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KOMATSU 730E-8 DUMP TRUCK SHOP MANUAL CEBM032406 – PDF DOWNLOAD
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Description
KOMATSU 730E-8 DUMP TRUCK SHOP MANUAL CEBM032406 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU 730E-8 DUMP TRUCK SHOP MANUAL CEBM032406 – PDF DOWNLOAD
Language : English
Pages : 1006
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU 730E-8 DUMP TRUCK SHOP MANUAL CEBM032406 – PDF DOWNLOAD
COVER................................................................................................ 1 00 Index and foreword................................................................................ 3 Index............................................................................................ 3 Composition of shop manual................................................................... 4 Table of contents............................................................................ 6 Foreword, safety and general information......................................................... 17 Foreword..................................................................................... 20 How to read the shop manual.................................................................. 21 Composition of shop manual............................................................... 21 Revision and distribution................................................................ 21 Symbols.................................................................................. 22 General safety............................................................................... 23 Safety rules............................................................................. 23 Safety features.......................................................................... 23 Fire extinguisher and first aid kit...................................................... 23 Clothing and personal items.............................................................. 23 Leaving the operator seat................................................................ 24 Mounting and dismounting................................................................. 24 Fire prevention for fuel and oil......................................................... 24 Precautions with high temperature fluids................................................. 25 Asbestos dust hazard prevention.......................................................... 25 Prevention of injury by work equipment................................................... 25 Unauthorized modification................................................................ 25 Precautions when using ROPS.............................................................. 25 Precautions for attachments.............................................................. 26 Precautions for starting the truck....................................................... 26 Precautions before operating the truck....................................................... 26 Safety at the worksite................................................................... 26 Fire prevention.......................................................................... 27 Ventilation in enclosed areas............................................................ 27 Preparing for operation.................................................................. 27 Mirrors, windows and lights.............................................................. 27 In operator cab (before starting the engine)............................................. 27 Seat Belts............................................................................... 27 Precautions while operating the truck........................................................ 28 When starting the engine................................................................. 28 General truck operation.................................................................. 28 Ensuring good visibility................................................................. 28 Traveling................................................................................ 29 Traveling in reverse..................................................................... 29 Traveling on slopes...................................................................... 29 Operating on snow or ice................................................................. 29 Avoid damage to dump body................................................................ 29 Driving near high voltage cables......................................................... 30 When dumping............................................................................. 30 When loading............................................................................. 30 Working on loose ground.................................................................. 30 Parking the truck........................................................................ 30 Towing................................................................................... 30 Working near batteries....................................................................... 31 Battery hazard prevention................................................................ 31 Starting with jumper cables.............................................................. 32 Jump starting with receptacles........................................................... 32 Precautions before performing service........................................................ 33 Warning tag.............................................................................. 33 Stopping the engine...................................................................... 33 Proper tools............................................................................. 33 Use of tie-off anchor during maintenance and repair...................................... 34 Securing the dump body................................................................... 35 Jack point locations..................................................................... 36 Precautions while performing service......................................................... 37 Keep the truck clean..................................................................... 37 Attachments.............................................................................. 37 Working under the truck.................................................................. 37 Rotating fan and belts................................................................... 37 Adding fuel or oil....................................................................... 37 Use of lighting.......................................................................... 37 Radiator coolant level................................................................... 38 Precautions with the battery............................................................. 38 Precautions with high pressure oil....................................................... 38 Handling high pressure hoses............................................................. 38 Precautions when performing maintenance near high temperature or high pressure........... 38 Waste materials.......................................................................... 38 Tires........................................................................................ 39 Inspection............................................................................... 39 Maintenance.............................................................................. 39 Storage.................................................................................. 40 Handling................................................................................. 41 Precautions for performing repairs........................................................... 42 Engine shutdown procedure after AC drive system failure.................................. 42 Precautions for welding on the truck......................................................... 43 Capacitor discharge system................................................................... 44 Necessary tools.......................................................................... 44 Warnings and cautions.................................................................... 45 Manual DC link capacitor discharge procedure............................................. 46 Failure of the discharge system.......................................................... 48 Manual discharge of capacitors........................................................... 49 Short isolated capacitor terminals....................................................... 51 Handling electrical equipment and hydraulic components....................................... 52 Points to remember when handling electrical equipment.................................... 52 Points to remember when handling hydraulic equipment..................................... 58 Standard tightening torques.................................................................. 60 Effect of special lubricants on fasteners and standard torque values..................... 60 Suggested sources for rust preventive grease............................................. 60 SAE grade 5 and grade 8 hex head capscrew and nut assemblies............................. 61 SAE grade 9 capscrews.................................................................... 62 Class 10.9 capscrews and class 10 nuts................................................... 62 Standard tightening torques for fittings................................................. 63 Standard tightening torques for clamps................................................... 65 Conversion tables............................................................................ 66 Common conversion multipliers............................................................ 66 01 Specification..................................................................................... 71 Specification and technical data................................................................. 71 Specification drawing........................................................................ 73 Specifications............................................................................... 74 Weight table................................................................................. 76 Fuel, coolant and lubricants................................................................. 77 Suspension cylinder oil and nitrogen specifications...................................... 78 10 Structure and functions........................................................................... 81 Steering circuit................................................................................. 81 Steering circuit operation................................................................... 83 Steering circuit components.................................................................. 85 Steering control unit.................................................................... 85 High pressure filter..................................................................... 85 Steering accumulators.................................................................... 85 Bleeddown manifold....................................................................... 86 Steering accumulator bleeddown solenoid.................................................. 86 Quick disconnect ports................................................................... 86 Flow amplifier........................................................................... 86 Steering/brake pump operation................................................................ 89 High altitude operation.................................................................. 89 Neutral position......................................................................... 90 Full pump volume......................................................................... 91 Half pump volume......................................................................... 91 Flow amplifier operation..................................................................... 92 No steer................................................................................. 92 Steering left............................................................................ 94 Steering right........................................................................... 96 No steer, external shock load............................................................ 98 Hoist circuit.................................................................................... 101 Hoist circuit operation...................................................................... 102 Hoist circuit components..................................................................... 103 Hydraulic tank........................................................................... 103 Hoist pump............................................................................... 103 High pressure filters.................................................................... 103 Hoist valve.............................................................................. 103 Hoist pilot valve........................................................................ 104 Hoist up limit solenoid.................................................................. 105 Hoist pilot manifold..................................................................... 105 Counterbalance manifold.................................................................. 105 Hoist pilot valve operation.................................................................. 106 Float position with body coming down..................................................... 106 Power up operation....................................................................... 108 Hold operation........................................................................... 110 Power down operation..................................................................... 112 Float operation.......................................................................... 114 Brake circuits................................................................................... 117 General information.......................................................................... 119 Service brake circuit operation.............................................................. 119 Secondary braking and auto apply............................................................. 121 Parking brake circuit operation.............................................................. 121 Normal operation (key switch ON, engine running)......................................... 121 Wheel brake lock circuit operation........................................................... 122 Brake warning circuit operation.............................................................. 122 Electrical system, 24 volt....................................................................... 125 Battery supply system........................................................................ 127 24VDC battery charging alternator........................................................ 127 Battery box.............................................................................. 127 24VDC auxiliary battery receptacles...................................................... 127 Isolation box................................................................................ 128 Engine shutdown switch................................................................... 128 Access ladder light switch............................................................... 128 Battery disconnect switches.............................................................. 128 Propel lockout lever..................................................................... 128 LED lights............................................................................... 128 Auxiliary control cabinet components......................................................... 129 VEC blocks............................................................................... 130 24VDC to 12VDC converter................................................................. 130 Circuit breakers......................................................................... 130 Engine service light timer............................................................... 130 Ground terminals......................................................................... 130 24VDC power terminals.................................................................... 130 Relays................................................................................... 131 Body-up switch............................................................................... 132 Hoist limit switch........................................................................... 133 Electrical system, AC drive...................................................................... 135 General system operation..................................................................... 136 AC drive system components................................................................... 138 Drive System Controller (DSC)............................................................ 138 Diagnostic information display (DID) panel............................................... 139 DSC software functions....................................................................... 140 Input Processing......................................................................... 140 State Machine............................................................................ 140 DC Link State............................................................................ 143 Engine Control........................................................................... 144 Alternator field control..................................................................... 144 Desired DC Link Voltage.................................................................. 144 Self-Load................................................................................ 144 Propel Torque Control.................................................................... 145 Retard Torque Control.................................................................... 145 Wheel Slide Control...................................................................... 145 Resistor Grid Control.................................................................... 146 Chopper Voltage Control.................................................................. 146 Event detection and processing............................................................... 146 Power-On Tests........................................................................... 146 Initiated Tests.......................................................................... 147 Periodic Tests........................................................................... 147 Event restrictions........................................................................... 147 Event logging and storage.................................................................... 147 Event History Buffer..................................................................... 148 Data Packs............................................................................... 148 Event Reset.............................................................................. 148 Abnormal conditions/overriding functions..................................................... 148 Fast Start............................................................................... 149 Engine Shutdown/Engine Not Running....................................................... 149 Limp Home Mode........................................................................... 149 Electronic accelerator and retard pedals..................................................... 149 Drive system component abbreviations & locations............................................. 150 Cab air conditioning............................................................................. 157 General information.......................................................................... 159 Environmental impact of air conditioning................................................. 159 Air conditioning for off-highway vehicles................................................ 159 Principles of refrigeration.................................................................. 160 Air conditioning......................................................................... 160 Refrigeration - the act of cooling....................................................... 160 The refrigeration cycle.................................................................. 160 Air conditioning system components........................................................... 162 Relays................................................................................... 162 Fan motor and speed control.............................................................. 162 Cab air filter........................................................................... 162 Heater core.............................................................................. 162 Actuators................................................................................ 162 Compressor (refrigerant pump)............................................................ 164 Service valves........................................................................... 164 Condenser................................................................................ 164 Receiver-drier........................................................................... 164 Expansion valve.......................................................................... 165 Accumulator.............................................................................. 165 Evaporator core.......................................................................... 165 Air conditioning system electrical circuit................................................... 166 Thermostat............................................................................... 166 Compressor clutch........................................................................ 166 Trinary™ switch.......................................................................... 167 20 Standard value table.............................................................................. 169 Standard value table............................................................................. 169 Standard value table for truck............................................................... 171 30 Testing and adjusting............................................................................. 177 Steering, hoist and auxiliary hydraulic systems.................................................. 177 General information on system checkout....................................................... 178 Hydraulic system checkout procedures......................................................... 179 Required equipment....................................................................... 179 Bleeddown procedure...................................................................... 179 Preliminary steps........................................................................ 181 Hydraulic system flushing procedure...................................................... 181 Flow amplifier adjustment................................................................ 185 Steering pump unloader valve adjustment.................................................. 185 Auxiliary accumulator pressure verification.............................................. 186 System diagnostics....................................................................... 186 Hoist pilot valve adjustment............................................................. 188 Hoist counterbalance valve adjustment.................................................... 188 Final steps.............................................................................. 189 Oil cleanliness check.................................................................... 190 Hydraulic system checkout data sheet......................................................... 191 Toe-in adjustment............................................................................ 195 Hoist cylinder leakage test.................................................................. 196 Steering cylinder leakage test............................................................... 196 Brake system..................................................................................... 199 General information on system checkout....................................................... 200 Brake circuit checkout procedure............................................................. 200 Initial system setup and service brake checkout.......................................... 202 Brake lock system checkout............................................................... 203 Parking brake checkout................................................................... 203 Parking brake troubleshooting............................................................ 203 Low brake pressure and auto apply........................................................ 204 Parking brake control logic checkout..................................................... 206 Brake lock control logic checkout........................................................ 207 Brake system checkout data sheet............................................................. 209 Service brake conditioning (burnishing)...................................................... 215 Front brake conditioning................................................................. 216 Rear brake conditioning.................................................................. 217 Parking brake adjustment procedure........................................................... 218 Brake bleeding procedure..................................................................... 219 Service brake............................................................................ 219 Parking brake (rear brake calipers only)................................................. 219 Piston assembly return spring force and built-in clearance (BIC)............................. 220 Piston assembly adjuster grip force...................................................... 221 Adjuster force........................................................................... 223 Piston return spring..................................................................... 224 Accumulators and suspensions..................................................................... 227 Accumulator charging and storage............................................................. 229 Temperature during precharge............................................................. 229 Bladder accumulator charging procedure....................................................... 230 Precharge maintenance.................................................................... 232 Bladder accumulator storage procedure.................................................... 232 Bladder storage.......................................................................... 232 Installing a bladder accumulator from storage............................................ 233 Bladder accumulator leak testing......................................................... 233 Piston accumulator charging procedure........................................................ 234 Piston accumulator storage................................................................... 237 Piston accumulator leak testing.............................................................. 238 Checking for improper suspension charge on operating trucks.................................. 239 Suspension oil change recommendations........................................................ 240 Suspension oiling and charging procedures.................................................... 241 Required equipment....................................................................... 241 Installing the charging kit.............................................................. 242 Removing the charging kit................................................................ 242 Support blocks for oiling and charging dimensions........................................ 243 Front suspensions........................................................................ 246 TOP FILL METHOD.......................................................................... 247 PRESSURE FILL METHOD..................................................................... 247 Rear suspensions......................................................................... 249 TOP FILL METHOD.......................................................................... 251 PRESSURE FILL METHOD..................................................................... 251 Suspension pressure test..................................................................... 253 Interface module 1 (IM1)......................................................................... 255 Required software and tools.................................................................. 257 Interface module checkout procedures......................................................... 258 Initial startup.......................................................................... 258 Checking digital inputs to the IM........................................................ 258 Checking analog inputs to the IM......................................................... 260 Checking serial communication to the IM.................................................. 260 Checking outputs from the IM............................................................. 260 IM checkout sheet............................................................................ 261 KOMTRAX Plus..................................................................................... 265 KOMTRAX Plus software and tools.............................................................. 267 KOMTRAX Plus controller setup procedure...................................................... 267 Preliminary steps........................................................................ 267 Setup procedure.......................................................................... 267 KOMTRAX Plus initialization form............................................................. 271 Precautions when replacing the KOMTRAX Plus controller....................................... 272 KOMTRAX Plus controller checkout procedure................................................... 274 Preliminary steps........................................................................ 274 Checkout procedure....................................................................... 274 Payload meter IV................................................................................. 277 Payload meter IV software and tools.......................................................... 279 Payload meter IV system configuration........................................................ 279 Connecting to the payload meter IV web server............................................ 279 Configuring a static IP address.......................................................... 279 Payload meter IV software installation....................................................... 281 Inclinometer calibration and clean truck tare................................................ 282 Payload meter IV checkout procedure.......................................................... 282 PLM IV system checkout data sheet............................................................ 288 Downloading PLM IV data and possible errors.................................................. 289 Komatsu wireless bridge (KWB).................................................................... 293 General information.......................................................................... 295 Software download and setup.................................................................. 296 Bullet M2 Titanium / PicoStation M2...................................................... 297 Bullet M2................................................................................ 299 Configuring a KWB_Connect device............................................................. 300 Access point configuration............................................................... 300 Bullet M2 configuration.................................................................. 301 KOMTRAX Plus downloads................................................................... 302 Configuring a TRUCK_NET device............................................................... 303 Access point configuration............................................................... 303 Bullet M2 configuration.................................................................. 304 Onboard controller access................................................................ 305 Changing a service computer’s IP address..................................................... 306 Connecting to a wireless network............................................................. 307 KWB_Connect troubleshooting.................................................................. 308 Step 1. Verify communication to the access point......................................... 308 Step 2. Verify communication to the Bullet M2............................................ 308 Step 3. Verify communication to KOMTRAX Plus............................................. 309 TRUCK_NET troubleshooting.................................................................... 310 Step 1. Verify communication to the access point......................................... 310 Step 2. Verify communication to the Bullet M2............................................ 311 KWB_Connect checkout data sheet.............................................................. 312 TRUCK_NET checkout data sheet................................................................ 313 Cab air conditioning............................................................................. 315 General information.......................................................................... 317 Service tools and equipment.................................................................. 318 Recovery/recycle station................................................................. 318 Leak detector............................................................................ 318 Manifold gauge set....................................................................... 319 Service valves........................................................................... 320 Vacuum pump.............................................................................. 320 Detecting leaks.............................................................................. 321 System performance test...................................................................... 322 Checking system oil.......................................................................... 323 System flushing.............................................................................. 324 Installing the manifold gauge set............................................................ 325 Purging air from the service hoses....................................................... 326 Recovering and recycling refrigerant......................................................... 327 Draining oil from previous recovery cycle................................................ 328 Recovery cycle........................................................................... 328 Recycling procedure...................................................................... 328 Evacuating the air conditioning system....................................................... 329 Charging the air conditioning system......................................................... 330 KomVision........................................................................................ 333 Requirements................................................................................. 335 Initial setup................................................................................ 336 Checkout data sheet.......................................................................... 345 Calibration sheets........................................................................... 350 Layout and assemblage.................................................................... 350 Unfolding a calibration sheet............................................................ 353 Folding a calibration sheet.............................................................. 354 Placement of calibration sheets.......................................................... 355 Camera calibration procedures................................................................ 357 Automatic 6 camera calibration........................................................... 357 Manual 6 camera calibration.............................................................. 361 1 camera calibration..................................................................... 364 Radar setting procedure...................................................................... 367 40 Troubleshooting................................................................................... 371 Fuse and circuit breaker locations............................................................... 371 Fuse and circuit breaker locations........................................................... 373 AC drive system fault codes (DSC)................................................................ 379 Fault code tables............................................................................ 381 Troubleshooting by fault code, Part 1............................................................ 409 Fault Code A001: Left front suspension pressure sensor signal high........................... 411 Related circuit diagram.................................................................. 411 Fault Code A002: Left front suspension pressure sensor signal low............................ 412 Related circuit diagram.................................................................. 412 Fault Code A003: Right front suspension pressure sensor signal high.......................... 413 Related circuit diagram.................................................................. 413 Fault Code A004: Right front suspension pressure sensor signal low........................... 414 Related circuit diagram.................................................................. 414 Fault Code A005: Left rear suspension pressure sensor signal high............................ 415 Related circuit diagram.................................................................. 415 Fault Code A006: Left rear suspension pressure sensor signal low............................. 416 Related circuit diagram.................................................................. 416 Fault Code A007: Right rear suspension pressure sensor signal high........................... 417 Related circuit diagram.................................................................. 417 Fault Code A008: Right rear suspension pressure sensor signal low............................ 418 Related circuit diagram.................................................................. 418 Fault Code A009: Incline sensor signal high.................................................. 419 Related circuit diagram.................................................................. 419 Fault Code A010: Incline sensor signal low................................................... 420 Related circuit diagram.................................................................. 420 Fault Code A011: Payload meter speed sensor signal has Failed................................ 421 Related circuit diagram.................................................................. 421 Fault Code A013: Body up switch has Failed................................................... 422 Related circuit diagram.................................................................. 422 Fault Code A014: Payload meter checksum computation has Failed............................... 423 Related circuit diagram.................................................................. 423 Fault Code A016: Payload meter write to flash memory has Failed.............................. 424 Related circuit diagram.................................................................. 424 Fault Code A017: Payload meter flash memory read has Failed.................................. 425 Related circuit diagram.................................................................. 425 Fault Code A018: Right rear flat suspension cylinder warning................................. 426 Related circuit diagram.................................................................. 427 Fault Code A019: Left rear flat suspension cylinder warning.................................. 428 Related circuit diagram.................................................................. 429 Fault Code A022: Carryback load excessive.................................................... 430 Related circuit diagram.................................................................. 431 Fault Code A101: High pressure detected across an hydraulic pump filter...................... 432 Related circuit diagram.................................................................. 432 Fault Code A103: Hydraulic Oil Temp - Tank Sensor Low........................................ 433 Related circuit diagram.................................................................. 433 Fault Code A104: Hydraulic oil temp - Tank sensor high....................................... 434 Related circuit diagram.................................................................. 434 Fault Code A105: Fuel level sensor shorted to ground indicating a false high fuel level...... 436 Related circuit diagram.................................................................. 437 Fault Code A109: GE has generated a propel system reduced level signal....................... 438 Related circuit diagram.................................................................. 438 Fault Code A111 & A247: Low steering pressure warnings....................................... 440 Related circuit diagram.................................................................. 441 Fault Code A115: Low steering precharge pressure detected.................................... 442 Related circuit diagram.................................................................. 442 Fault Code A117: Low brake accumulator pressure warnings..................................... 444 Related circuit diagram.................................................................. 445 Fault Code A118: Brake pressure is low while in brake lock................................... 446 Related circuit diagram.................................................................. 446 Fault Code A123: GE has generated a reduced retarding caution................................ 447 Related circuit diagram.................................................................. 447 Fault Code A124: GE has generated a no propel / no retard warning............................ 448 Related circuit diagram.................................................................. 448 Fault Code A125: GE has generated a no propel warning........................................ 449 Related circuit diagram.................................................................. 449 Fault Code A126: Oil level in the hydraulic tank is low...................................... 450 Related circuit diagram.................................................................. 450 Fault Code A127: IM-furnished +5 volt output for sensors is low.............................. 451 Related circuit diagram.................................................................. 451 Fault Code A128: IM-furnished +5 volt output for sensors is high............................. 452 Related circuit diagram.................................................................. 452 Fault Code A139 & A310: Low fuel warnings.................................................... 454 Related circuit diagram.................................................................. 455 Troubleshooting by fault code, Part 2............................................................ 457 Fault Code A152: Starter failure............................................................. 459 Related circuit diagram.................................................................. 459 Fault Code A153: Battery voltage is low with the truck in operation.......................... 460 Related circuit diagram.................................................................. 461 Fault Code A154: Battery charging voltage is excessive....................................... 462 Related circuit diagram.................................................................. 462 Fault Code A155: Battery charging voltage is low............................................. 463 Related circuit diagram.................................................................. 463 Fault Code A158: Fuel level sensor open or shorted high indicating a false low fuel level.... 464 Related circuit diagram.................................................................. 464 Fault Code A184: J1939 data link is not connected............................................ 465 Related circuit diagram.................................................................. 465 Fault Code A190: Auto lube control has detected an incomplete lube cycle..................... 466 Related circuit diagram.................................................................. 467 Fault Code A193: Hydraulic tank oil temperature is high...................................... 468 Related circuit diagram.................................................................. 468 Fault Code A198: Hoist pressure 1 sensor is high............................................. 469 Related circuit diagram.................................................................. 469 Fault Code A200: Steering pressure sensor is high............................................ 470 Related circuit diagram.................................................................. 470 Fault Code A201: Brake pressure sensor is high............................................... 471 Related circuit diagram.................................................................. 471 Fault Code A202: Hoist pressure 1 sensor is low.............................................. 472 Related circuit diagram.................................................................. 472 Fault Code A204: Steering pressure sensor is low............................................. 473 Related circuit diagram.................................................................. 473 Fault Code A205: Brake pressure sensor is low................................................ 474 Related circuit diagram.................................................................. 474 Fault Code A206: Ambient temperature sensor is high.......................................... 475 Related circuit diagram.................................................................. 475 Fault Code A207: Ambient temperature sensor is low........................................... 476 Related circuit diagram.................................................................. 476 Fault Code A213: Parking brake should have applied; detected as not having applied........... 478 Related circuit diagram.................................................................. 479 Fault Code A214: Parking brake should have released; detected as not having released......... 480 Related circuit diagram.................................................................. 481 Fault Code A216: Open or short to ground in parking brake command valve circuit.............. 482 Related circuit diagram.................................................................. 483 Fault Code A223: Excessive engine cranking occurred or a jump start attempted................ 484 Related circuit diagram.................................................................. 485 Fault Code A230: Parking brake has been requested while truck still moving................... 486 Related circuit diagram.................................................................. 487 Fault Code A231: The body is up while traveling or intending to travel....................... 488 Related circuit diagram.................................................................. 489 Fault Code A233: Drive system CAN/RPC Control Link not connected............................. 490 Related circuit diagram.................................................................. 491 Fault Code A235: Steering accumulator is in the process of being bled down................... 492 Related circuit diagram.................................................................. 493 Fault Code A236: The steering accumulator has not properly bled after 90 seconds............. 494 Related circuit diagram.................................................................. 494 Fault Code A237: The CAN/RPC connection to the display is open............................... 495 Related circuit diagram.................................................................. 495 Fault Code A240: The key switch input to the interface module is open........................ 496 Related circuit diagram.................................................................. 496 Troubleshooting by fault code, Part 3............................................................ 499 Fault Code A242: Fuel gauge within the display panel is defective............................ 501 Related circuit diagram.................................................................. 501 Fault Code A243: Engine coolant temperature gauge within the display panel is defective...... 502 Related circuit diagram.................................................................. 502 Fault Code A244: Drive system temperature gauge within the display panel is defective........ 503 Related circuit diagram.................................................................. 503 Fault Code A245: Hydraulic oil temperature gauge within the display panel is defective....... 504 Related circuit diagram.................................................................. 504 Fault Code A246: Payload meter reports truck overload........................................ 505 Related circuit diagram.................................................................. 505 Fault Code A248: Status module within the display panel is defective......................... 506 Related circuit diagram.................................................................. 506 Fault Code A249: Red warning lamp within the display (driven by IM) is shorted............... 507 Related circuit diagram.................................................................. 507 Fault Code A250: Battery voltage is low with the truck parked................................ 508 Related circuit diagram.................................................................. 509 Fault Code A251: Sonalert used with display (driven by IM) is open or shorted to ground...... 510 Related circuit diagram.................................................................. 510 Fault Code A252: Start enable output circuit is open or shorted to ground.................... 511 Related circuit diagram.................................................................. 511 Fault Code A253: Steering bleed circuit is not open while running............................ 512 Related circuit diagram.................................................................. 512 Fault Code A255: IM has detected a fault on IM output 1N..................................... 513 Related circuit diagram.................................................................. 513 Fault Code A256: Red warning lamp in the display (driven by IM) is open...................... 514 Related circuit diagram.................................................................. 514 Fault Code A257: Payload CAN/RPC is not connected............................................ 515 Related circuit diagram.................................................................. 515 Fault Code A258: Steering accumulator bleed pressure switch circuit is defective............. 516 Related circuit diagram.................................................................. 516 Fault Code A260: Parking brake failure....................................................... 518 Related circuit diagram.................................................................. 519 Fault Code A261: Low brake accumulator pressure warnings..................................... 520 Related circuit diagram.................................................................. 521 Fault Code A262: Steering bleed valve circuit open during shutdown........................... 522 Related circuit diagram.................................................................. 523 Fault Code A264: Parking brake relay circuit is defective.................................... 524 Related circuit diagram.................................................................. 524 Fault Code A265: Service brake failure....................................................... 526 Related circuit diagram.................................................................. 527 Fault Code A266: Selector lever was not in park while attempting to crank engine............. 528 Related circuit diagram.................................................................. 528 Fault Code A267: Parking brake was not set while attempting to crank engine.................. 529 Related circuit diagram.................................................................. 529 Fault Code A268: Secondary engine shutdown while cranking.................................... 530 Related circuit diagram.................................................................. 530 Fault Code A270: Brake lock switch power supply is not on when required...................... 532 Related circuit diagram.................................................................. 533 Fault Code A271: Shifter not in gear......................................................... 534 Related circuit diagram.................................................................. 534 Fault Code A272: Brake lock switch power supply is not off when required..................... 536 Related circuit diagram.................................................................. 537 Fault Code A273: Fault detected in hoist or steering filter pressure switch circuit.......... 538 Related circuit diagram.................................................................. 538 Fault Code A274: A brake setting fault has been detected..................................... 540 Related circuit diagram.................................................................. 541 Fault Code A275: A starter has been detected as engaged without a cranking attempt........... 542 Related circuit diagram.................................................................. 542 Troubleshooting by fault code, Part 4............................................................ 545 Fault Code A277: Parking brake applied while loading......................................... 547 Related circuit diagram.................................................................. 547 Fault Code A278: Service brake applied while loading......................................... 548 Related circuit diagram.................................................................. 548 Fault Code A279: Low steering pressure switch is defective................................... 549 Related circuit diagram.................................................................. 549 Fault Code A280: Steering accumulator bleed down switch is defective......................... 550 Related circuit diagram.................................................................. 550 Fault Code A281: Brake lock degrade switch is defective...................................... 551 Related circuit diagram.................................................................. 551 Fault Code A282: Excessive cranking or jump starts without the engine running................ 552 Related circuit diagram.................................................................. 553 Fault Code A283: Engine shutdown delay aborted; parking brake not set........................ 554 Related circuit diagram.................................................................. 555 Fault Code A284: Engine shutdown delay aborted; secondary shutdown switch used............... 556 Related circuit diagram.................................................................. 556 Fault Code A285: The parking brake was not set when the key switch was turned off............ 557 Related circuit diagram.................................................................. 557 Fault Code A286: A fault was detected in the shutdown delay relay circuit.................... 558 Related circuit diagram.................................................................. 558 Fault Code A292: Shutdown delay relay stayed on after latched keyswitch circuit is off....... 559 Related circuit diagram.................................................................. 559 Fault Code A303: Shifter is defective........................................................ 560 Fault Code A304: Auto lube grease level fault................................................ 561 Related circuit diagram.................................................................. 561 Fault Code A305: Auto lube circuit is defective.............................................. 562 Related circuit diagram.................................................................. 562 Fault Code A307: Both GE Inverters disabled.................................................. 563 Fault Code A309: No brakes applied when expected............................................. 564 Related circuit diagram.................................................................. 565 Fault Code A311: Brake lock switch on when it shouldn’t be................................... 566 Related circuit diagram.................................................................. 566 Fault Code A312: The DCDC Converter 12 volt circuit sensing is producing low readings........ 567 Related circuit diagram.................................................................. 567 Fault Code A313: The DCDC converter 12 volt circuit sensing is producing high readings....... 568 Related circuit diagram.................................................................. 568 Fault Code A315: The DCDC converter 12 volt circuit is low................................... 569 Related circuit diagram.................................................................. 569 Fault Code A316: Starter engagement has been attempted with engine running................... 570 Related circuit diagram.................................................................. 571 Fault Code A318: Unexpected power loss to Interface Module................................... 572 Related circuit diagram.................................................................. 572 Fault Code A328: Drive system not powered up................................................. 573 Related circuit diagram.................................................................. 573 Fault Code A333: The hydraulic ladder controller has declared a ladder fault................. 574 Related circuit diagram.................................................................. 574 Fault Code A334: Selector switch not in park when propel was either not ready or at rest..... 575 Related circuit diagram.................................................................. 575 Fault Code A335: Manual/Auto Apply Pressure Fault............................................ 576 Troubleshooting by fault code, Part 5............................................................ 579 Fault Code A350: Overload on output 1B....................................................... 580 Related circuit diagram.................................................................. 580 Fault Code A351: Overload on output 1E....................................................... 581 Related circuit diagram.................................................................. 581 Fault Code A352: Overload on output 1H....................................................... 582 Related circuit diagram.................................................................. 582 Fault Code A353: Overload on output 1J....................................................... 583 Related circuit diagram.................................................................. 583 Fault Code A354: Overload on output 1K....................................................... 584 Related circuit diagram.................................................................. 584 Fault Code A355: Overload on output 1L....................................................... 585 Related circuit diagram.................................................................. 585 Fault Code A356: Overload on output 1M....................................................... 586 Related circuit diagram.................................................................. 586 Fault Code A357: Overload on output 1N....................................................... 587 Related circuit diagram.................................................................. 587 Fault Code A358: Overload on output 1P....................................................... 588 Related circuit diagram.................................................................. 588 Fault Code A359: Overload on output 1R....................................................... 589 Related circuit diagram.................................................................. 589 Fault Code A360: Overload on output 1S....................................................... 590 Related circuit diagram.................................................................. 590 Fault Code A361: Overload on output 1T....................................................... 591 Related circuit diagram.................................................................. 591 Fault Code A362: Overload on output 1U....................................................... 592 Related circuit diagram.................................................................. 592 Fault Code A363: Overload on output 1X....................................................... 593 Related circuit diagram.................................................................. 593 Fault Code A364: Overload on output 1Y....................................................... 594 Related circuit diagram.................................................................. 594 Fault Code A365: Overload on output 1Z....................................................... 595 Related circuit diagram.................................................................. 595 Cab air conditioning............................................................................. 597 Preliminary checks........................................................................... 599 Diagnosis of gauge readings and system performance........................................... 599 Troubleshooting by manifold gauge set readings............................................... 600 Steering system.................................................................................. 607 Steering circuit troubleshooting chart....................................................... 609 Steering circuit troubleshooting guidelines.................................................. 611 Basic hydraulic system checks................................................................ 612 System leakage check......................................................................... 613 Steering pump troubleshooting guide.......................................................... 615 Pump pressure control checks................................................................. 618 Pump fails to unload..................................................................... 619 Pump fails to develop pressure........................................................... 619 Pump slow in developing pressure......................................................... 620 Pump control valve inspection............................................................ 620 Pump case drain check.................................................................... 622 Setting pump pressure controls........................................................... 622 Steering pump adjustment................................................................. 623 KomVision........................................................................................ 625 KomVision fault codes........................................................................ 627 Automatic lubrication (auto lube) system......................................................... 637 Autolube troubleshooting chart............................................................... 639 50 Disassembly and assembly.......................................................................... 643 Service tools.................................................................................... 643 Special tool group........................................................................... 645 KomVision calibration tools.................................................................. 645 Additional service tools..................................................................... 646 Locally made tools........................................................................... 647 Wheels, spindles and rear axle................................................................... 651 General precautions for tires and rims....................................................... 653 Wheel stud maintenance....................................................................... 654 Rear outer wheel stud installation........................................................... 655 Removal and installation of front wheel...................................................... 656 Removal.................................................................................. 656 Installation............................................................................. 657 Removal and installation of rear wheel....................................................... 658 Removal.................................................................................. 658 Installation............................................................................. 659 Rim components............................................................................... 661 Rim and tire service......................................................................... 662 Lubricants............................................................................... 662 Tire inflation........................................................................... 662 Removal (5-piece standard rim)........................................................... 662 Preparation before assembly.............................................................. 666 Installation (5-piece standard rim)...................................................... 666 Removal and installation of front wheel hub and spindle...................................... 668 Removal.................................................................................. 668 Spindle removal (off the truck).......................................................... 674 Installation............................................................................. 676 Disassembly and assembly of front wheel hub and spindle...................................... 677 Cross Section View....................................................................... 677 Disassembly.............................................................................. 678 Cleaning and inspection.................................................................. 682 Assembly................................................................................. 683 Wheel bearing adjustment................................................................. 687 Speed sensor installation and adjustment................................................. 689 Hub floating ring seal assembly and installation............................................. 691 Removal and installation of rear axle........................................................ 696 Removal.................................................................................. 696 Cleaning and inspection.................................................................. 697 Installation............................................................................. 698 Removal and installation of anti-sway bar.................................................... 699 Removal.................................................................................. 699 Installation............................................................................. 701 Removal and installation of pivot pin........................................................ 702 Removal.................................................................................. 702 Installation............................................................................. 703 Pivot eye and bearing service................................................................ 704 Bearing replacement...................................................................... 704 Pivot eye repair......................................................................... 705 Removal and installation of wheel motor...................................................... 706 Preparation.............................................................................. 706 Removal.................................................................................. 706 Cleaning and inspection.................................................................. 709 Installation............................................................................. 709 Brake system..................................................................................... 715 Removal and installation of brake valve...................................................... 717 Removal.................................................................................. 717 Disassembly and assembly of brake valve/pedal assembly....................................... 720 Disassembly.............................................................................. 720 Assembly................................................................................. 721 Removal and installation of brake manifold................................................... 722 Removal.................................................................................. 722 Installation............................................................................. 723 Disassembly and assembly of brake manifold................................................... 724 Disassembly.............................................................................. 724 Assembly................................................................................. 724 Disassembly and assembly of brake accumulator................................................ 725 Cleaning and inspection.................................................................. 726 Assembly................................................................................. 727 Removal and installation of front brake caliper.............................................. 729 Removal.................................................................................. 729 Inspection............................................................................... 730 Installation............................................................................. 730 Disassembly and assembly of front brake caliper.............................................. 731 Disassembly.............................................................................. 731 Cleaning and inspection.................................................................. 731 Brake lining replacement................................................................. 734 Assembly................................................................................. 734 Removal and installation of rear brake caliper............................................... 734 Removal.................................................................................. 734 Inspection............................................................................... 737 Installation............................................................................. 738 Disassembly and assembly of rear brake caliper............................................... 741 Disassembly.............................................................................. 741 Piston subassembly....................................................................... 744 Cleaning and inspection.................................................................. 745 Assembly................................................................................. 746 Piston subassembly....................................................................... 746 Brake caliper............................................................................ 747 Steering system.................................................................................. 755 Removal and installation of steering control unit............................................ 757 Removal.................................................................................. 757 Installation............................................................................. 758 Disassembly and assembly of steering control unit............................................ 759 Disassembly.............................................................................. 759 Assembly................................................................................. 761 Removal and installation of steering column.................................................. 764 Removal.................................................................................. 764 Inspection............................................................................... 765 Installation............................................................................. 766 Removal and installation of steering wheel................................................... 767 Removal.................................................................................. 767 Installation............................................................................. 767 Removal and installation of bleeddown manifold............................................... 768 Removal.................................................................................. 768 Installation............................................................................. 771 Removal and installation of flow amplifier................................................... 771 Removal.................................................................................. 771 Installation............................................................................. 773 Removal and installation of steering cylinders and tie rod................................... 774 Removal.................................................................................. 774 Installation............................................................................. 776 Disassembly and assembly of steering cylinders............................................... 777 Disassembly.............................................................................. 777 Cleaning and inspection.................................................................. 779 Assembly................................................................................. 780 Removal and installation of steering/brake pump.............................................. 780 Removal.................................................................................. 780 Installation............................................................................. 783 Removal and installation of piston steering accumulator...................................... 784 Removal.................................................................................. 784 Installation............................................................................. 786 Disassembly and assembly of piston steering accumulators..................................... 787 Disassembly.............................................................................. 787 Cleaning and inspection.................................................................. 789 Piston seal replacement.................................................................. 790 Assembly................................................................................. 791 Suspensions...................................................................................... 793 Removal and installation of front suspension................................................. 795 Preparation.............................................................................. 795 Removal.................................................................................. 795 Cleaning and Inspection.................................................................. 797 Installation............................................................................. 798 Disassembly and assembly of front suspension................................................. 804 Disassembly.............................................................................. 804 Cleaning and inspection.................................................................. 806 Assembly................................................................................. 807 Removal and installation of rear suspension.................................................. 809 Removal.................................................................................. 809 Installation............................................................................. 812 Disassembly and assembly of rear suspension.................................................. 815 Disassembly.............................................................................. 815 Cleaning and inspection.................................................................. 817 Assembly................................................................................. 818 Hoist circuit.................................................................................... 821 Removal and installation of hoist pump....................................................... 823 Removal.................................................................................. 823 Installation............................................................................. 827 Disassembly and assembly of hoist pump....................................................... 828 Disassembly.............................................................................. 828 Inspection............................................................................... 833 Assembly................................................................................. 834 Removal and installation of hoist valve...................................................... 837 Removal.................................................................................. 837 Installation............................................................................. 839 Disassembly and assembly of hoist valve...................................................... 839 O-ring replacement....................................................................... 839 Disassembly of inlet section............................................................. 841 Assembly of inlet section................................................................ 842 Disassembly of spool section............................................................. 843 Assembly of spool section................................................................ 845 Overcenter manifold service.................................................................. 846 Removal and installation of hoist pilot valve................................................ 847 Removal.................................................................................. 847 Installation............................................................................. 847 Disassembly and assembly of hoist pilot valve................................................ 849 Disassembly.............................................................................. 849 Cleaning and inspection.................................................................. 850 Assembly................................................................................. 851 Removal and installation of hoist cylinders.................................................. 852 Removal.................................................................................. 852 Installation............................................................................. 855 Disassembly and assembly of hoist cylinders.................................................. 858 Disassembly.............................................................................. 858 Cleaning and inspection.................................................................. 862 Installation of the quill................................................................ 863 Assembly................................................................................. 865 Body and structures.............................................................................. 871 Removal and installation of dump body........................................................ 873 Removal.................................................................................. 873 Inspection............................................................................... 874 Installation............................................................................. 875 Removal and installation of body pads........................................................ 876 Removal.................................................................................. 876 Installation............................................................................. 876 Body pad shimming procedure.............................................................. 877 Removal and installation of diagonal ladder/ hood and grille assembly........................ 878 Removal.................................................................................. 878 Installation............................................................................. 878 Removal and installation of RH deck.......................................................... 880 Removal.................................................................................. 880 Installation............................................................................. 880 Removal and installation of LH deck.......................................................... 882 Removal.................................................................................. 882 Installation............................................................................. 882 Removal and installation of fuel tank........................................................ 884 Removal.................................................................................. 884 Cleaning and inspection.................................................................. 886 Installation............................................................................. 886 Removal and installation of fuel gauge sender................................................ 887 Removal.................................................................................. 887 Installation............................................................................. 887 Removal and installation of hydraulic tank................................................... 888 Removal.................................................................................. 888 Installation............................................................................. 890 Removal and installation of hydraulic tank strainers......................................... 890 Removal.................................................................................. 890 Cleaning and inspection.................................................................. 891 Installation............................................................................. 891 Operator cab..................................................................................... 893 Removal and installation of operator cab..................................................... 895 Removal.................................................................................. 895 Installation............................................................................. 898 Removal and installation of cab door......................................................... 899 Removal.................................................................................. 899 Installation............................................................................. 899 Disassembly and assembly of cab door......................................................... 900 Removing door panel...................................................................... 900 Installing door panel.................................................................... 901 Replacing the door window regulator...................................................... 901 Replacing door handle or latch assembly.................................................. 902 Replacing door assembly seal and door hinge seal......................................... 903 Replacing door opening seal.............................................................. 903 Removing door glass...................................................................... 904 Installing door glass.................................................................... 905 Adjustment of cab door....................................................................... 907 Door jamb bolt adjustment................................................................ 907 Door handle plunger adjustment........................................................... 908 Removal and installation of side window glass................................................ 909 Recommended tools and supplies........................................................... 909 Removal.................................................................................. 910 Installation............................................................................. 910 Removal and installation of windshield and rear window glass................................. 911 Removal.................................................................................. 911 Installation............................................................................. 911 Removal and installation of windshield wiper motor........................................... 912 Removal.................................................................................. 912 Installation............................................................................. 913 Removal and installation of windshield wiper arm............................................. 913 Removal.................................................................................. 913 Installation............................................................................. 913 Removal and installation of windshield wiper linkage......................................... 914 Removal.................................................................................. 914 Installation............................................................................. 914 Removal and installation of operator seat.................................................... 915 Inspection............................................................................... 915 Removal.................................................................................. 915 Installation............................................................................. 915 Replacing the seat compressor (standard seat)................................................ 916 Removal and installation of passenger seat (standard seat)................................... 921 Removal.................................................................................. 921 Installation............................................................................. 921 Removal and installation of seat belts (standard seat)....................................... 922 Removal.................................................................................. 922 Installation............................................................................. 923 Removal and installation of seat belts (optional seat)....................................... 924 General.................................................................................. 924 Removal.................................................................................. 924 Installation............................................................................. 926 Cab air conditioning............................................................................. 929 Replacement of air conditioning system components............................................ 931 Hoses and fittings....................................................................... 931 Lines.................................................................................... 931 Expansion valve.......................................................................... 931 Receiver-drier........................................................................... 931 Thermostat............................................................................... 931 Compressor............................................................................... 932 Accumulator.............................................................................. 932 Clutch................................................................................... 932 Power module..................................................................................... 935 Removal and installation of power module..................................................... 937 General.................................................................................. 937 Removal.................................................................................. 938 Installation............................................................................. 946 Exhaust tube installation.................................................................... 949 Exhaust blanket installation................................................................. 949 Removal and installation of alternator....................................................... 950 Removal.................................................................................. 950 Installation............................................................................. 953 Removal and installation of radiator......................................................... 961 Removal.................................................................................. 961 Installation............................................................................. 966 Repairing the radiator....................................................................... 967 Internal inspection...................................................................... 967 External cleaning........................................................................ 967 Disassembly.............................................................................. 968 Cleaning and inspection.................................................................. 969 Assembly................................................................................. 969 Pressure testing......................................................................... 970 Removal and installation of engine........................................................... 971 Removal.................................................................................. 971 Service.................................................................................. 972 Installation............................................................................. 972 90 Diagrams and drawings............................................................................. 975 Hydraulic circuit diagrams....................................................................... 975 Steering and hoist hydraulic circuit diagram - 58D-60-00521................................ 977 Brake hydraulic circuit diagram - XS7600................................................... 978 Auxiliary hydraulic circuit diagram - 58E-60-01680......................................... 979 Electrical circuit diagrams...................................................................... 982 Electrical circuit diagram - 58D-06-00445.................................................. 984 Connectors table and arrangement drawing - HE491...........................................1004
DESCRIPTION:
KOMATSU 730E-8 DUMP TRUCK SHOP MANUAL CEBM032406 – PDF DOWNLOAD
- This manual is written for use by the operator and/or the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all of its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel should read and understand the information in this manual before operating the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings, and cautions should be understood and followed when operating the truck or performing repairs on the truck.
- The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example, the disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed repairs.
- The illustrations used in this manual are typical of the component shown and may not be an exact reproduction of what is found on the truck.
- This manual shows dimensioning of U.S. standard and metric (SI) units throughout. All references to “right,” “left,” “front,” or “rear” are made with respect to the operator’s normal seated position unless specifically stated otherwise.
When assembly instructions are provided without references to specific torque values, standard torque values should be used. Standard torque values are shown in torque charts later in this section. Specific torques, when provided in the text, are in bold face type, such as 135 N·m (100 ft lb). All torque specifications have ±10% tolerance unless otherwise specified. - A product identification plate is located on the frame in front of the right side front wheel. It designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum GVW (Gross Vehicle Weight) rating
S.S 27/12/24
