Komatsu 730E Dump Truck Shop Manual – CEBM018000 Complete Service & Repair PDF

Description

Komatsu 730E Dump Truck Shop Manual – CEBM018000

This is the full Komatsu 730E Dump Truck Shop Manual with document number CEBM018000, covering serial numbers A30427 & UP. The manual is written for the service technician and is designed to help personnel become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently. Every major serviceable component has its own dedicated section, with disassembly, service, and reassembly procedures provided in full detail.

The 730E is an electric drive, off-highway rear dump truck with a gross vehicle weight of 324,322 kg (715,000 lbs) and a nominal payload of 185 t (203 tons). It is powered by the Komatsu SSA16V159 engine rated at 2000 HP (1492 kW), driving a General Electric GTA-22 alternator and two General Electric 788 wheel motors. All procedures, specifications, torque values, and safety notices in this manual apply directly to that machine.

File Details

• Manual Type: Shop Manual (Service & Repair)
• Brand: Komatsu
• Model: 730E Dump Truck
• Document Number: CEBM018000
• Serial Numbers Covered: A30427 & UP
• Language: English
• File Format: PDF
• Page Count: 1102 pages

Chapters Covered

This Komatsu 730E Shop Manual is organised into the following major sections:

• Section A – General Information: Major components and specifications, general safety and operation, warnings and cautions, standard torque charts and conversion tables, storage procedures.
• Section B – Structures: Structural components (ladders, grille and hood, right-hand deck, center deck, left-hand deck), dump body, fuel tank (removal, repair, cleaning, installation, fuel gauge sender, low fuel sender, tank breather valve).
• Section C – Engine, Fuel, Cooling and Air Cleaner: Power module (general information, removal, installation), cooling system (radiator removal, service, installation, fill procedure, repair, pressure testing, coolant system troubleshooting), power train (alternator removal and installation, engine removal and installation), air cleaners (service checks, filter element replacement, main filter cleaning, precleaner section, air intake troubleshooting), fan drive clutch (general description, components, operation modes, maintenance, troubleshooting, disassembly, reassembly, inspection).
• Section D – Electric System (24 VDC, Non-Propulsion): 24VDC electric supply system (batteries, maintenance, troubleshooting, battery charging alternator, 24VDC electric start system, cranking motors, engine prelub system), 24VDC electrical system components (passenger seat base compartment, battery equalizer box, body-up switch, hoist limit switch, relay boards, diode board, circuit breakers), battery charging alternator (testing, regulator testing, bench testing, static testing, field coil tests, stator tests, thermal switch test, troubleshooting, repair), VHMS components, VHMS software, VHMS checkout and troubleshooting, VHMS forms, Payload Meter III (operation, component description, operator display and switch, payload operation and calculation, haul cycle data, PC software, downloading, troubleshooting, checkout procedure).
• Section E – Electric Propulsion and Control: Electrical propulsion components (general system description, control system, FL275 panel, card replacement, computer description, software, two-digit display panel, portable test unit, configuration files, programming the truck, statistical data, electrical control cabinet, abbreviations, card identification), Statex III electrical system checkout procedure (communications port check, sequence tests, control system self-test, throttle system check and adjustment, retard system check and adjustment, reverser and propulsion contactors check, retard contactors operation check, ground fault sensing check, ground fault in retard operation check, override operation check, anti-reversal function check, overspeed retard operation check, hoist interlock operation check, motor blower fault light operation check, digital input/output signals test, analog input signals test, speed event checks, retard speed control system check, load test using truck retard grids, motor field current check in retarding, miscellaneous component test and adjustment, miscellaneous charts).
• Section G – Drive Axle, Spindle, and Wheels: Tires and rims (general information, handling tires, tire maintenance, storing tires, front tires and rims, rear tires and rims, rim, tire removal, rim and tire preparation, lubricants, tire installation), front wheel hub and spindle (removal, installation, disassembly, cleaning and inspection, assembly, wheel bearing adjustment, steering cylinders and tie rod, spherical bearing wear limits, toe-in adjustment), rear axle housing attachment (pivot pin, pivot eye bearing, pivot eye repair, anti-sway bar), rear axle housing (removal, installation, wheel motor removal and installation, bumper pad).
• Section H – Suspensions: Front suspension (removal, installation, turn-of-the-nut tightening procedure, disassembly, cleaning and inspection, assembly, suspension pressure test), rear suspensions (removal, installation, disassembly, cleaning and inspection, assembly, suspension pressure test), oiling and charging procedures (general, equipment list, Hydrair charging kit, front suspension oiling and nitrogen charging, rear suspension oiling and nitrogen charging, oil and nitrogen specifications).
• Section J – Brake Circuit: Brake circuit (general description, service brake circuit, secondary braking and automatic apply, parking brake circuit, brake lock circuit, warning circuit), brake circuit component service (brake valve, rebuild criteria, removal, installation, disassembly, cleaning and inspection, assembly, differential pressure switch, valve bench test and adjustment, hydraulic brake accumulators, brake accumulator charging, accumulator storage), brake circuit check-out procedure (equipment required, initial system set-up, parking brake, service brakes, brake lock/secondary, low brake pressure and auto apply, reapplications, differential pressure switch, troubleshooting, check-out procedure, hydraulic brake system data sheet), Rockwell wheel speed front disc brakes (brake caliper removal, installation, disassembly, cleaning and inspection, assembly, brake lining replacement, front service brake burnishing, brake bleeding procedure), Rockwell armature speed rear disc brakes (caliper, disc, and parking brake removal and installation, caliper piston, functional test of piston assembly, brake lining replacement, service brake burnishing, brake bleeding procedure), Rockwell disc parking brake (general information, lining thickness inspection, removal, installation, adjustment, disassembly, cleaning and inspection, assembly, lining replacement, burnishing procedure, brake bleeding procedure).
• Section L – Hydraulic System: Hydraulic system (general information, hoist circuit operation, steering circuit operation), hydraulic component repair (hoist pump removal, installation, disassembly, inspection, assembly, troubleshooting; hydraulic tank filling, removal, installation, strainer and diffuser), steering circuit (operation, component description, steering control valve, unloader valve, bleed-down manifold valve, flow amplifier, flow amplifier system operation, steering pump, high pressure filter, accumulators, low precharge warning switch), steering control unit (general information, removal, installation, rebuild, disassembly, cleaning and inspection, assembly, steering/brake pump removal, installation, disassembly, inspection, assembly), steering circuit component repair (bleed-down manifold, accumulator, flow amplifier, steering cylinders, troubleshooting chart), hoist circuit (operation, component description, hydraulic tank, hydraulic pump, high pressure filter, hoist valve, hoist pilot valve, bleed-down manifold, counterbalance manifold, hoist-up limit solenoid, pilot operated check valve, hoist valve operation, float operation, power up operation, hold operation, power down operation), hoist circuit component repair (hoist valve, inlet section, rear spool section, hoist pilot valve, hoist up limit solenoid valve, hoist cylinders, counterbalance manifold), hydraulic system filters (hoist circuit filter, steering circuit filter, indicator switch), hydraulic check-out procedure (initial start up and flushing, component checkout and adjustment, adjustment procedure for hoist counterbalance cartridge valve, oil cleanliness check, disabled truck dumping procedure).
• Section M – Options and Special Tools: Engine oil heaters (general information, troubleshooting, heater element removal and installation), special tool group (accumulator charging valve, roll-out assembly, offset wrench, torque adapter, handle, seal installer, sleeve alignment tools, harness, quick disconnect coupling, sockets and adapters, eye bolt, accumulator wrench, miscellaneous tools, pusher tools, front spindle removal).
• Section N – Operator’s Cab: Truck cab (description, removal, installation, cab door removal, installation, adjustment, door jam bolt adjustment, door handle plunger adjustment, replace door glass, replace door window regulator, replace door handle or latch assembly, door and door hinge seal replacement, door opening seal removal, installation, glass replacement, adhesive-bonded windows, windshield and rear glass removal and installation), cab components (windshield wipers, wiper motor replacement, wiper arm replacement, wiper linkage replacement, windshield washer operation and service), operator comfort (heater/air conditioner controls, components, air conditioning system, principles of refrigeration, air conditioner system components, electrical circuit, thermostat, compressor clutch, Trinary switch, system servicing, service tools and equipment, system performance test, system oil, refrigerant, system leak testing, recovering and recycling the refrigerant, system repair, component replacement, evacuating the system, charging the A/C system, air conditioner drive belt, pulley alignment, belt tension, troubleshooting, preventative maintenance schedule), operator controls and equipment (steering wheel and controls, steering wheel, horn button, tilt/telescope lever, multi-function turn signal switch, steering column removal, inspection, installation, pedals, service brake pedal, dynamic retarder pedal, throttle pedal, overhead panel controls and components, grade/speed warning chart, radio speakers, warning alarm buzzer, cab radio, warning lights dimmer control, warning/status indicator light panel, air cleaner vacuum gauges, windshield wipers, center console, truck controls, F-N-R selector switch, hoist control lever, console switches and controls, payload meter, cab climate control, heater/air conditioner vents, operator seat adjustment, instrument panel, control symbols, control switches and gauges, overhead status/warning indicator light panel, Centry fuel system diagnostics, Vehicle Health Monitoring System).
• Section P – Lubrication and Service: Lubrication and service (general information, hydraulic tank service, cooling system, 10 hour lube and maintenance checks, 50 hour, 100 hour, 250 hour, 500 hour, 1000 hour, 1500 hour, 2500 hour, 5000 hour, 10,000 hour lubrication and maintenance checks), automatic lubrication system (general description, system components, filter assembly, hydraulic motor and grease pump, reservoir, fixed pressure reducing valve, flow control valve, solenoid valve, vent valve, 24VDC lubrication cycle timer, time delay module, pump cutoff pressure switch, unloader valve, pressure switch, pressure gauge, manual override button, injectors, system operation, pressure failure detection circuits, general instructions, lubricant required, system priming, lubricant pump, filter and reservoir, injectors, system checkout, lubrication cycle timer check and adjustment, preventive maintenance inspection, pump rebuild, vent valve rebuild, troubleshooting chart), motorized wheel maintenance schedule (axle box, armature area, at tire change, generator/alternator, grid blower motor, control equipment checks, auxiliary equipment and air ventilation system, vehicle operations tests).
• Section R – System Schematics: Hydraulic brake system schematic, hydraulic system schematic, electrical schematic (33 sheets covering power distribution, retarding grids, drive system control circuits, two-digit display, G.E. analog inputs, G.E. digital inputs and lube control, rear tail lights and dimmer control, 5 minute timer and spares, windows, radio, gauges, contactor feedback, contactor coil, machine control circuits, accelerator and retard pedals, hydraulic controls and alarms, heater/AC and windshield wiper controls, light control circuits, instruments and diagnostic ports, modular mining dispatch, Cummins K2000 engine, Payload Meter III installation, Cummins QSK engine with HVP prelube, wiper turn signal, wiper washer turn signal, heater/AC controls, power retarding), VHMS system schematic (5 sheets).

This Komatsu 730E Dump Truck Shop Manual is not a general overview. It is a complete service and repair reference covering every major system on the truck — from the engine and cooling system through the electric propulsion and control system, the hydraulic system, brakes, suspensions, drive axle, and operator’s cab. Each section provides step-by-step removal, disassembly, inspection, assembly, and installation instructions, along with specifications, torque values, wear limits, and troubleshooting guidance. The electrical schematics section alone spans 33 sheets, giving a technician the wiring detail needed to trace circuits, diagnose faults, and repair the electrical system correctly.

What This Manual Enables You to Do

With the Komatsu 730E Shop Manual CEBM018000 in hand, a service technician can perform the full range of repairs and maintenance on the 730E dump truck. That includes engine removal and installation, cooling system service, alternator and wheel motor service, hydraulic pump and valve repair, brake caliper and disc service, suspension removal and charging, hoist cylinder repair, steering system diagnosis, and complete electrical troubleshooting through the Statex III control system. The manual also covers the Vehicle Health Monitoring System (VHMS), Payload Meter III, and the automatic lubrication system — all critical to keeping the truck productive and reliable.

Correct procedures and specifications matter on a machine this size. Using the wrong torque value, missing a wear limit, or skipping a critical adjustment can lead to component failure, downtime, or unsafe operation. This manual provides the exact figures and sequences the manufacturer specifies, so the work is done right the first time.

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Instant PDF Delivery — No Shipping, No Waiting

This Komatsu 730E Dump Truck Shop Manual is delivered as an instant PDF download after payment. There is no physical book to ship, no waiting for delivery, and no risk of a damaged or lost manual. You can access the file immediately on any device — laptop, tablet, or smartphone — and print the pages you need for the shop floor. Keep it on a USB drive, store it on a shop computer, or print a complete bound copy for the service truck. The PDF format means you can zoom in on detailed illustrations, wiring diagrams, and exploded views for a closer look at every component.