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KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30212 & A30218) KOMATSU 730E – PDF DOWNLOAD
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- KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL
- SERIAL NUMBER:A30212 & A30218
- PUBLICATION NUMBER:CEBM010900
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Description
KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30212 & A30218) KOMATSU 730E
KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30212 & A30218) KOMATSU 730E – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30212 & A30218) KOMATSU 730E
- This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck.
- All safety notices, warnings and cautions should be understood and followed when accomplishing 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, at times, typical of the component shown and may not necessarily depict a specific model.
- This manual shows dimensioning of U.S. standard and metric (SI) units throughout and all references to “Right”, “Left”, “Front”, or “Rear” are made with respect to the operator’s normal seated position, unless specifically stated otherwise. Standard torque requirements are shown in torque charts in the general information section and individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque.
- All torque specifications have æ10% tolerance unless otherwise specified. A Product Identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating. The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 730E). The three numbers represent the basic truck model.
- The letter “M” designates a Mechanical drive and the letter “E” designates an Electrical propulsion system. The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.
- The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight (GVW) and this means the total weight: the Empty Vehicle Weight + the fuel & lubricants + the payload.
TABLE OF CONTENTS:
KOMATSU 730E DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30212 & A30218) KOMATSU 730E
MAIN MENU................................................................... 0 COVER....................................................................... 1 FOREWARD.................................................................... 4 CONTENTS.................................................................... 6 A. GENERAL INFORMATION...................................................... 8 TRUCK COMPONENT DESCRIPTION & SPECIFICATIONS............................ 10 GENERAL SAFETY AND TRUCK OPERATION...................................... 14 WARNINGS AND CAUTIONS................................................... 38 CHARTS AND TABLES....................................................... 46 STORAGE PROCEDURES...................................................... 52 B. STRUCTURES............................................................... 72 STRUCTURAL COMPONENTS................................................... 74 GRILLE AND HOOD..................................................... 74 LADDERS............................................................. 75 DECKS............................................................... 75 RIGHT DECK AND COMPONENTS....................................... 75 LEFT DECK....................................................... 75 DUMP BODY............................................................... 78 INSTALLATION........................................................ 78 REMOVAL............................................................. 78 BODY PADS........................................................... 79 BODY GUIDE.......................................................... 80 BODY SLING.......................................................... 80 BODY POSITION INDICATOR............................................. 80 ROCK EJECTORS....................................................... 81 HOIST LIMIT SWITCHES................................................ 81 FUEL TANK............................................................... 82 REMOVAL............................................................. 82 INSTALLATION........................................................ 83 CLEANING............................................................ 83 VENT................................................................ 83 FUEL GAUGE SENDER................................................... 83 C. ENGINE, FUEL, COOLING, AND AIR CLEANER................................... 84 POWER MODULE............................................................ 86 REMOVAL............................................................. 86 INSTALLATION........................................................ 90 COOLING SYSTEM.......................................................... 92 RADIATOR............................................................ 92 REMOVAL......................................................... 92 SERVICE......................................................... 93 INSTALLATION.................................................... 93 RADIATOR FILL PROCEDURE......................................... 94 COOLING SYSTEM TROUBLESHOOTING.................................. 95 POWER TRAIN............................................................. 96 ALTERNATOR REMOVAL AND INSTALLATION PROCEDURE....................... 96 REMOVAL......................................................... 96 ENGINE / ALTERNATOR MATING.......................................... 98 ALTERNATOR MEASUREMENT.......................................... 98 ENGINE END PLAY MEASUREMENT..................................... 99 DETERMINING SHIM REQUIREMENTS................................... 99 INSTALLATION....................................................100 ENGINE..............................................................102 REMOVAL.........................................................102 INSTALLATION....................................................102 AIR CLEANERS............................................................104 FILTER ELEMENT REPLACEMENT..........................................104 MAIN FILTER ELEMENT CLEANING........................................106 PRECLEANER SECTION..................................................107 D. ELECTRIC SYSTEM (24 VDC, NON-PROPULSION).................................110 24 VDC ELECTRIC SUPPLY SYSTEM...........................................112 ELECTRICAL SYSTEM DESCRIPTION.......................................112 BATTERY - MAINTENANCE AND SERVICE...................................112 ELECTRIC START SYSTEM...............................................114 OPERATION.......................................................114 REMOVAL.....................................................114 INSTALLATION................................................114 CRANKING MOTOR TROUBLESHOOTING..................................115 DISASSEMBLY.....................................................116 SOLENOID CHECKS.................................................119 ASSEMBLY........................................................120 ENGINE PRELUB STARTER SYSTEM........................................123 OPERATION.......................................................123 TROUBLESHOOTING.................................................125 24 VDC ELECTRICAL SYSTEM COMPONENTS.....................................128 PASSENGER SEAT BASE COMPARTMENT.....................................128 TAIL LIGHT RESISTOR DIODE ASSEMBLIES............................128 5 MINUTE IDLE TIMER COMPONENTS..................................130 ALARM INDICATING DEVICE (A.I.D. SYSTEM).........................131 BODY UP SWITCH......................................................134 HOIST LIMIT SWITCH..................................................134 24 VDC RELAY AND DIODE BOARDS.......................................135 DESCRIPTION.....................................................135 RELAY BOARD 1 (TURN SIGNAL).....................................137 RELAY BOARD 2 (PAYLOAD METER)...................................137 RELAY BOARD 3 (STOP LIGHTS).....................................138 RELAY BOARD 4 (PARKING BRAKE)...................................138 RELAY BOARD 5 (HEADLIGHTS)......................................138 RELAY BOARD 6 (AUXILIARY PANEL).................................139 DIODE BOARD 1...................................................140 CIRCUIT BREAKER CHART...........................................141 E. ELECTRIC PROPULSION AND CONTROL..........................................142 ELECTRICAL PROPULSION COMPONENTS........................................144 GENERAL SYSTEM DESCRIPTION..........................................144 CONTROL SYSTEM......................................................144 FL275 PANEL.........................................................146 COMPUTER DESCRIPTION............................................148 SOFTWARE........................................................148 2-DIGIT DISPLAY PANEL...............................................151 EVENTS..........................................................151 FRAMES..........................................................152 WINDOWS.........................................................152 EVENT CODE DESCRIPTIONS (TABLE I)...........................154 SUBCODE DESCRIPTIONS (TABLE II).............................161 PORTABLE TEST UNIT (PTU)............................................164 DESCRIPTION.....................................................164 SOFTWARE INSTALLATION PREPARATION...............................165 THE MAIN MENU...............................................167 PTU SOFTWARE MENU TREE......................................168 CONFIGURATION (CFG) FILE CONVERSION.........................169 STATEX CONFIGURATION FILES......................................173 PROGRAMMING THE TRUCK...........................................184 PTU HOOKUP..................................................184 DOWNLOAD CONFIGURATION FILES................................186 EVENT DATA......................................................188 STATISTICAL DATA................................................191 STATISTICAL DATA CODES - COUNTERS (TABLE III)...............192 STATISTICAL DATA CODES - PROFILES (TABLE IV)................197 TRUCK SPECIFIC INFORMATION......................................201 TEMPORARY TRUCK SETTINGS........................................202 MISCELLANEOUS SOFTWARE FEATURES.................................203 SAVING DATA.................................................203 PTU ABBREVIATIONS...........................................204 MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS..........................205 ALTERNATOR..........................................................205 ELECTRIC WHEEL MOTORS...............................................205 RETARDING GRIDS.....................................................205 ELECTRONIC ACCELERATOR AND RETARD CONTROL...........................205 COOLING BLOWER WARNING SYSTEM.......................................207 ELECTRICAL CONTROL CABINET..........................................208 STATEX III ELECTRIC DRIVE COMPONENTS ABBREVIATIONS..................213 ELECTRICAL CHECKOUT PROCEDURE...........................................216 G. DRIVE AXLE, SPINDLES AND WHEELS..........................................268 TIRES AND RIMS (G02012).................................................270 FRONT TIRES AND RIMS................................................271 REMOVAL.........................................................271 INSTALLATION....................................................272 REAR TIRES AND RIMS.................................................272 REMOVAL.........................................................272 INSTALLATION....................................................273 RIM.................................................................274 TIRE REMOVAL....................................................274 TIRE INSTALLATION...............................................275 FRONT WHEEL HUB AND SPINDLE ASSEMBLY (G03012)...........................276 WHEEL HUB AND SPINDLE ASSEMBLY......................................276 REMOVAL......................................................... 0 INSTALLATION....................................................278 DISASSEMBLY.....................................................278 CLEANING AND INSPECTION.........................................279 ASSEMBLY........................................................279 WHEEL BEARING ADJUSTMENT (TIRE REMOVED).........................281 WHEEL BEARING ADJUSTMENT (TIRE MOUNTED).........................282 STEERING CYLINDERS AND TIE ROD......................................284 REMOVAL.........................................................284 INSTALLATION....................................................284 BEARING REPLACEMENT.............................................284 TOE-IN ADJUSTMENT...................................................286 REAR AXLE HOUSING ATTACHMENT (G04010)...................................288 PIVOT PIN...........................................................288 REMOVAL.........................................................288 INSTALLATION....................................................288 DISASSEMBLY.....................................................289 ASSEMBLY........................................................289 ANTI-SWAY BAR.......................................................291 REMOVAL.........................................................291 INSTALLATION....................................................291 DISASSEMBLY.....................................................291 CLEANING AND INSPECTION.........................................291 ASSEMBLY........................................................291 REAR AXLE HOUSING (G05004)..............................................292 REAR AXLE HOUSING...................................................292 REMOVAL.........................................................292 INSTALLATION....................................................292 WHEEL MOTOR.........................................................292 REMOVAL.........................................................292 CLEANING AND INSPECTION.........................................293 INSTALLATION....................................................293 H. HYDRAIR II SUSPENSIONS...................................................294 FRONT SUSPENSION........................................................296 REMOVAL.............................................................296 INSTALLATION........................................................297 DISASSEMBLY.....................................................300 ASSEMBLY (BEARING RETAINER ONLY)................................302 ASSEMBLY (COMPLETE).............................................302 SUSPENSION PRESSURE TEST............................................303 REAR SUSPENSION.........................................................304 REMOVAL.............................................................304 INSTALLATION........................................................306 DISASSEMBLY.....................................................307 ASSEMBLY........................................................307 SUSPENSION PRESSURE TEST............................................309 OILING AND CHARGING PROCEDURES..........................................310 GENERAL.............................................................310 EQUIPMENT LIST......................................................310 FRONT SUSPENSION....................................................312 FRONT SUSPENSION OILING.........................................312 FRONT SUSPENSION NITROGEN CHARGING..............................313 REAR SUSPENSION.....................................................314 REAR SUSPENSION OILING..........................................314 REAR SUSPENSION NITROGEN CHARGING...............................315 OIL AND NITROGEN SPECIFICATIONS.........................................317 J. BRAKE CIRCUIT............................................................318 BRAKE CIRCUIT...........................................................320 SERVICE BRAKE CIRCUIT OPERATION.....................................320 SECONDARY BRAKING AND AUTOMATIC APPLY...............................322 PARKING BRAKE CIRCUIT...............................................322 BRAKE LOCK CIRCUIT..................................................323 WARNING CIRCUIT.....................................................323 BRAKE VALVE CUT-AWAY................................................324 BRAKE CIRCUIT COMPONENT SERVICE.........................................326 BRAKE VALVE.........................................................326 REMOVAL.........................................................326 INSTALLATION....................................................328 DISASSEMBLY.....................................................330 CLEANING AND INSPECTION.........................................332 ASSEMBLY........................................................336 BENCH TEST AND ADJUSTMENT.......................................336 INSTALLATION OF BRAKE PEDAL ACTUATOR ASSEMBLY TO BRAKE VALVE....340 INSTALLATION OF RETARD PEDAL (IF EQUIPPED) TO BRAKE VALVE.......342 HYDRAULIC BRAKE ACCUMULATORS........................................343 REMOVAL.........................................................343 INSTALLATION....................................................343 DISASSEMBLY.....................................................343 CLEANING AND INSPECTION.........................................344 ASSEMBLY........................................................345 CHARGING PROCEDURE..............................................346 BRAKE CIRCUIT CHECKOUT PROCEDURE........................................348 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING...........................354 HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDURE DATA SHEET...................358 FRONT BRAKES (ROCKWELL).................................................360 BRAKE CALIPER.......................................................360 BRAKE LINING........................................................364 BRAKE PAD CONDITIONING (BURNISHING) PROCEDURE.......................365 BRAKE BLEEDING PROCEDURE............................................366 REAR BRAKES (ROCKWELL)..................................................368 BRAKE CALIPER, DISC AND PARKING BRAKE...............................368 CALIPER PISTON ASSEMBLY.............................................373 BENCH TEST..........................................................374 BRAKE LINING........................................................380 BRAKE PAD CONDITIONING (BURNISHNG) PROCEDURE........................383 BRAKE BLEEDING PROCEDURE............................................385 PARKING BRAKE (ROCKWELL)................................................386 CALIPER.............................................................386 REMOVAL.........................................................386 INSTALLATION....................................................387 PARKING BRAKE ADJUSTMENT (SCL 70)...............................387 PARKING BRAKE ADJUSTMENT................................................387 PARK BRAKE CALIPER DISASSEMBLY......................................389 CLEANING AN INSPECTION..............................................389 PARK BRAKE CALIPER ASSEMBLY.........................................390 PARK BRAKE LINING.......................................................391 REPLACEMENT.........................................................391 CONDITIONING (BURNISHING PROCEDURE).................................391 BRAKE BLEEDING PROCEDURE................................................391 L. HYDRAULIC SYSTEM.........................................................392 HYDRAULIC SYSTEM........................................................394 HOIST CIRCUIT OPERATION.............................................394 STEERING CIRCUIT OPERATION..........................................396 HYDRAULIC COMPONENT REPAIR..............................................400 HOIST PUMP..........................................................400 REMOVAL.........................................................400 INSTALLATION....................................................401 DISASSEMBLY.....................................................402 INSPECTION......................................................404 ASSEMBLY........................................................405 TROUBLESHOOTING GUIDE...........................................409 HYDRAULIC TANK..........................................................410 FILLING INSTRUCTIONS................................................410 REMOVAL.............................................................411 INSTALLATION........................................................411 STRAINER AND DIFFUSER...............................................411 STEERING CIRCUIT........................................................414 STEERING CIRCUIT OPERATION..........................................414 COMPONENT DESCRIPTION...............................................415 STEERING CONTROL VALVE..........................................415 UNLOADER VALVE..................................................415 BLEED DOWN MANIFOLD VALVE.......................................416 FLOW AMPLIFIER..................................................420 STEERING PUMP...................................................429 ACCUMULATORS....................................................429 STEERING CONTROL VALVE..............................................430 REMOVAL.........................................................430 INSTALLATION....................................................430 REBUILD PROCEDURE...............................................431 DISASSEMBLY.................................................431 CLEANING AND INSPECTION.....................................432 ASSEMBLY....................................................434 STEERING PUMP...................................................437 REMOVAL.....................................................437 INSTALLATION................................................437 DISASSEMBLY.................................................439 INSPECTION..................................................439 ASSEMBLY....................................................439 STEERING CIRCUIT COMPONENT REPAIR...................................442 BLEEDDOWN MANIFOLD VALVE........................................442 STEERING ACCUMULATORS...........................................443 STEERING ACCUMULATORS CHARGING PROCEDURE........................447 FLOW AMPLIFIER..................................................448 STEERING CYLINDERS..............................................452 HOIST CIRCUIT.......................................................454 HOIST CIRCUIT OPERATION.........................................454 COMPONENT DESCRIPTION...........................................455 HOIST CIRCUIT COMPONENT REPAIR......................................468 HOIST VALVE.....................................................468 HOIST PILOT VALVE...............................................476 HOIST-UP LIMIT SOLENOID VALVE...................................479 HOIST CYLINDERS.................................................479 HYDRAULIC SYSTEM FILTERS............................................488 HOIST CIRCUIT FILTER............................................488 STEERING CIRCUIT FILTER.........................................490 HYDRAULIC CHECKOUT PROCEDURES.......................................494 STEERING CIRCUIT TEST PROCEDURE.................................494 COMPONENT LEAKAGE TEST......................................496 TROUBLESHOOTING CHART...........................................498 CHECKING HOIST SYSTEM RELIEF VALVE PRESSURES....................501 POWER UP RELIEF PRESSURE TEST...............................501 POWER DOWN RELIEF PRESSURE TEST.............................502 HOIST COUNTERBALANCE VALVE ADJUSTMENT.......................503 DISABLED TRUCK DUMPING PROCEDURE................................504 HYDRAULIC SYSTEM FLUSHING PROCEDURE.............................505 M. OPTIONS AND SPECIAL TOOLS................................................508 FIRE CONTROL SYSTEMS....................................................510 ANSUL FIRE CONTROL PNEUMATIC SYSTEM.................................510 ANSUL FIRE CONTROL ELECTRIC SYSTEM..................................516 ANSUL FIRE CONTROL SYSTEM MANUAL....................................526 OPERATION.......................................................526 INSPECTION AND MAINTENANCE......................................526 RECHARGING PROCEDURES...........................................527 WIGGINS QUICK FILL FUEL SYSTEM..........................................528 TANK BREATHER VALVE.................................................529 FUEL RECEIVER.......................................................528 FAN DRIVE CLUTCH - HYDRAULIC ACTUATED...................................532 GENERAL DESCRIPTION.................................................532 MAINTENANCE.........................................................535 TROUBLESHOOTING.....................................................537 FIELD CHECK DIAGNOSIS...............................................538 THERMAL SENSOR AND SOLENOID VALVE...............................539 TROUBLESHOOTING CHART...............................................542 DISASSEMBLY.........................................................546 REASSEMBLY..........................................................553 INSPECTION OF PARTS.................................................564 REBUILD TOOLS.......................................................569 ENGINE COOLANT HEATER SYSTEM - HOT START - 220 VOLT.....................570 HEATING ELEMENT.....................................................570 THERMOSTAT..........................................................571 ENGINE OIL HEATERS - HOT START - 220 VOLT...............................572 TROUBLESHOOTING..................................................... 0 HEATING ELEMENT.....................................................572 ENGINE AND COOLANT HEATERS - 440 VOLT...................................574 TROUBLESHOOTING.....................................................575 COOLANT HEATING ELEMENT.............................................576 OIL HEATING ELEMENT.................................................577 SPECIAL TOOL GROUP......................................................580 HEATER / AIR CONDITIONING SYSTEM........................................588 ENVIRONMENTAL IMPACT................................................588 OPERATOR CAB CONDITIONING...........................................589 PRINCIPLES OF REFRIGERATION.........................................589 MAJOR SYSTEM COMPONENTS.............................................591 SYSTEM SERVICING....................................................595 EVACUATING THE SYSTEM...............................................612 SYSTEM TROUBLESHOOTING..............................................614 24 VDC ELECTRIC SUPPLY SYSTEM...........................................624 ELECTRICAL SYSTEM DESCRIPTION.......................................624 BATTERY - MAINTENANCE AND SERVICE...................................624 BATTERY CHARGING SYSTEM.............................................626 GENERAL DESCRIPTION.............................................626 TROUBLESHOOTING PROCEDURES......................................626 NIEHOFF 250 AMP ALTERNATOR OVERHAUL MANUAL..............................634 DIMENSIONS..........................................................635 SPECIFICATIONS......................................................636 SERVICE PARTS LIST..................................................637 EXPLODED VIEW.......................................................638 ON VEHICLE TEST.....................................................639 BENCH TEST..........................................................641 STATIC TESTS........................................................642 ALTERNATOR DISASSEMBLY..............................................645 ALTERNATOR ASSEMBLY.................................................650 SERVICE TOOL INSTRUCTIONS...........................................659 FUEL - WATER SEPARATOR..................................................662 INSTALLATION........................................................662 OPERATION...........................................................662 FILTER SERVICE......................................................663 PAYLOAD METER III.......................................................664 OPERATION SECTION...................................................667 INTRODUCTION........................................................667 DATA SUMMARY........................................................667 DATA GATHERING......................................................667 COMPONENT DESCRIPTION...............................................668 SYSTEM DIAGRAM..................................................668 SUSPENSION PRESSURE SENSORS.....................................668 INCLINOMETER....................................................668 OPERATOR DISPLAY................................................668 OPERATOR SWITCH.................................................669 SPEED INPUT.....................................................669 BODY-UP SWITCH..................................................669 BRAKE LOCK SWITCH...............................................669 PAYLOAD METER...................................................669 COMMUNICATIONS PORT.............................................669 KEYSWITCH INPUT.................................................670 PAYLOAD METER POWER.............................................670 LOAD LIGHTS.....................................................670 WIRING AND TERMINATION..........................................671 TCI OUTPUTS.....................................................671 OPERATOR'S DISPLAY AND SWITCH.......................................672 READING THE SPEEDOMETER.........................................672 READING THE LOAD DISPLAY........................................672 USING THE OPERATOR ID...........................................672 USING THE LOAD AND TON COUNTER..................................672 TOTAL TON COUNTER...........................................664 TOTAL LOAD COUNTER..........................................673 CLEARING THE COUNTERS.......................................673 VIEWING LIVE SENSOR DATA........................................673 OTHER DISPLAY MESSAGES..........................................673 PAYLOAD OPERATION AND CALCULATION...................................674 DESCRIPTION OF HAUL CYCLE STATES................................674 STAGES OF A TYPICAL HAUL CYCLE..............................674 HAUL CYCLE DESCRIPTION......................................674 LOAD CALCULATION................................................675 CARRY BACK......................................................675 MEASUREMENT ACCURACY............................................675 SOURCES FOR PAYLOAD ERROR.......................................675 PAYLOAD ERROR...............................................675 LOADING CONDITIONS..........................................676 PRESSURE SENSORS............................................676 SWINGLOADS..................................................676 SPEED AND DISTANCE..........................................676 HAUL CYCLE DATA.....................................................677 HAUL CYCLE DATA.................................................677 HAUL CYCLE WARNING FLAGS........................................678 ALARM RECORDS...................................................679 FRAME TORQUE DATA...............................................679 SPRUNG WEIGHT DATA..............................................680 MAXIMUM SPEED DATA..............................................680 PC SOFTWARE OVERVIEW................................................680 PC OVERVIEW.....................................................680 SYSTEM CONFIGURATION............................................680 INSTALLING THE PAYLOAD METER III SOFTWARE.......................680 DOWNLOADING DATA....................................................681 PLM III SYSTEM CONFIGURATION........................................682 STARTING COMMUNICATIONS.........................................682 DISPLAYED PAYLOAD UNITS.....................................682 TIME UNITS..................................................682 CONNECTION MENU.................................................682 CONNECTING TO THE PAYLOAD METER.................................683 CONFIGURE THE PAYLOAD METER.....................................683 SETTING THE DATE AND TIME...................................683 SETTING THE TRUCK TYPE......................................684 SETTING THE GAUGE DISPLAY UNITS.............................684 SETTING THE FRAME SERIAL NUMBER.............................684 SETTING THE TRUCK NUMBER....................................684 SETTING THE KOMATSU DISTRIBUTOR.............................684 SETTING THE KOMATUS CUSTOMER................................684 CLEAN TRUCK TARE................................................685 INCLINOMETER CALIBRATION........................................685 DATA ANALYSIS.......................................................686 CREATING A QUERY................................................686 SORTING ON TRUCK UNIT NUMBER................................686 SORTING ON TRUCK TYPE.......................................686 SORTING ON DATE RANGE.......................................687 SORTING ON TIME RANGE.......................................687 PAYLOAD DETAIL SCREEN...........................................688 CREATING REPORTS................................................688 SUMMARY - ONE PAGE REPORT...................................689 DETAILED - MULTI PAGE REPORT................................689 CREATING GRAPHS.................................................690 EXPORTING DATA..................................................690 CSV EXPORT..................................................690 COMPRESSED..................................................691 IMPORTING DATA..................................................692 DELETING HAUL CYCLE RECORDS.....................................692 VIEWING ALARMS..................................................693 DELETING HAUL CYCLE RECORDS.....................................693 VIEWING ALARMS..................................................693 DELETING ALARM RECORDS..........................................693 TROUBLESHOOTING SECTION.............................................694 TROUBLESHOOTING.................................................694 VIEWING ACTIVE ALARMS...........................................694 REAL-TIME DATA DISPLAY..........................................694 TESTING THE PAYLOAD LIGHTS......................................694 CREATING LOG FILES OF INPUTS....................................695 DAILY INSPECTIONS...............................................695 PERIODIC MAINTENANCE............................................695 ABNORMAL DISPLAYS AT POWER-UP...................................696 NO PAYLOAD DISPLAY WHEN KEYSWITCH IS TURNED ON..................697 NO DISPLAY ON SPEEDOMETER.......................................698 NO DISPLAY ON OPERATOR DISPLAY..................................698 NO COMMUNICATIONS WITH PC.......................................699 LOAD LIGHTS DON'T LIGHT DURING LOADING..........................700 LOAD LIGHTS REMAIN ON...........................................701 LOAD LIGHTS REMAIN ON DURING DUMPING............................701 DISPLAY DOESN'T CLEAR WHEN THE LOAD IS DUMPED..................701 CALIBRATION PROBLEMS............................................702 ALARM 1 - LEFT FRONT PRESSURE HIGH..............................703 ALARM 2 - LEFT FRONT PRESSURE LOW...............................703 TROUBLESHOOT WIRING TO LEFT FRONT SUSPENSION....................703 ALARM 3 - RIGHT FRONT PRESSURE HIGH.............................704 ALARM 4 - RIGHT FRONT PRESSURE LOW..............................704 TROUBLESHOOT WIRING TO RIGHT FRONT SUSPENSION...................704 ALARM 5 - LEFT REAR PRESSURE HIGH...............................705 ALARM 6 - LEFT REAR PRESSURE LOW................................705 TROUBLESHOOT WIRING TO LEFT REAR SUSPENSION.....................705 ALARM 7 - RIGHT REAR PRESSURE HIGH..............................706 ALARM 8 - RIGHT REAR PRESSURE LOW...............................706 TROUBLESHOOT WIRING TO RIGHT REAR SUSPENSION....................706 ALARM 9 - INCLINOMETER HIGH.....................................707 ALARM 10 - INCLINOMETER LOW.....................................707 TROUBLESHOOTING INCLINOMETER WIRING.............................707 ALARM 13 - BODY UP INPUT FAILURE................................708 ALARM 15 - MEMORY WRITE FAILURE.................................709 ALARM 16 - MEMORY READ FAILURE..................................709 ALARM 24 - SYSTEM KEY-ON STATUS.................................709 OPERATOR SWITCH DOESN'T WORK....................................710 ALARM 26 - USER SWITCH FAULT - SELECT...........................710 ALARM 27 - USER SWITCH FAULT - SET..............................710 CONNECTOR MAP...................................................711 CONNECTORS......................................................712 CHECKOUT PROCEDURE SECTION..........................................714 PLM III CHECKOUT PROCEDURE......................................714 GENERAL DESCRIPTION.........................................714 TOOLS REQUIRED..............................................714 CHECKOUT PROCEDURE..........................................714 PLM III CHECKOUT PROCEDURE CONFIRMATION.........................718 1.1 FLASHBURN PROGRAMMING - GENERAL INSTRUCTIONS............718 CONFIRMATION CHECKLIST......................................720 COMPONENTS AND SCHEMATICS SECTION...................................721 PAYLOAD METER III COMPONENTS....................................721 PRESSURE SENSOR.............................................721 CONTROLLER..................................................721 SPEEDOMETER.................................................721 PAYLOAD METER III - SCHEMATICS..................................814 ELECTRICAL SCHEMATIC FOR 730E...............................814 N. OPERATOR'S CAB...........................................................722 TRUCK CAB...............................................................724 DESCRIPTION.........................................................724 REMOVAL.........................................................725 INSTALLATION....................................................726 CAB DOOR............................................................727 REMOVAL.........................................................727 INSTALLATION....................................................727 DOOR ADJUSTMENT.................................................727 DOOR GLASS REPLACEMENT..........................................730 DOOR HANDLE OR LATCH REPLACEMENT................................734 DOOR AND DOOR HINGE SEAL REPLACEMENT............................735 GLASS REPLACEMENT...................................................736 ADHESIVE BONDED WINDOWS.........................................736 WINDSHIELD AND REAR GLASS REPLACEMENT...........................736 CAB COMPONENTS.......................................................... 0 WINDSHIELD WIPER....................................................740 WINDSHIELD WASHER...................................................742 OPERATOR COMFORT........................................................744 OPERATOR SEAT.......................................................744 ADJUSTMENT......................................................744 REMOVAL.........................................................744 INSTALLATION....................................................744 HEATER / AIR CONDITIONER................................................745 OPERATION...........................................................745 HEATER COMPONENTS.......................................................746 CIRCUIT BREAKERS....................................................746 HEATER CONTROL COMPONENTS...........................................746 HEATER CORE.........................................................747 FAN MOTOR AND SPEED CONTROL.........................................747 ACTUATORS...........................................................747 FILTER..............................................................747 OPERATOR CONTROLS.......................................................750 STEERING COLUMN.....................................................751 REMOVAL.........................................................751 INSTALLATION....................................................751 PEDAL CONTROLS......................................................753 SERVICE BRAKE PEDAL.............................................753 DUAL FUNCTION / SINGLE BRAKE PEDAL..............................753 DYNAMIC RETARDING PEDAL.........................................753 THROTTLE PEDAL..................................................753 CONSOLE CONTROLS........................................................754 INSTRUMENT PANEL........................................................757 INDICATOR LIGHTS........................................................761 CENTRY FUEL SYSTEM......................................................767 DIAGNOSTICS.........................................................767 DETERMINING FAULT CODES.............................................768 P. LUBRICATION AND SERVICE..................................................770 LUBRICATION AND SERVICE.................................................772 SERVICE CAPACITIES..................................................772 HYDRAULIC TANK SERVICE..............................................772 HYDRAULIC TANK SERVICE (FILLING INSTRUCTIONS)....................... 0 COOLANT LEVEL CHECK.................................................773 RADIATOR FILLING PROCEDURE..........................................773 COOLING SYSTEM RECOMMENDATIONS......................................773 LUBRICATION CHART...................................................774 10 HOURS........................................................775 50 HOURS........................................................777 100 HOURS.......................................................778 250 HOURS.......................................................779 500 HOURS.......................................................781 1000 HOURS......................................................782 5000 HOURS......................................................783 LINCOLN AUTOMATIC LUBRICATION SYSTEM....................................784 GENERAL DESCRIPTION.................................................784 SYSTEM COMPONENTS...................................................786 SYSTEM OPERATION....................................................787 GENERAL INSTRUCTIONS................................................790 SYSTEM PRIMING..................................................790 LUBRICANT PUMP..................................................790 FILTER AND RESERVOIR............................................791 INJECTORS.......................................................792 SYSTEM CHECK-OUT....................................................793 24 VDC SOLID STATE TIMER CHECK-OUT AND ADJUSTMENT...................793 PUMP REBUILD........................................................794 DISASSEMBLY.....................................................794 CLEANING AND INSPECTION.........................................794 ASSEMBLY........................................................796 PREVENTATIVE MAINTENANCE PROCEDURE..................................800 MOTORIZED WHEEL MAINTENANCE SCHEDULE....................................802 Q. ALPHABETICAL INDEX.......................................................806 R. SYSTEM SCHEMATICS........................................................810 HYDRAULIC BRAKE SYSTEM SCHEMATIC........................................812 HYDRAULIC SYSTEM SCHEMATIC (HUSCO VALVE)................................813 ELECTRICAL SCHEMATIC....................................................814
PLEASE NOTE:
⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
