR SERVICE…3641
COOLANT LEVEL SERVICE…3641
Radiator Filling Procedure…3642
Coolant Specifications…3642
Unacceptable Practices…3642
CAB AIR FILTER SERVICE…3642
FUEL SYSTEM SERVICE…3643
Fuel Tank Cleaning…3643
Fuel Filter Service…3643
INTAKE AIR CLEANER SERVICE…3644
FRONT WHEEL SERVICE…3645
Oil Sampling…3645
FRONT ENGINE MOUNT TRUNNION SERVICE…3645
QUICK FILL SERVICE CENTER…3645
TIE ROD INSPECTION AND TORQUE PROCEDURE…3646
LUBRICATION CHART…3648
EVERY 10 HOUR (DAILY) MAINTENANCE…3649
INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION…3651
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION…3652
EVERY 250 HOUR LUBRICATION AND MAINTENANCE…3653
EVERY 500 HOUR LUBRICATION AND MAINTENANCE…3655
EVERY 1000 HOURS LUBRICATION AND MAINTENANCE…3657
EVERY 2500 HOUR MAINTENANCE…3658
EVERY 5000 HOUR MAINTENANCE…3659
8 SPECIFICATIONS…3662
MAJOR COMPONENT DESCRIPTION…3662
Truck And Engine…3662
Alternator…3662
AC Induction Traction Motorized Wheels…3662
Suspension…3662
Operator's Cab…3662
Power Steering…3662
Dynamic Retarding Grid…3662
Brake System…3662
SPECIFICATIONS…3663
Engine…3663
AC Electric Drive System…3663
Dynamic Retarding…3663
Battery Electric System…3663
Service Capacities…3663
Hydraulic Systems…3663
Service Brakes…3664
Parking Brake…3664
Steering…3664
Standard Dump Body Capacities And Dimensions…3664
Tires…3664
Weight Distribution…3664
Overall Truck Dimensions…3665
9 RADIO…3668
RADIO OPERATION…3668
GENERAL RADIO RECEIVER FUNCTIONS…3668
Turning On the Power…3668
One-Hour Timer…3668
Finding a Station…3668
Setting the Presets…3669
Adjusting the Receiver Audio Settings…3669
Display…3670
Adjusting the Receiver Menu Settings…3670
Front Auxiliary Mode…3670
Rear Auxiliary Mode…3670
CLOCK…3671
Clock/Alarm Button…3671
Setting the Clock…3671
Setting the Alarm…3671
Turning the Alarm Off…3672
Activating Snooze…3672
CD PLAYER…3673
Playing a Compact Disc…3673
Playing an MP3 DISC…3673
CD Mode Displays…3673
Button Functions…3673
MP3 PLAYER…3675
Playing MP3 Files…3675
MP3 Mode Displays…3675
Button Functions…3675
iPod®…3677
Playing an iPod®…3677
iPod® Mode Displays…3677
Button Functions…3677
WEATHERBAND (USA Only)…3679
TROUBLESHOOTING…3680
Tips About the Audio System…3680
Understanding Radio Reception…3680
Care of the Compact Discs…3680
CEAW004103 – Dump Truck 730E Field Assembly Manual…3681
COVER…3681
FOREWARD…3683
TABLE OF CONTENTS…3685
SAFETY RULES, TOOLS & EQUIPMENT…3687
SAFETY RULES…3687
TOOLS AND EQUIPMENT FOR ASSEMBLY…3688
LIFTING SLING GENERAL INFORMATION…3689
ASSEMBLY SCHEDULE AND RESOURCE LAYOUT…3694
MAJOR COMPONENTS AND SPECIFICATIONS…3697
SPECIFICATIONS…3699
Komatsu SSA16V159…3699
MAJOR COMPONENT WEIGHTS…3701
FIELD WELDING FOR ASSEMBLY OR REPAIR…3703
WELDER QUALIFICATION AND TRAINING…3703
WELD PROCEDURES…3703
APPROVED CONSUMABLES…3703
WELD QUALITY REQUIREMENTS…3703
MATERIALS, CONTROLS, AND PRECAUTIONS…3704
WELD INSPECTION…3704
RECORDS…3705
ANNEX A…3705
ANNEX B…3707
1.0 TOE HAMMER PEENING…3707
Procedure…3707
2.0 TOE GRINDING WITH A ROTARY BURR…3707
Procedure…3707
BIBLIOGRAPHY…3710
SPECIAL PRECAUTIONS WHEN SERVICING AN A/C DRIVE SYSTEM TRUCK…3710
General Welding Guidelines…3711
RECEIVING & ASSEMBLY PREPARATION…3713
ASSEMBLY LAYOUT…3714
CHASSIS ASSEMBLY…3715
RECOMMENDED ASSEMBLY DATA…3715
BASIC ASSEMBLY PROCEDURE…3715
GENERAL PRECAUTIONS AND INSTRUCTION…3717
Turn-Of-The-Nut Tightening Procedure…3737
GENERAL INFORMATION…3777
BODY ASSEMBLY…3778
BODY WELDING…3780
DUMP BODY ASSEMBLY…3777
DUMP BODY INSTALLATION…3785
Installation…3785
BODY SLING…3789
BODY PADS…3789
Adjustment…3790
BODY GUIDE…3791
ROCK EJECTORS…3791
Inspection…3791
BODY SWITCHES…3792
FINAL ASSEMBLY…3792
FINAL CHECKOUT…3795
APPENDIX…3797
LUBRICATION CHART…3799
SUSPENSION OILING AND CHARGING…3801
GENERAL…3801
EQUIPMENT LIST…3801
Hydrair® Charging Kit…3801
Installation of Charging Kit…3801
Removal of Charging Kit…3802
Support Blocks For Oiling and Charging Dimensions…3802
FRONT SUSPENSION…3803
Front Suspension Oiling…3803
Front Suspension Nitrogen Charging…3804
REAR SUSPENSION…3806
Rear Suspension Oiling…3806
Rear Suspension Nitrogen Charging…3808
OIL AND NITROGEN SPECIFICATIONS CHART…3809
TOE-IN ADJUSTMENT…3811
TOE-IN ADJUSTMENT…3811
AUTOMATIC LUBRICATION SYSTEM…3813
LUBRICANT REQUIRED FOR SYSTEM…3813
SYSTEM PRIMING…3813
LUBRICANT PUMP…3813
Pump Housing Oil Level…3813
Pump Pressure Control…3813
INJECTORS (SL-1 Series H)…3814
Injector Specifications…3814
Injector Adjustment…3814
SYSTEM CHECKOUT…3815
Lubrication Cycle Timer Check…3815
Lubrication Cycle Timer Adjustment…3816
PREVENTIVE MAINTENANCE INSPECTION…3816
10 Hour Lubrication System Inspection…3816
100 Hour Inspection…3816
250 Hour Inspection…3816
500 Hour Inspection…3817
1000 Hour Inspection…3817
A/C CHECKOUT PROCEDURE…3819
A/C DRIVE BELT ADJUSTMENT PROCEDURE…3821
HYDRAULIC CHECKOUT PROCEDURE…3823
BRAKE SYSTEM CHECKOUT PROCEDURE…3833
VHMS SYSTEM CHECKOUT PROCEDURE…3841
PAYLOAD METER SYSTEM CHECKOUT PROCEDURE…3857
STATEX III CHECKOUT PROCEDURE…3871
STANDARD TORQUE CHARTS AND CONVERSION TABLES…3927
Suggested* Sources for Rust Preventive Grease:…3928
HYDRAULIC SYSTEM FLUSHING PROCEDURE…3933
SYSTEM FLUSHING…3933
Hydraulic System Flushing Procedure…3933
FIELD ASSEMBLY INSPECTION REPORT…3939
50 HOUR POST COMMISSIONING CHECKSHEET…3944
CEAW007800 – Dump Truck 730E-8 Field Assembly Manual…3951
COVER…3951
INTRODUCTION…3952
SAFETY RULES, TOOLS & EQUIPMENT…3956
TRUCK COMPONENTS & SPECIFICATIONS…3964
MAJOR COMPONENT WEIGHTS…3970
FIELD WELDING FOR ASSEMBLY OR REPAIR…3972
RECEIVING & ASSEMBLY PREPARATION…3982
CHASSIS ASSEMBLY…3984
DUMP BODY ASSEMBLY…4038
DUMP BODY INSTALLATION…4046
FINAL CHECKOUT…4056
APPENDIX…4058
LUBRICATION CHART…4060
SUSPENSION OILING AND CHARGING…4062
ACCUMULATOR CHARGING…4072
TOE-IN ADJUSTMENT…4076
STEERING COLUMN ALIGNMENT PROCEDURE…4078
SEAT BELTS AND TETHERS CHECKOUT PROCEDURE…4080
AUTOMATIC LUBRICATION SYSTEM CHECKOUT PROCEDURE…4084
AIR CONDITIONING SYSTEM CHECKOUT PROCEDURE…4086
HYDRAULIC HOIST AND STEERING SYSTEM CHECKOUT PROCEDURE…4088
AUXILIARY HYDRAULIC SYSTEM CHECKOUT PROCEDURE…4110
HYDRAULIC BRAKE SYSTEM CHECKOUT PROCEDURE…4118
KOMTRAX PLUS SETUP PROCEDURE…4136
KOMTRAX PLUS CHECKOUT PROCEDURE…4144
PAYLOAD METER III CHECKOUT PROCEDURE…4148
ELECTRICAL SYSTEM CHECKOUT PROCEDURE…4160
INTERFACE MODULE (IM) CHECKOUT PROCEDURE…4168
TORQUE TABLES AND CONVERSION CHARTS…4176
FIELD ASSEMBLY INSPECTION REPORT…4186
50 HOUR POST-COMMISIONING CHECKSHEET…4192
DG756 – Dump Truck 730E Operation & Maintenance Manual…4199
Komatsu Dump Trucks 730E Operation & Maintenance Manuals