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KOMATSU 730E-8 DUMP TRUCK SHOP MANUAL CEBM032601 – PDF DOWNLOAD
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Description
KOMATSU 730E-8 DUMP TRUCK SHOP MANUAL CEBM032601 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU 730E-8 DUMP TRUCK SHOP MANUAL CEBM032601 – PDF DOWNLOAD
Language : English
Pages : 942
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU 730E-8 DUMP TRUCK SHOP MANUAL CEBM032601 – PDF DOWNLOAD
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...................................... 33 Securing the dump body................................................................... 34 Jack point locations..................................................................... 35 Precautions while performing service......................................................... 36 Keep the truck clean..................................................................... 36 Attachments.............................................................................. 36 Working under the truck.................................................................. 36 Rotating fan and belts................................................................... 36 Adding fuel or oil....................................................................... 36 Use of lighting.......................................................................... 36 Radiator coolant level................................................................... 37 Precautions with the battery............................................................. 37 Precautions with high pressure oil....................................................... 37 Handling high pressure hoses............................................................. 37 Precautions when performing maintenance near high temperature or high pressure........... 37 Waste materials.......................................................................... 37 Tires........................................................................................ 38 Inspection............................................................................... 38 Maintenance.............................................................................. 38 Storage.................................................................................. 39 Handling................................................................................. 40 Precautions for performing repairs........................................................... 41 Engine shutdown procedure after AC drive system failure.................................. 41 Precautions for welding on the truck......................................................... 42 Capacitor discharge system................................................................... 43 Necessary tools.......................................................................... 43 Warnings and cautions.................................................................... 44 Manual DC link capacitor discharge procedure............................................. 45 Failure of the discharge system.......................................................... 47 Manual discharge of capacitors........................................................... 48 Short isolated capacitor terminals....................................................... 50 Handling electrical equipment and hydraulic components....................................... 51 Points to remember when handling electrical equipment.................................... 51 Points to remember when handling hydraulic equipment..................................... 57 Standard tightening torques.................................................................. 59 Effect of special lubricants on fasteners and standard torque values..................... 59 Suggested sources for rust preventive grease............................................. 59 SAE grade 5 and grade 8 hex head capscrew and nut assemblies............................. 60 SAE grade 9 capscrews.................................................................... 61 Class 10.9 capscrews and class 10 nuts................................................... 61 Standard tightening torques for fittings................................................. 62 Standard tightening torques for clamps................................................... 64 Conversion tables............................................................................ 65 Common conversion multipliers............................................................ 65 01 Specification..................................................................................... 69 Specification and technical data................................................................. 69 Specification drawing........................................................................ 71 Specifications............................................................................... 72 Weight table................................................................................. 74 Fuel, coolant and lubricants................................................................. 75 Suspension cylinder oil and nitrogen specifications...................................... 76 10 Structure and functions........................................................................... 79 Steering circuit................................................................................. 79 Steering circuit operation................................................................... 81 Steering circuit components.................................................................. 83 Steering control unit.................................................................... 83 High pressure filter..................................................................... 83 Steering accumulators.................................................................... 83 Bleeddown manifold....................................................................... 84 Steering accumulator bleeddown solenoid.................................................. 84 Quick disconnect ports................................................................... 84 Flow amplifier........................................................................... 84 Steering/brake pump operation................................................................ 87 High altitude operation.................................................................. 87 Neutral position......................................................................... 88 Full pump volume......................................................................... 89 Half pump volume......................................................................... 89 Flow amplifier operation..................................................................... 90 No steer................................................................................. 90 Steering left............................................................................ 92 Steering right........................................................................... 94 No steer, external shock load............................................................ 96 Hoist circuit.................................................................................... 99 Hoist circuit operation......................................................................100 Hoist circuit components.....................................................................101 Hydraulic tank...........................................................................101 Hoist pump...............................................................................101 High pressure filters....................................................................101 Hoist valve..............................................................................101 Hoist pilot valve........................................................................102 Hoist up limit solenoid..................................................................103 Hoist pilot manifold.....................................................................103 Counterbalance manifold..................................................................103 Hoist pilot valve operation..................................................................104 Float position with body coming down.....................................................104 Power up operation.......................................................................106 Hold operation...........................................................................108 Power down operation.....................................................................110 Float operation..........................................................................112 Brake circuits...................................................................................115 General information..........................................................................117 Service brake circuit operation..............................................................117 Secondary braking and auto apply.............................................................119 Parking brake circuit operation..............................................................119 Normal operation (key switch ON, engine running).........................................119 Wheel brake lock circuit operation...........................................................120 Brake warning circuit operation..............................................................120 Electrical system, 24 volt.......................................................................123 Battery supply system........................................................................125 24VDC battery charging alternator........................................................125 Battery box..............................................................................125 Engine start relays......................................................................125 24VDC auxiliary battery receptacles......................................................125 Isolation box................................................................................125 Engine shutdown switch...................................................................126 Access ladder light switch...............................................................126 Battery disconnect switches..............................................................126 Propel lockout lever.....................................................................126 LED lights...............................................................................126 Auxiliary control cabinet components.........................................................127 24VDC to 12VDC converter.................................................................127 Circuit breaker..........................................................................127 Power distribution terminals.............................................................127 Relays...................................................................................127 Fuses....................................................................................127 Relay boards.................................................................................128 Relay functions..........................................................................129 Electric cranking motor system (with prelube)................................................130 Operation................................................................................130 Body-up switch...............................................................................131 Hoist limit switch...........................................................................132 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............................................................................142 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..........................................................................158 Environmental impact of air conditioning.................................................158 Air conditioning for off-highway vehicles................................................158 Principles of refrigeration..................................................................159 Air conditioning.........................................................................159 Refrigeration - the act of cooling.......................................................159 The refrigeration cycle..................................................................159 Air conditioning system components...........................................................161 Relays...................................................................................161 Fan motor and speed control..............................................................161 Cab air filter...........................................................................161 Heater core..............................................................................161 Actuators................................................................................161 Compressor (refrigerant pump)............................................................163 Service valves...........................................................................163 Condenser................................................................................163 Receiver-drier...........................................................................163 Expansion valve..........................................................................164 Accumulator..............................................................................164 Evaporator core..........................................................................164 Air conditioning system electrical circuit...................................................165 Thermostat...............................................................................165 Compressor clutch........................................................................165 Trinary™ switch..........................................................................166 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) procedure............................................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 Valve bench test and adjustment..............................................................226 Test set up procedure....................................................................227 Brake valve output pressure adjustment...................................................227 Differential pressure switch test........................................................228 Final test and adjustment................................................................229 Accumulators and suspensions.....................................................................233 Accumulator charging and storage.............................................................234 Temperature During Precharge.............................................................234 Bladder accumulator charging procedure.......................................................235 Precharge maintenance....................................................................237 Bladder accumulator storage procedure....................................................238 Bladder storage..........................................................................238 Installing a bladder accumulator from storage............................................238 Bladder accumulator leak testing.............................................................239 Piston accumulator charging procedure........................................................240 Piston accumulator storage...................................................................242 Piston accumulator leak testing..............................................................242 Checking for improper suspension charge......................................................243 Suspension oiling and charging procedures....................................................244 Required equipment.......................................................................244 Installing the charging kit..............................................................245 Removing the charging kit................................................................245 Support blocks for oiling and charging dimensions........................................246 Front suspensions........................................................................247 Rear suspensions.........................................................................250 Suspension pressure test.....................................................................253 Interface module (IM)............................................................................255 General information..........................................................................257 Interface module software....................................................................258 Flashburn program installation...........................................................258 Interface module application code installation...........................................259 Interface module realtime data monitor software installation.............................259 Interface module checkout procedures.........................................................260 Necessary equipment......................................................................260 Preliminary..............................................................................261 Checking Inputs and Outputs From The Interface Module....................................261 Check digital inputs to the interface module.............................................262 Check serial interfaces to the interface module..........................................264 Check analog inputs to the interface module..............................................265 CHECKOUT PROCEDURE...........................................................................266 KOMTRAX Plus.....................................................................................271 KOMTRAX Plus software and tools..............................................................273 KOMTRAX Plus controller setup procedure......................................................273 Preliminary steps........................................................................273 Setup procedure..........................................................................273 KOMTRAX Plus initialization form.............................................................277 Precautions when replacing the KOMTRAX Plus controller.......................................278 KOMTRAX Plus controller checkout procedure...................................................280 Preliminary steps........................................................................280 Checkout procedure.......................................................................280 Payload meter IV.................................................................................283 Payload meter IV software and tools..........................................................284 Payload meter IV system configuration........................................................284 Connecting to the payload meter IV web server............................................284 Configuring a static IP address..........................................................284 Payload meter IV software installation.......................................................286 Payload meter IV checkout procedure..........................................................287 PLM IV system checkout data sheet............................................................291 Komatsu wireless bridge (KWB)....................................................................293 General information..........................................................................294 Software download and setup..................................................................295 Bullet M2 Titanium / PicoStation M2......................................................296 Bullet M2................................................................................298 Configuring a KWB_Connect device.............................................................299 Access point configuration...............................................................299 Bullet M2 configuration..................................................................300 KOMTRAX Plus downloads...................................................................301 Configuring a TRUCK_NET device...............................................................302 Access point configuration...............................................................302 Bullet M2 configuration..................................................................303 Onboard controller access................................................................304 Changing a service computer’s IP address.....................................................305 Connecting to a wireless network.............................................................306 KWB_Connect troubleshooting..................................................................307 Step 1. Verify communication to the access point.........................................307 Step 2. Verify communication to the Bullet M2............................................307 Step 3. Verify communication to KOMTRAX Plus.............................................308 TRUCK_NET troubleshooting....................................................................309 Step 1. Verify communication to the access point.........................................309 Step 2. Verify communication to the Bullet M2............................................310 KWB_Connect checkout data sheet..............................................................311 TRUCK_NET checkout data sheet................................................................312 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.......................................................325 Recovering and recycling refrigerant.........................................................326 Draining oil from previous recovery cycle................................................327 Recovery cycle...........................................................................327 Recycling procedure......................................................................327 Evacuating the air conditioning system.......................................................328 Charging the air conditioning system.........................................................329 40 Troubleshooting...................................................................................331 Fuse and circuit breaker locations...............................................................331 Fuse and circuit breaker locations...........................................................333 AC drive system fault codes (DSC)................................................................339 Fault code tables............................................................................341 Troubleshooting by fault code, Part 1............................................................369 Fault Code A001: Left front suspension pressure sensor signal high...........................371 Related circuit diagram..................................................................371 Fault Code A002: Left front suspension pressure sensor signal low............................372 Related circuit diagram..................................................................372 Fault Code A003: Right front suspension pressure sensor signal high..........................373 Related circuit diagram..................................................................373 Fault Code A004: Right front suspension pressure sensor signal low...........................374 Related circuit diagram..................................................................374 Fault Code A005: Left rear suspension pressure sensor signal high............................375 Related circuit diagram..................................................................375 Fault Code A006: Left rear suspension pressure sensor signal low.............................376 Related circuit diagram..................................................................376 Fault Code A007: Right rear suspension pressure sensor signal high...........................377 Related circuit diagram..................................................................377 Fault Code A008: Right rear suspension pressure sensor signal low............................378 Related circuit diagram..................................................................378 Fault Code A009: Incline sensor signal high..................................................379 Related circuit diagram..................................................................379 Fault Code A010: Incline sensor signal low...................................................380 Related circuit diagram..................................................................380 Fault Code A011: Payload meter speed sensor signal has Failed................................381 Related circuit diagram..................................................................381 Fault Code A013: Body up switch has Failed...................................................382 Related circuit diagram..................................................................382 Fault Code A014: Payload meter checksum computation has Failed...............................383 Related circuit diagram..................................................................383 Fault Code A016: Payload meter write to flash memory has Failed..............................384 Related circuit diagram..................................................................384 Fault Code A017: Payload meter flash memory read has Failed..................................385 Related circuit diagram..................................................................385 Fault Code A018: Right rear flat suspension cylinder warning.................................386 Related circuit diagram..................................................................387 Fault Code A019: Left rear flat suspension cylinder warning..................................388 Related circuit diagram..................................................................389 Fault Code A022: Carryback load excessive....................................................390 Related circuit diagram..................................................................391 Fault Code A101: High pressure detected across an hydraulic pump filter......................392 Related circuit diagram..................................................................392 Fault Code A103: Hydraulic Oil Temp - Tank Sensor Low........................................393 Related circuit diagram..................................................................393 Fault Code A104: Hydraulic oil temp - Tank sensor high.......................................394 Related circuit diagram..................................................................394 Fault Code A105: Fuel level sensor shorted to ground indicating a false high fuel level......396 Related circuit diagram..................................................................397 Fault Code A109: GE has generated a propel system reduced level signal.......................398 Related circuit diagram..................................................................398 Fault Code A111 & A247: Low steering pressure warnings.......................................400 Related circuit diagram..................................................................401 Fault Code A115: Low steering precharge pressure detected....................................402 Related circuit diagram..................................................................402 Fault Code A117: Low brake accumulator pressure warnings.....................................404 Related circuit diagram..................................................................405 Fault Code A118: Brake pressure is low while in brake lock...................................406 Related circuit diagram..................................................................406 Fault Code A123: GE has generated a reduced retarding caution................................407 Related circuit diagram..................................................................407 Fault Code A124: GE has generated a no propel / no retard warning............................408 Related circuit diagram..................................................................408 Fault Code A125: GE has generated a no propel warning........................................409 Related circuit diagram..................................................................409 Fault Code A126: Oil level in the hydraulic tank is low......................................410 Related circuit diagram..................................................................410 Fault Code A127: IM-furnished +5 volt output for sensors is low..............................411 Related circuit diagram..................................................................411 Fault Code A128: IM-furnished +5 volt output for sensors is high.............................412 Related circuit diagram..................................................................412 Fault Code A139 & A310: Low fuel warnings....................................................414 Related circuit diagram..................................................................415 Troubleshooting by fault code, Part 2............................................................417 Fault Code A152: Starter failure.............................................................419 Related circuit diagram..................................................................419 Fault Code A153: Battery voltage is low with the truck in operation..........................420 Related circuit diagram..................................................................421 Fault Code A154: Battery charging voltage is excessive.......................................422 Related circuit diagram..................................................................422 Fault Code A155: Battery charging voltage is low.............................................423 Related circuit diagram..................................................................423 Fault Code A158: Fuel level sensor open or shorted high indicating a false low fuel level....424 Related circuit diagram..................................................................424 Fault Code A184: J1939 data link is not connected............................................425 Related circuit diagram..................................................................425 Fault Code A190: Auto lube control has detected an incomplete lube cycle.....................426 Related circuit diagram..................................................................427 Fault Code A193: Hydraulic tank oil temperature is high......................................428 Related circuit diagram..................................................................428 Fault Code A198: Hoist pressure 1 sensor is high.............................................429 Related circuit diagram..................................................................429 Fault Code A200: Steering pressure sensor is high............................................430 Related circuit diagram..................................................................430 Fault Code A201: Brake pressure sensor is high...............................................431 Related circuit diagram..................................................................431 Fault Code A202: Hoist pressure 1 sensor is low..............................................432 Related circuit diagram..................................................................432 Fault Code A204: Steering pressure sensor is low.............................................433 Related circuit diagram..................................................................433 Fault Code A205: Brake pressure sensor is low................................................434 Related circuit diagram..................................................................434 Fault Code A206: Ambient temperature sensor is high..........................................435 Related circuit diagram..................................................................435 Fault Code A207: Ambient temperature sensor is low...........................................436 Related circuit diagram..................................................................436 Fault Code A213: Parking brake should have applied; detected as not having applied...........438 Related circuit diagram..................................................................439 Fault Code A214: Parking brake should have released; detected as not having released.........440 Related circuit diagram..................................................................441 Fault Code A216: Open or short to ground in parking brake command valve circuit..............442 Related circuit diagram..................................................................443 Fault Code A223: Excessive engine cranking occurred or a jump start attempted................444 Related circuit diagram..................................................................445 Fault Code A230: Parking brake has been requested while truck still moving...................446 Related circuit diagram..................................................................447 Fault Code A231: The body is up while traveling or intending to travel.......................448 Related circuit diagram..................................................................449 Fault Code A233: Drive system CAN/RPC Control Link not connected.............................450 Related circuit diagram..................................................................451 Fault Code A235: Steering accumulator is in the process of being bled down...................452 Related circuit diagram..................................................................453 Fault Code A236: The steering accumulator has not properly bled after 90 seconds.............454 Related circuit diagram..................................................................454 Fault Code A237: The CAN/RPC connection to the display is open...............................455 Related circuit diagram..................................................................455 Fault Code A240: The key switch input to the interface module is open........................456 Related circuit diagram..................................................................456 Troubleshooting by fault code, Part 3............................................................459 Fault Code A242: Fuel gauge within the display panel is defective............................461 Related circuit diagram..................................................................461 Fault Code A243: Engine coolant temperature gauge within the display panel is defective......462 Related circuit diagram..................................................................462 Fault Code A244: Drive system temperature gauge within the display panel is defective........463 Related circuit diagram..................................................................463 Fault Code A245: Hydraulic oil temperature gauge within the display panel is defective.......464 Related circuit diagram..................................................................464 Fault Code A246: Payload meter reports truck overload........................................465 Related circuit diagram..................................................................465 Fault Code A248: Status module within the display panel is defective.........................466 Related circuit diagram..................................................................466 Fault Code A249: Red warning lamp within the display (driven by IM) is shorted...............467 Related circuit diagram..................................................................467 Fault Code A250: Battery voltage is low with the truck parked................................468 Related circuit diagram..................................................................469 Fault Code A251: Sonalert used with display (driven by IM) is open or shorted to ground......470 Related circuit diagram..................................................................470 Fault Code A252: Start enable output circuit is open or shorted to ground....................471 Related circuit diagram..................................................................471 Fault Code A253: Steering bleed circuit is not open while running............................472 Related circuit diagram..................................................................472 Fault Code A255: IM has detected a fault on IM output 1N.....................................473 Related circuit diagram..................................................................473 Fault Code A256: Red warning lamp in the display (driven by IM) is open......................474 Related circuit diagram..................................................................474 Fault Code A257: Payload CAN/RPC is not connected............................................475 Related circuit diagram..................................................................475 Fault Code A258: Steering accumulator bleed pressure switch circuit is defective.............476 Related circuit diagram..................................................................476 Fault Code A260: Parking brake failure.......................................................478 Related circuit diagram..................................................................479 Fault Code A261: Low brake accumulator pressure warnings.....................................480 Related circuit diagram..................................................................481 Fault Code A262: Steering bleed valve circuit open during shutdown...........................482 Related circuit diagram..................................................................483 Fault Code A264: Parking brake relay circuit is defective....................................484 Related circuit diagram..................................................................484 Fault Code A265: Service brake failure.......................................................486 Related circuit diagram..................................................................487 Fault Code A266: Selector lever was not in park while attempting to crank engine.............488 Related circuit diagram..................................................................488 Fault Code A267: Parking brake was not set while attempting to crank engine..................489 Related circuit diagram..................................................................489 Fault Code A268: Secondary engine shutdown while cranking....................................490 Related circuit diagram..................................................................490 Fault Code A270: Brake lock switch power supply is not on when required......................492 Related circuit diagram..................................................................493 Fault Code A271: Shifter not in gear.........................................................494 Related circuit diagram..................................................................494 Fault Code A272: Brake lock switch power supply is not off when required.....................496 Related circuit diagram..................................................................497 Fault Code A273: Fault detected in hoist or steering filter pressure switch circuit..........498 Related circuit diagram..................................................................498 Fault Code A274: A brake setting fault has been detected.....................................500 Related circuit diagram..................................................................501 Fault Code A275: A starter has been detected as engaged without a cranking attempt...........502 Related circuit diagram..................................................................502 Troubleshooting by fault code, Part 4............................................................505 Fault Code A277: Parking brake applied while loading.........................................507 Related circuit diagram..................................................................507 Fault Code A278: Service brake applied while loading.........................................508 Related circuit diagram..................................................................508 Fault Code A279: Low steering pressure switch is defective...................................509 Related circuit diagram..................................................................509 Fault Code A280: Steering accumulator bleed down switch is defective.........................510 Related circuit diagram..................................................................510 Fault Code A281: Brake lock degrade switch is defective......................................511 Related circuit diagram..................................................................511 Fault Code A282: Excessive cranking or jump starts without the engine running................512 Related circuit diagram..................................................................513 Fault Code A283: Engine shutdown delay aborted; parking brake not set........................514 Related circuit diagram..................................................................515 Fault Code A284: Engine shutdown delay aborted; secondary shutdown switch used...............516 Related circuit diagram..................................................................516 Fault Code A285: The parking brake was not set when the key switch was turned off............517 Related circuit diagram..................................................................517 Fault Code A286: A fault was detected in the shutdown delay relay circuit....................518 Related circuit diagram..................................................................518 Fault Code A292: Shutdown delay relay stayed on after latched keyswitch circuit is off.......519 Related circuit diagram..................................................................519 Fault Code A303: Shifter is defective........................................................520 Fault Code A304: Auto lube grease level fault................................................521 Related circuit diagram..................................................................521 Fault Code A305: Auto lube circuit is defective..............................................522 Related circuit diagram..................................................................522 Fault Code A307: Both GE Inverters disabled..................................................523 Fault Code A309: No brakes applied when expected.............................................524 Related circuit diagram..................................................................525 Fault Code A311: Brake lock switch on when it shouldn’t be...................................526 Related circuit diagram..................................................................526 Fault Code A312: The DCDC Converter 12 volt circuit sensing is producing low readings........527 Related circuit diagram..................................................................527 Fault Code A313: The DCDC converter 12 volt circuit sensing is producing high readings.......528 Related circuit diagram..................................................................528 Fault Code A315: The DCDC converter 12 volt circuit is low...................................529 Related circuit diagram..................................................................529 Fault Code A316: Starter engagement has been attempted with engine running...................530 Related circuit diagram..................................................................531 Fault Code A318: Unexpected power loss to Interface Module...................................532 Related circuit diagram..................................................................532 Fault Code A328: Drive system not powered up.................................................533 Related circuit diagram..................................................................533 Fault Code A333: The hydraulic ladder controller has declared a ladder fault.................534 Related circuit diagram..................................................................534 Fault Code A334: Selector switch not in park when propel was either not ready or at rest.....535 Related circuit diagram..................................................................535 Troubleshooting by fault code, Part 5............................................................537 Fault Code A350: Overload on output 1B.......................................................538 Related circuit diagram..................................................................538 Fault Code A351: Overload on output 1E.......................................................539 Related circuit diagram..................................................................539 Fault Code A352: Overload on output 1H.......................................................540 Related circuit diagram..................................................................540 Fault Code A353: Overload on output 1J.......................................................541 Related circuit diagram..................................................................541 Fault Code A354: Overload on output 1K.......................................................542 Related circuit diagram..................................................................542 Fault Code A355: Overload on output 1L.......................................................543 Related circuit diagram..................................................................543 Fault Code A356: Overload on output 1M.......................................................544 Related circuit diagram..................................................................544 Fault Code A357: Overload on output 1N.......................................................545 Related circuit diagram..................................................................545 Fault Code A358: Overload on output 1P.......................................................546 Related circuit diagram..................................................................546 Fault Code A359: Overload on output 1R.......................................................547 Related circuit diagram..................................................................547 Fault Code A360: Overload on output 1S.......................................................548 Related circuit diagram..................................................................548 Fault Code A361: Overload on output 1T.......................................................549 Related circuit diagram..................................................................549 Fault Code A362: Overload on output 1U.......................................................550 Related circuit diagram..................................................................550 Fault Code A363: Overload on output 1X.......................................................551 Related circuit diagram..................................................................551 Fault Code A364: Overload on output 1Y.......................................................552 Related circuit diagram..................................................................552 Fault Code A365: Overload on output 1Z.......................................................553 Related circuit diagram..................................................................553 Cab air conditioning.............................................................................555 Preliminary checks...........................................................................557 Diagnosis of gauge readings and system performance...........................................557 Troubleshooting by manifold gauge set readings...............................................558 Steering system..................................................................................565 Steering circuit troubleshooting chart.......................................................566 Steering circuit troubleshooting guidelines..................................................568 Basic hydraulic system checks................................................................569 System leakage check.........................................................................570 Steering pump troubleshooting guide..........................................................572 Pump pressure control checks.................................................................575 Pump fails to unload.....................................................................576 Pump fails to develop pressure...........................................................576 Pump slow in developing pressure.........................................................577 Pump control valve inspection and trouble shooting.......................................577 Pump case drain check....................................................................579 Setting pump pressure controls...........................................................579 Automatic lubrication (auto lube) system.........................................................583 Autolube troubleshooting chart...............................................................585 50 Disassembly and assembly..........................................................................589 Service tools....................................................................................589 Special tool group...........................................................................591 Additional service tools.....................................................................592 Locally made tools...........................................................................593 Wheels, spindles and rear axle...................................................................599 General precautions for tires and rims.......................................................601 Rim components...............................................................................602 Wheel stud maintenance.......................................................................603 Removal and installation of front wheel......................................................604 Removal..................................................................................604 Installation.............................................................................605 Removal and installation of rear wheel.......................................................606 Removal..................................................................................606 Installation.............................................................................607 Rim and tire service.........................................................................609 Lubricants...............................................................................609 Tire inflation...........................................................................609 Removal (5-piece standard rim)...........................................................609 Preparation before assembly..............................................................613 Installation (5-piece standard rim)......................................................613 Removal and installation of front wheel hub and spindle......................................616 Removal..................................................................................616 Spindle removal (off the truck)..........................................................621 Installation.............................................................................623 Disassembly and assembly of front wheel hub and spindle......................................624 Cross Section View.......................................................................624 Disassembly..............................................................................625 Cleaning and inspection..................................................................629 Assembly.................................................................................630 Wheel bearing adjustment.................................................................634 Speed sensor installation and adjustment.................................................636 Hub floating ring seal assembly and installation.............................................637 Removal and installation of rear axle........................................................642 Removal..................................................................................642 Cleaning and inspection..................................................................643 Installation.............................................................................644 Removal and installation of anti-sway bar....................................................645 Removal..................................................................................645 Installation.............................................................................647 Removal and installation of pivot pin........................................................648 Removal..................................................................................648 Installation.............................................................................649 Pivot eye and bearing service................................................................650 Bearing replacement......................................................................650 Pivot eye repair.........................................................................651 Removal and installation of wheel motor......................................................652 Preparation..............................................................................652 Removal..................................................................................652 Cleaning and inspection..................................................................655 Installation.............................................................................655 Brake system.....................................................................................661 Removal and installation of brake valve......................................................663 Removal..................................................................................663 Disassembly and assembly of brake valve/pedal assembly.......................................666 Disassembly..............................................................................666 Assembly.................................................................................667 Removal and installation of brake manifold...................................................668 Removal..................................................................................668 Installation.............................................................................669 Disassembly and assembly of brake manifold...................................................670 Disassembly..............................................................................670 Assembly.................................................................................670 Disassembly and assembly of brake accumulator................................................671 Cleaning and inspection..................................................................672 Assembly.................................................................................673 Removal and installation of front brake caliper..............................................675 Removal..................................................................................675 Inspection...............................................................................676 Installation.............................................................................676 Disassembly and assembly of front brake caliper..............................................677 Disassembly..............................................................................677 Cleaning and inspection..................................................................677 Brake lining replacement.................................................................680 Assembly.................................................................................680 Removal and installation of rear brake caliper...............................................680 Removal..................................................................................680 Inspection...............................................................................683 Installation.............................................................................683 Disassembly and assembly of rear brake caliper...............................................686 Disassembly..............................................................................686 Piston subassembly.......................................................................689 Cleaning and inspection..................................................................690 Assembly.................................................................................692 Piston subassembly.......................................................................692 Brake caliper............................................................................693 Steering system..................................................................................701 Removal and installation of steering control unit............................................703 Removal..................................................................................703 Installation.............................................................................704 Disassembly and assembly of steering control unit............................................705 Disassembly..............................................................................705 Assembly.................................................................................707 Removal and installation of steering column..................................................710 Removal..................................................................................710 Inspection...............................................................................711 Installation.............................................................................712 Removal and installation of steering wheel...................................................713 Removal..................................................................................713 Installation.............................................................................713 Removal and installation of bleeddown manifold...............................................714 Removal..................................................................................714 Installation.............................................................................716 Removal and installation of flow amplifier...................................................717 Removal..................................................................................717 Installation.............................................................................719 Removal and installation of steering cylinders and tie rod...................................719 Removal..................................................................................719 Installation.............................................................................721 Disassembly and assembly of steering cylinders...............................................722 Disassembly..............................................................................722 Cleaning and inspection..................................................................724 Assembly.................................................................................725 Removal and installation of steering/brake pump..............................................725 Removal..................................................................................725 Installation.............................................................................728 Removal and installation of piston steering accumulator......................................729 Removal..................................................................................729 Installation.............................................................................731 Disassembly and assembly of piston steering accumulators.....................................732 Disassembly..............................................................................732 Cleaning and inspection..................................................................734 Piston seal replacement..................................................................734 Assembly.................................................................................735 Suspensions......................................................................................737 Removal and installation of front suspension.................................................739 General information......................................................................739 Removal..................................................................................739 Installation.............................................................................741 Upper mounting joint - 60° advance.......................................................745 Lower mounting joint - 90° advance.......................................................746 Inspection...............................................................................746 Disassembly and assembly of front suspension.................................................747 Disassembly..............................................................................747 Cleaning and inspection..................................................................749 Assembly.................................................................................750 Removal and installation of rear suspension..................................................752 General information......................................................................752 Removal..................................................................................752 Installation.............................................................................755 Disassembly and assembly of rear suspension..................................................756 Disassembly..............................................................................756 Cleaning and inspection..................................................................758 Assembly.................................................................................759 Hoist circuit....................................................................................761 Removal and installation of hoist pump.......................................................763 Removal..................................................................................763 Installation.............................................................................767 Disassembly and assembly of hoist pump.......................................................768 Disassembly..............................................................................768 Inspection...............................................................................773 Assembly.................................................................................774 Removal and installation of hoist valve......................................................777 Removal..................................................................................777 Installation.............................................................................779 Disassembly and assembly of hoist valve......................................................779 O-ring replacement.......................................................................779 Disassembly of inlet section.............................................................781 Assembly of inlet section................................................................782 Disassembly of spool section.............................................................783 Assembly of spool section................................................................785 Overcenter manifold service..................................................................786 Removal and installation of hoist pilot valve................................................787 Removal..................................................................................787 Installation.............................................................................787 Disassembly and assembly of hoist pilot valve................................................789 Disassembly..............................................................................789 Cleaning and inspection..................................................................790 Assembly.................................................................................790 Removal and installation of hoist cylinders..................................................791 Removal..................................................................................791 Installation.............................................................................793 Disassembly and assembly of hoist cylinders..................................................794 Disassembly..............................................................................794 Cleaning and inspection..................................................................798 Installation of the quill................................................................799 Assembly.................................................................................801 Body and structures..............................................................................807 Removal and installation of dump body........................................................809 Removal..................................................................................809 Inspection...............................................................................810 Installation.............................................................................811 Removal and installation of body pads........................................................812 Removal..................................................................................812 Installation.............................................................................812 Body pad shimming procedure..............................................................813 Removal and installation of diagonal ladder/ hood and grille assembly........................814 Removal..................................................................................814 Installation.............................................................................814 Removal and installation of RH deck..........................................................816 Removal..................................................................................816 Installation.............................................................................816 Removal and installation of LH deck..........................................................818 Removal..................................................................................818 Installation.............................................................................818 Removal and installation of fuel tank........................................................820 Removal..................................................................................820 Cleaning and inspection..................................................................822 Installation.............................................................................822 Removal and installation of fuel gauge sender................................................823 Removal..................................................................................823 Installation.............................................................................823 Removal and installation of hydraulic tank...................................................824 Removal..................................................................................824 Installation.............................................................................826 Removal and installation of hydraulic tank strainers.........................................826 Removal..................................................................................826 Cleaning and inspection..................................................................827 Installation.............................................................................827 Operator cab.....................................................................................829 Removal and installation of operator cab.....................................................831 Removal..................................................................................831 Installation.............................................................................834 Removal and installation of cab door.........................................................835 Removal..................................................................................835 Installation.............................................................................835 Disassembly and assembly of cab door.........................................................836 Removing door panel......................................................................836 Installing door panel....................................................................837 Replacing the door window regulator......................................................837 Replacing door handle or latch assembly..................................................838 Replacing door assembly seal and door hinge seal.........................................839 Replacing door opening seal..............................................................839 Removing door glass......................................................................840 Installing door glass....................................................................841 Adjustment of cab door.......................................................................843 Door jamb bolt adjustment................................................................843 Door handle plunger adjustment...........................................................844 Removal and installation of side window glass................................................845 Recommended tools and supplies...........................................................845 Removal..................................................................................846 Installation.............................................................................846 Removal and installation of windshield and rear window glass.................................847 Removal..................................................................................847 Installation.............................................................................847 Removal and installation of windshield wiper motor...........................................848 Removal..................................................................................848 Installation.............................................................................849 Removal and installation of windshield wiper arm.............................................849 Removal..................................................................................849 Installation.............................................................................849 Removal and installation of windshield wiper linkage.........................................850 Removal..................................................................................850 Installation.............................................................................850 Removal and installation of operator seat....................................................851 Inspection...............................................................................851 Removal..................................................................................851 Installation.............................................................................851 Replacing the seat compressor (standard seat)................................................852 Removal and installation of passenger seat (standard seat)...................................857 Removal..................................................................................857 Installation.............................................................................857 Removal and installation of seat belts (standard seat).......................................858 Removal..................................................................................858 Installation.............................................................................859 Removal and installation of seat belts (optional seat).......................................860 General..................................................................................860 Removal..................................................................................860 Installation.............................................................................862 Cab air conditioning.............................................................................865 Replacement of air conditioning system components............................................867 Hoses and fittings.......................................................................867 Lines....................................................................................867 Expansion valve..........................................................................867 Receiver-drier...........................................................................867 Thermostat...............................................................................867 Compressor...............................................................................868 Accumulator..............................................................................868 Clutch...................................................................................868 Power module.....................................................................................871 Removal and installation of power module.....................................................873 General..................................................................................873 Removal..................................................................................874 Installation.............................................................................882 Removal and installation of alternator.......................................................885 Removal..................................................................................885 Installation.............................................................................888 Removal and installation of radiator.........................................................896 Removal..................................................................................896 Installation.............................................................................901 Repairing the radiator.......................................................................902 Internal inspection......................................................................902 External cleaning........................................................................902 Disassembly..............................................................................903 Cleaning and inspection..................................................................904 Assembly.................................................................................904 Pressure testing.........................................................................905 Removal and installation of engine...........................................................906 Removal..................................................................................906 Service..................................................................................907 Installation.............................................................................907 90 Diagrams and drawings.............................................................................909 Hydraulic circuit diagrams.......................................................................909 Steering and hoist hydraulic circuit diagram.................................................911 Brake hydraulic circuit diagram..............................................................912 Auxiliary hydraulic circuit diagram..........................................................913 Electrical circuit diagrams......................................................................916 Electrical circuit diagram...................................................................918 Connectors table and arrangement drawing.....................................................940 Blank Page........................................................................................... 2
DESCRIPTION:
KOMATSU 730E-8 DUMP TRUCK SHOP MANUAL CEBM032601 – 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 Nꞏm (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 26/12/24
