Komatsu 730E-10 Dump Truck Shop Manual CEBM033405 – PDF DOWNLOAD

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Komatsu 730E-10 Dump Truck Shop Manual CEBM033405 – PDF DOWNLOAD

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TABLE OF CONTENTS:

Komatsu 730E-10 Dump Truck Shop Manual CEBM033405 – PDF DOWNLOAD

00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword, safety and general information 21
Foreword 24
How to read the shop manual 25
Composition of shop manual 25
Revision and distribution 25
Symbols 26
General safety 27
Safety rules 27
Safety features 27
Fire extinguisher and first aid kit 27
Clothing and personal items 27
Leaving the operator seat 28
Mounting and dismounting 28
Fire prevention for fuel and oil 28
Precautions with high temperature fluids 29
Asbestos dust hazard prevention 29
Prevention of injury by work equipment 29
Unauthorized modification 29
Precautions when using ROPS 29
Precautions for attachments 30
Precautions for starting the truck 30
Precautions before operating the truck 30
Safety at the worksite 30
Fire prevention 31
Ventilation in enclosed areas 31
Preparing for operation 31
Mirrors, windows and lights 31
In operator cab (before starting the engine) 31
Seat Belts 31
Precautions while operating the truck 32
When starting the engine 32
General truck operation 32
Ensuring good visibility 32
Traveling 33
Traveling in reverse 33
Traveling on slopes 33
Operating on snow or ice 33
Avoid damage to dump body 33
Driving near high voltage cables 34
When dumping 34
When loading 34
Working on loose ground 34
Parking the truck 34
Towing 34
Working near batteries 35
Battery hazard prevention 35
Starting with jumper cables 36
Jump starting with receptacles 36
Precautions before performing service 37
Warning tag 37
Stopping the engine 37
Proper tools 37
Use of Tie-Off Anchor During Maintenance and Repair 37
Securing the dump body 38
Jack point locations 39
Precautions while performing service 40
Keep the truck clean 40
Attachments 40
Working under the truck 40
Rotating fan and belts 40
Adding fuel or oil 40
Use of lighting 40
Radiator coolant level 41
Precautions with the battery 41
Precautions with high pressure oil 41
Handling high pressure hoses 41
Precautions when performing maintenance near high temperature or high pressure 41
Waste materials 41
Tires 42
Inspection 42
Maintenance 42
Storage 43
Handling 44
Precautions for performing repairs 45
Engine shutdown procedure after AC drive system failure 45
Precautions for welding on the truck 46
Control cabinet capacitor discharge system 47
Handling electrical equipment and hydraulic components 49
Points to remember when handling electrical equipment 49
Points to remember when handling hydraulic equipment 55
Actions taken to meet exhaust gas regulations 57
About DEF 57
Precautions for diesel exhaust fluid (DEF) 58
About DEF 58
Precautions for handling DEF 58
Precautions for storing DEF 58
Precautions for disposing of DEF 59
Crystallization management 59
Precautions for cold weather operation 59
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
Wheel motor oil 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 88
Steering accumulator bleeddown solenoid 88
Quick disconnect ports 88
Flow amplifier 88
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 103
Hoist circuit components 103
Hydraulic tank 103
Hoist pump 103
High pressure filters 103
Hoist valve 105
Overcenter manifold 106
Hoist pilot valve 107
Hoist limit solenoid 107
Pilot operated check valve 107
Hoist pilot valve operation 108
Float position with body coming down 108
Power up operation 110
Hold operation 112
Power down operation 114
Float operation 116
Brake circuits 119
General information 121
Service brake circuit operation 121
Secondary braking and auto apply 123
Parking brake circuit operation 123
Normal operation (key switch ON, engine on) 123
Wheel brake lock circuit operation 124
Brake warning circuit operation 124
Electrical system, 24 volt 127
Battery supply system 129
Batteries 129
24VDC auxiliary battery receptacles 129
Isolation box 130
Ground level shutdown switch 130
Battery disconnect switches 130
Propel lockout lever 130
System busy light 130
LED lights 130
Engine starting system with prelube 131
Prelube operation 131
Auxiliary control cabinet components 132
VEC blocks 133
24VDC to 12VDC converter 133
Circuit breakers 133
Engine service light timer 133
Ground terminals 133
24VDC power terminals 133
Relays 134
Body-up switch 135
Hoist limit switch 136
Heating/air conditioning (HVAC) system 139
Basic air conditioning system operation 141
HVAC components 143
Control panel 143
Water valve 143
Expansion valve 143
Actuators 143
Blower 143
Heater core 143
Evaporator core 143
Cab air temperature sensor 143
ECU module 143
Air filters 145
Compressor (refrigerant pump) 145
Compressor clutch 145
Trinary™ switch 146
Receiver-drier 146
Condenser 146
Accumulator 146
Automatic lubrication (auto lube) system 149
General information 151
System operation 152
Engine emissions aftertreatment system 155
About emissions aftertreatment 158
DEF injection system 158
DEF heating system 158
Sensors 158
Exhaust system cleaning 159
Propel lockout precaution 159
Inducement strategy 159
20 Standard value table 161
Standard value table 161
Standard value table for truck 163
30 Testing and adjusting 169
Steering, hoist and auxiliary hydraulic systems 169
Hydraulic system bleeddown procedure 171
General information on system checkout 173
Hydraulic system checkout procedures 173
Required equipment 173
Preliminary steps 174
Hydraulic system flushing procedure 174
Flow amplifier adjustment 177
Steering pump unloader valve adjustment 178
Auxiliary accumulator pressure verification 179
System diagnostics 180
Hoist pilot valve adjustment 182
Hoist counterbalance valve adjustment 183
Final steps 184
Oil cleanliness check 184
Hydraulic system checkout data sheet 185
Toe-in adjustment 189
Hoist cylinder leakage test 190
Steering cylinder leakage test 190
Brake system 193
Brake circuit checkout procedure 194
General information 194
Required equipment 194
Preliminary steps 194
Initial startup and service brake checkout 196
Brake lock system checkout 197
Parking brake checkout 197
Low brake pressure and auto apply 198
Parking brake control logic checkout 200
Brake lock control logic checkout 201
Brake system checkout data sheet 204
Service brake conditioning (burnishing) 215
Front brake conditioning 216
Rear brake conditioning 217
Brake bleeding procedure 218
Service brake 218
Parking brake (rear brake calipers only) 218
Piston assembly return spring force and built-in clearance (BIC) 220
Piston assembly adjuster grip force 221
Adjuster force 223
Piston return spring 224
Brake valve bench test and adjustment 226
Test setup procedure 227
Brake valve output pressure adjustment 227
Final test and adjustment 228
Installing brake pedal actuator to brake valve 230
Installing retard pedal to brake pedal 230
Accumulators and suspensions 233
Accumulator charging and storage 235
Temperature during precharge 235
Bladder accumulator charging procedure 236
Precharge maintenance 238
Bladder accumulator storage procedure 238
Bladder storage 238
Installing a bladder accumulator from storage 239
Bladder accumulator leak testing 239
Piston accumulator charging procedure 240
Piston accumulator storage 243
Piston accumulator leak testing 244
Checking for improper suspension charge 245
Suspension oiling and charging procedures 246
Required equipment 246
Installing the charging kit 247
Removing the charging kit 247
Support blocks for oiling and charging dimensions 248
Front suspensions 249
Rear suspensions 252
Suspension pressure test 255
Electrical systems 257
General information on system checkout 259
Truck shutdown procedure 260
Required software and tools 260
Electrical system checkout procedures 262
Visual inspection 262
Resistance checks 262
Voltage checks 262
Truck function checks 263
Interface module (IM) checks 264
KOMTRAX Plus II checks 264
Payload meter (PLM) checks 264
Drive system checks 265
Engine delayed shutdown Smart Timer check 265
Body hoist limit switch check 265
Electrical checkout sheet 266
Interface module 1 (IM1) 271
Required software and tools 273
Interface module checkout procedures 274
Initial startup 274
Checking digital inputs to the IM 274
Checking analog inputs to the IM 276
Checking serial communication to the IM 276
Checking outputs from the IM 276
IM checkout sheet 277
Interface module 2 (IM2) 281
Required tools 283
Programming the IM2 283
Updating the software 283
Configuring the IM2 284
Veiwing IM2 real-time data 284
Interface module checkout procedures 285
Checking for IM fault codes 285
Checking digital inputs to the IM 285
Checking analog inputs to the IM 288
Checking serial communication to the IM 288
Checking outputs from the IM 289
IM checkout sheet 291
Payload meter IV 297
Payload meter IV software and tools 299
Payload meter IV system configuration 299
Connecting to the payload meter IV web server 299
Configuring a static IP address 299
Payload meter IV software installation 301
Payload meter IV checkout procedure 302
PLM IV system checkout data sheet 308
Downloading PLM IV data and possible errors 309
KOMTRAX Plus II 313
Required software and tools 315
Ethernet connection to KOMTRAX Plus II controller 315
KOMTRAX Plus II configuration 317
GPS connection test 319
Iridium satellite system opening 321
Data download over ethernet connection for KOMTRAX Plus II initialization 324
Komatsu wireless bridge (KWB) 327
General information 329
Required software and tools 329
Download tools, firmware and scripts 329
Configure Mikrotik radio 330
Verify KWB_Connect bridge configuration 332
Verify KWB_Connect access point configuration 332
Verify 0002KPLUS access point configuration 332
Verify 0002KPLUS bridge configuration 332
Cab air conditioning 335
General information 337
Service tools and equipment 338
Recovery/recycle station 338
Leak detector 338
Manifold gauge set 339
Service valves 340
Vacuum pump 340
Detecting leaks 341
System performance test 342
Checking system oil 343
System flushing 344
Installing the manifold gauge set 345
Purging air from the service hoses 345
Recovering and recycling refrigerant 346
Draining oil from previous recovery cycle 347
Recovery cycle 347
Recycling procedure 347
Evacuating the air conditioning system 348
Charging the air conditioning system 349
Automatic lubrication (auto lube) system 351
Priming the system 353
Checkout procedure 355
Adjusting the lubrication cycle timing 355
KomVision 357
Requirements 359
Initial setup 359
Checkout data sheet 366
Calibration sheets 371
Layout and assemblage 371
Unfolding a calibration sheet 374
Folding a calibration sheet 375
Placement of calibration sheets 376
Camera calibration procedures 378
Automatic 6 camera calibration 378
Manual 6 camera calibration 382
1 camera calibration 385
Radar setting procedure 388
Tire monitoring system 393
Tire monitoring system software and tools 395
Tire monitoring system configuration 395
Connecting to the tire monitoring system web server 395
Configuring a static IP address 395
Tire monitoring system software installation 397
Tire monitoring system checkout procedure 398
Field Troubleshooting 398
Ethernet troubleshooting 399
Tire monitoring system configuration 399
CAN RPC Troubleshooting 399
Resetting the tire monitoring system 399
Tire monitoring system checkout data sheet 400
40 Troubleshooting 403
Fuse, diode and relay locations 403
Vehicle Electrical Center (VEC-89) 404
Vehicle Electrical Center (VEC-90) 406
Vehicle Electrical Center (VEC-91) 408
Vehicle Electrical Center (VEC-92) 410
Rear Terminal Mini-fuse and Relay (RTMR3) 411
Rear Terminal Mini-fuse and Relay (RTMR4) 412
Circuit breakers 412
Troubleshooting by fault code, Part 1 415
Fault Code A001 417
Fault Code A002 418
Fault Code A003 419
Fault Code A004 420
Fault Code A005 421
Fault Code A006 422
Fault Code A007 423
Fault Code A008 424
Fault Code A011 425
Fault Code A013 426
Fault Code A014 427
Fault Code A016 428
Fault Code A017 429
Fault Code A018 430
Fault Code A019 431
Fault Code A022 432
Fault Code A101 433
Fault Code A103 434
Fault Code A104 435
Fault Code A105 436
Fault Code A109 437
Fault Code A111 438
Fault Code A115 439
Fault Code A117 440
Fault Code A118 441
Fault Code A123 442
Fault Code A124 443
Fault Code A125 444
Fault Code A126 445
Fault Code A127 446
Fault Code A128 447
Fault Code A139 448
Troubleshooting by fault code, Part 2 451
Fault Code A145 453
Fault Code A146 454
Fault Code A152 455
Fault Code A153 456
Fault Code A154 457
Fault Code A155 458
Fault Code A158 459
Fault Code A166 460
Fault Code A167 461
Fault Code A168 462
Fault Code A169 463
Fault Code A170 464
Fault Code A171 465
Fault Code A172 466
Fault Code A173 467
Fault Code A184 468
Fault Code A190 469
Fault Code A193 470
Fault Code A194 471
Fault Code A195 472
Fault Code A196 473
Fault Code A197 474
Fault Code A198 475
Fault Code A199 476
Fault Code A200 477
Fault Code A201 478
Fault Code A202 479
Fault Code A203 480
Fault Code A204 481
Fault Code A205 482
Fault Code A206 483
Fault Code A207 484
Fault Code A213 485
Fault Code A214 486
Fault Code A215 487
Fault Code A216 488
Fault Code A223 489
Fault Code A230 490
Fault Code A231 491
Fault Code A233 492
Fault Code A235 493
Fault Code A236 494
Fault Code A237 495
Fault Code A240 496
Fault Code A242 497
Fault Code A243 498
Fault Code A244 499
Fault Code A245 500
Fault Code A246 501
Troubleshooting by fault code, Part 3 503
Fault Code A247 505
Fault Code A248 506
Fault Code A249 507
Fault Code A250 508
Fault Code A251 509
Fault Code A252 510
Fault Code A253 511
Fault Code A256 512
Fault Code A257 513
Fault Code A258 514
Fault Code A260 515
Fault Code A261 516
Fault Code A262 517
Fault Code A264 518
Fault Code A265 519
Fault Code A266 520
Fault Code A267 521
Fault Code A268 522
Fault Code A270 523
Fault Code A272 524
Fault Code A273 525
Fault Code A274 526
Fault Code A275 527
Fault Code A277 528
Fault Code A278 529
Fault Code A279 530
Fault Code A280 531
Fault Code A281 532
Fault Code A282 533
Fault Code A283 534
Fault Code A284 535
Fault Code A285 536
Fault Code A286 537
Fault Code A292 538
Troubleshooting by fault code, Part 4 541
Fault Code A303 544
Fault Code A304 545
Fault Code A305 546
Fault Code A307 547
Fault Code A309 548
Fault Code A310 549
Fault Code A311 550
Fault Code A312 551
Fault Code A313 552
Fault Code A315 553
Fault Code A316 554
Fault Code A317 555
Fault Code A318 556
Fault Code A328 557
Fault Code A332 558
Fault Code A333 559
Fault Code A334 560
Fault Code A335 561
Fault Code A337 562
Fault Code A338 563
Fault Code A339 564
Fault Code A340 565
Fault Code A341 566
Fault Code A342 567
Fault Code A343 568
Fault Code A344 569
Fault Code A345 570
Fault Code A346 571
Fault Code A347 572
Fault Code A348 573
Fault Code A349 574
Fault Code A350 575
Fault Code A351 576
Fault Code A352 577
Fault Code A353 578
Fault Code A354 579
Fault Code A355 580
Fault Code A356 581
Fault Code A357 582
Fault Code A358 583
Fault Code A359 584
Fault Code A360 585
Fault Code A361 586
Fault Code A362 587
Fault Code A363 588
Fault Code A364 589
Fault Code A365 590
Fault Code A366 591
Troubleshooting by fault code, Part 5 593
Fault Code A400 596
Fault Code A401 597
Fault Code A402 598
Fault Code A403 599
Fault Code A404 600
Fault Code A405 601
Fault Code A406 602
Fault Code A407 603
Fault Code A408 604
Fault Code A409 605
Fault Code A410 606
Fault Code A411 607
Fault Code A412 608
Fault Code A413 609
Fault Code A414 610
Fault Code A415 611
Fault Code A416 612
Fault Code A417 613
Fault Code A418 614
Fault Code A419 615
Fault Code A420 616
Fault Code A421 617
Fault Code A422 618
Fault Code A423 619
Fault Code A424 620
Fault Code A425 621
Fault Code A426 622
Fault Code A427 623
Fault Code A428 624
Fault Code A429 625
Fault Code A430 626
Fault Code A431 627
Fault Code A432 628
Fault Code A433 629
Fault Code A434 630
Fault Code A435 631
Fault Code A436 632
Fault Code A437 633
Fault Code A438 634
Fault Code A439 635
Fault Code A440 636
Fault Code A441 637
Fault Code A442 638
Fault Code A443 639
Fault Code A444 640
Fault Code A445 641
Fault Code A446 642
Fault Code A447 643
Aftertreatment system fault codes 645
Fault Code CA256 649
Fault Code CA1677 651
Fault Code CA1678 653
Fault Code CA1682 656
Fault Code CA1683 663
Fault Code CA1684 665
Fault Code CA1685 667
Fault Code CA1686 669
Fault Code CA1712 671
Fault Code CA1713 673
Fault Code CA1714 675
Fault Code CA1715 676
Fault Code CA1887 678
Fault Code CA2771 679
Fault Code CA3142 683
Fault Code CA3143 685
Fault Code CA3146 687
Fault Code CA3147 689
Fault Code CA3232 691
Fault Code CA3497 694
Fault Code CA3498 695
Fault Code CA3547 696
Fault Code CA3558 697
Fault Code CA3559 699
Fault Code CA3562 701
Fault Code CA3563 703
Fault Code CA3567 705
Fault Code CA3571 707
Fault Code CA3572 709
Fault Code CA3573 712
Fault Code CA3574 714
Fault Code CA3575 716
Fault Code CA3712 718
Fault Code CA3713 719
Fault Code CA3714 722
Fault Code CA3867 723
Fault Code CA3868 725
Fault Code CA3878 728
Fault Code CA3988 729
Fault Code CA3995 733
Fault Code CA4113 735
Fault Code CA4114 737
Fault Code CA4119 739
Fault Code CA4121 741
Fault Code CA4152 743
Fault Code CA4164 747
Fault Code CA4165 749
Fault Code CA4166 752
Fault Code CA4168 754
Fault Code CA4169 756
Fault Code CA4174 758
Fault Code CA4175 760
Fault Code CA4233 763
Fault Code CA4234 764
Fault Code CA4243 765
Fault Code CA4277 766
Fault Code CA4457 768
Fault Code CA4458 770
Fault Code CA4459 773
Fault Code CA4461 775
Fault Code CA4462 777
Fault Code CA4464 779
Fault Code CA4465 781
Fault Code CA4466 784
Fault Code CA4467 791
Fault Code CA4474 793
Fault Code CA4475 795
Fault Code CA4572 798
Fault Code CA4677 802
Fault Code CA4679 806
Fault Code CA4682 807
Fault Code CA4731 808
Fault Code CA4732 809
Fault Code CA4736 810
Fault Code CA4737 811
Fault Code CA4738 812
Fault Code CA4739 813
Fault Code CA4745 814
Fault Code CA4768 815
Fault Code CA4769 817
Fault Code CA4842 819
Fault Code CA4863 820
Fault Code CA4947 821
Fault Code CA5115 822
Fault Code CA5116 825
Fault Code CA5117 828
Fault Code CA5247 831
Fault Code CA5653 833
Fault Code CA5654 836
Fault Code CA5725 838
Fault Code CA5727 843
Fault Code CA5728 846
Fault Code CA5729 849
Fault Code CA5748 851
Fault Code CA5749 853
Fault Code CA5751 855
Fault Code CA5753 857
Fault Code CA5755 860
Fault Code CA5756 865
Fault Code CA5758 867
Fault Code CA5768 869
Fault Code CA5769 871
Fault Code CA5771 874
Fault Code CA5772 876
Fault Code CA5773 879
Fault Code CA5774 882
Fault Code CA5775 884
Fault Code CA5776 889
Fault Code CA5778 891
Fault Code CA5779 893
Fault Code CA5887 895
Fault Code CA5888 896
Fault Code CA5889 897
Fault Code CA5891 898
Fault Code CA5892 899
Fault Code CA5893 900
Fault Code CA6692 901
Fault Code CA6693 903
Fault Code CA6694 905
Fault Code CA6695 907
Fault Code CA6696 909
Fault Code CA6697 911
Fault Code CA6855 913
Fault Code CA6856 916
Steering system 919
Steering circuit troubleshooting chart 920
Steering circuit troubleshooting guidelines 922
Basic hydraulic system checks 923
System leakage check 924
Steering pump troubleshooting guide 926
Pump pressure control checks 929
Pump fails to unload 930
Pump fails to develop pressure 930
Pump slow in developing pressure 931
Pump control valve inspection and trouble shooting 931
Pump case drain check 933
Setting pump pressure controls 933
KomVision 937
KomVision fault codes 939
Automatic lubrication (auto lube) system 949
Autolube troubleshooting chart 951
Heating/air conditioning (HVAC) system 955
Control panel configurations 957
Diagnostics mode 958
Error codes 958
Advanced diagnostics 958
Firmware version 959
Additional HVAC troubleshooting chart 959
Voltage levels 961
50 Disassembly and assembly 963
Service tools 963
Special tool group 965
Additional service tools 966
KomVision calibration tools 966
Locally made tools 967
Wheels, spindles and rear axle 971
General precautions for tires and rims 972
Rim components 973
Wheel stud maintenance 974
Wheel stud installation height 975
Required materials 975
Installation of wheel studs 975
Removal and installation of front wheel 976
Removal 976
Installation 977
Removal and installation of rear wheel 978
Removal 978
Installation 979
Rim and tire service 981
Lubricants 981
Tire inflation 981
Removal (5-piece standard rim) 981
Preparation before assembly 985
Installation (5-piece standard rim) 985
Removal and installation of front wheel hub and spindle 987
Removal 987
Spindle removal (off the truck) 992
Installation 994
Disassembly and assembly of front wheel hub and spindle 995
Cross Section View 995
Disassembly 996
Cleaning and inspection 1000
Assembly 1001
Wheel bearing adjustment 1005
Speed sensor installation and adjustment 1007
Hub floating ring seal assembly and installation 1008
Floating seal test procedure 1015
Removal and installation of rear axle 1016
Removal 1016
Cleaning and inspection 1017
Installation 1018
Removal and installation of anti-sway bar 1018
Removal 1018
Installation 1021
Removal and installation of pivot pin 1022
Removal 1022
Installation 1023
Pivot eye and bearing service 1024
Bearing replacement 1024
Pivot eye repair 1025
Removal and installation of wheel motor 1026
Preparation 1026
Removal 1026
Cleaning and inspection 1029
Installation 1029
Brake system 1035
Removal and installation of brake valve 1037
Removal 1037
Disassembly and assembly of brake valve/pedal assembly 1040
Disassembly 1040
Assembly 1041
Removal and installation of brake manifold 1043
Removal 1043
Installation 1044
Disassembly and assembly of brake manifold 1045
Disassembly 1045
Assembly 1045
Installation of pressure reducing valve 1046
Disassembly and assembly of brake accumulator 1047
Cleaning and inspection 1048
Assembly 1049
Removal and installation of front brake caliper 1051
Removal 1051
Inspection 1052
Installation 1052
Disassembly and assembly of front brake caliper 1053
Disassembly 1053
Cleaning and inspection 1053
Brake lining replacement 1056
Assembly 1056
Removal and installation of rear brake caliper 1056
Removal 1056
Inspection 1059
Installation 1059
Disassembly and assembly of rear brake caliper 1062
Disassembly 1062
Piston subassembly 1065
Cleaning and inspection 1066
Assembly 1068
Piston subassembly 1068
Brake caliper 1069
Steering system 1077
Removal and installation of steering control unit 1079
Removal 1079
Installation 1080
Disassembly and assembly of steering control unit 1081
Disassembly 1081
Assembly 1083
Removal and installation of steering column 1086
Removal 1086
Installation 1087
Removal and installation of steering wheel 1088
Removal 1088
Installation 1088
Removal and installation of bleeddown manifold 1089
Removal 1089
Installation 1090
Removal and installation of flow amplifier 1091
Removal 1091
Installation 1091
Removal and installation of steering cylinders and tie rod 1092
Removal 1092
Installation 1092
Disassembly and assembly of steering cylinders 1094
Disassembly 1094
Cleaning and inspection 1096
Assembly 1097
Removal and installation of steering/brake pump 1097
Removal 1097
Installation 1099
Removal and installation of piston steering accumulator 1099
Removal 1099
Installation 1101
Disassembly and assembly of piston steering accumulator 1102
Disassembly 1102
Cleaning and inspection 1104
Piston seal replacement 1104
Assembly 1105
Suspensions 1107
Removal and installation of front suspension 1109
General information 1109
Removal 1109
Installation 1111
Upper mounting joint – 60° advance 1115
Lower mounting joint – 90° advance 1116
Inspection 1116
Disassembly and assembly of front suspension 1117
Disassembly 1117
Cleaning and inspection 1119
Assembly 1120
Removal and installation of rear suspension 1122
General information 1122
Removal 1122
Installation 1125
Disassembly and assembly of rear suspension 1126
Disassembly 1126
Cleaning and inspection 1128
Assembly 1129
Hoist circuit 1131
Removal and installation of hoist pump 1133
Removal 1133
Installation 1137
Disassembly and assembly of hoist pump 1138
Disassembly 1138
Inspection 1143
Assembly 1144
Removal and installation of hoist valve 1147
Removal 1147
Installation 1149
Disassembly and assembly of hoist valve 1149
O-ring replacement 1149
Disassembly of inlet section 1151
Assembly of inlet section 1152
Disassembly of spool section 1153
Assembly of spool section 1155
Overcenter manifold service 1156
Removal and installation of hoist pilot valve 1157
Removal 1157
Installation 1157
Disassembly and assembly of hoist pilot valve 1159
Disassembly 1159
Cleaning and inspection 1160
Assembly 1160
Removal and installation of hoist cylinders 1161
Removal 1161
Installation 1163
Disassembly and assembly of hoist cylinders 1164
Disassembly 1164
Cleaning and inspection 1168
Installation of the quill 1169
Assembly 1171
Body and structures 1177
Removal and installation of dump body 1179
Removal 1179
Inspection 1180
Installation 1181
Removal and installation of body pads 1182
Removal 1182
Installation 1182
Body pad shimming procedure 1183
Removal and installation of diagonal ladder/ hood and grille assembly 1184
Removal 1184
Installation 1184
Removal and installation of RH deck 1186
Removal 1186
Installation 1186
Removal and installation of LH deck 1188
Removal 1188
Installation 1188
Removal and installation of fuel tank 1190
Removal 1190
Cleaning and inspection 1192
Installation 1192
Removal and installation of fuel gauge sender 1193
Removal 1193
Installation 1193
Removal and installation of hydraulic tank 1194
Removal 1194
Installation 1196
Removal and installation of hydraulic tank strainers 1196
Removal 1196
Cleaning and inspection 1197
Installation 1197
Operator cab 1199
Removal and installation of operator cab 1201
Removal 1201
Installation 1204
Removal and installation of cab door 1204
Removal 1204
Installation 1205
Disassembly and assembly of cab door 1206
Removing the window regulator 1206
Installing the window regulator 1207
Removing the door glass 1208
Installing the door glass 1209
Replacing the inner door seal 1211
Replacing the outer door seal 1211
Removing the interior door handle and door latch 1212
Installing the interior door handle and door latch 1214
Adjustment of cab door 1215
Door jamb bolt adjustment 1215
Exterior door handle release button adjustment 1217
Removal and installation of side window glass 1218
Recommended tools and supplies 1218
Removal 1218
Installation 1219
Removal and installation of windshield and rear window glass 1220
Removal 1220
Installation 1220
Removal and installation of windshield wiper components 1221
Removing the windshield wiper motor 1221
Installing the windshield wiper motor 1221
Removing the windshield wiper arm and linkage 1222
Installing the windshield wiper arm and linkage 1223
Removal and installation of cab seats 1223
Removal 1223
Servicing the seat 1224
Installation 1224
Removal and installation of seat belts 1225
Removal 1225
Installation 1226
Power module 1229
Removal and installation of power module 1231
General 1231
Removal 1232
Installation 1240
Exhaust tube installation 1244
Exhaust blanket installation 1244
Removal and installation of alternator 1245
Removal 1245
Installation 1248
Removal and installation of radiator 1256
Removal 1256
Installation 1261
Repairing the radiator 1262
Internal inspection 1262
External cleaning 1262
Disassembly 1263
Cleaning and inspection 1264
Assembly 1264
Pressure testing 1265
Removal and installation of engine 1266
Removal 1266
Service 1267
Installation 1267
90 Diagrams and drawings 1269
Hydraulic circuit diagrams 1269
Electrical circuit diagrams 1276

Need help? Contact: [email protected]

DESCRIPTION:

Komatsu 730E-10 Dump Truck Shop Manual CEBM033405 – PDF DOWNLOAD

SERIAL NUMBERS 730E-10 A50002 – A50021
ENGINE 16V159

Composition of shop manual:

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
: New module (to be filed additionally) : Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tab No. with No. indicated next
to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accordingly.

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

S.V