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KOMATSU 730E Shop Manual DUMP TRUCK with TROLLEY ASSIST SL NO A30197 – A30200 -PDF DOWNLOAD
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KOMATSU 730E Shop Manual DUMP TRUCK with TROLLEY ASSIST
SL NO:A30197 – A30200
Pub Num:CEBM008501
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Description
KOMATSU 730E Shop Manual DUMP TRUCK with TROLLEY ASSIST SL NOA30197 – A30200
KOMATSU 730E SHOP MANUAL DUMP TRUCK WITH TROLLEY ASSIST SL NO A30197 – A30200 -PDF DOWNLOAD:
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TABLE OF CONTENTS:
KOMATSU 730E Shop Manual DUMP TRUCK with TROLLEY ASSIST SL NOA30197 – A30200
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................................................... 44 CHARTS AND TABLES....................................................... 52 STORAGE PROCEDURES...................................................... 58 B. STRUCTURES............................................................... 78 STRUCTURAL COMPONENTS................................................... 80 GRILLE AND HOOD..................................................... 80 LADDERS............................................................. 81 DECKS............................................................... 81 RIGHT DECK AND COMPONENTS....................................... 81 LEFT DECK....................................................... 81 DUMP BODY............................................................... 84 INSTALLATION........................................................ 84 REMOVAL............................................................. 84 BODY PADS........................................................... 85 BODY GUIDE.......................................................... 86 BODY SLING.......................................................... 86 BODY POSITION INDICATOR............................................. 86 ROCK EJECTORS....................................................... 87 HOIST LIMIT SWITCHES................................................ 87 FUEL TANK............................................................... 88 REMOVAL............................................................. 88 INSTALLATION........................................................ 89 CLEANING............................................................ 89 VENT................................................................ 89 FUEL GAUGE SENDER................................................... 89 C. ENGINE, FUEL, COOLING, AND AIR CLEANER................................... 90 POWER MODULE............................................................ 92 REMOVAL............................................................. 92 INSTALLATION........................................................ 96 COOLING SYSTEM.......................................................... 98 RADIATOR............................................................ 98 REMOVAL......................................................... 98 SERVICE......................................................... 99 INSTALLATION.................................................... 99 RADIATOR FILL PROCEDURE.........................................100 COOLING SYSTEM TROUBLESHOOTING..................................101 POWER TRAIN.............................................................102 ALTERNATOR REMOVAL AND INSTALLATION PROCEDURE.......................102 REMOVAL.........................................................102 ENGINE / ALTERNATOR MATING..........................................104 ALTERNATOR MEASUREMENT..........................................104 ENGINE END PLAY MEASUREMENT.....................................105 DETERMINING SHIM REQUIREMENTS...................................105 INSTALLATION....................................................106 ENGINE..............................................................108 REMOVAL.........................................................108 INSTALLATION....................................................108 AIR CLEANERS............................................................110 FILTER ELEMENT REPLACEMENT..........................................110 MAIN FILTER ELEMENT CLEANING........................................112 PRECLEANER SECTION..................................................113 D. ELECTRIC SYSTEM (24 VDC, NON-PROPULSION..................................116 24 VDC ELECTRIC SUPPLY SYSTEM...........................................118 ELECTRICAL SYSTEM DESCRIPTION.......................................118 BATTERY - MAINTENANCE AND SERVICE...................................118 ELECTRIC START SYSTEM...............................................120 OPERATION.......................................................120 REMOVAL.....................................................120 INSTALLATION................................................120 CRANKING MOTOR TROUBLESHOOTING..................................121 DISASSEMBLY.....................................................122 SOLENOID CHECKS.................................................125 ASSEMBLY........................................................126 ENGINE PRELUB STARTER SYSTEM........................................130 OPERATION.......................................................130 TROUBLESHOOTING.................................................132 24 VDC ELECTRICAL SYSTEM COMPONENTS.....................................134 PASSENGER SEAT BASE COMPARTMENT.....................................134 TAIL LIGHT RESISTOR DIODE ASSEMBLIES............................134 5 MINUTE IDLE TIMER COMPONENTS..................................134 ALARM INDICATING DEVICE (A.I.D. SYSTEM..........................136 BODY UP SWITCH......................................................138 HOIST LIMIT SWITCH..................................................139 GROUND LEVEL SHUTDOWN...............................................140 24 VDC RELAY AND DIODE BOARDS.......................................141 DESCRIPTION.....................................................142 RELAY BOARD 1 (TURN SIGNAL).....................................144 RELAY BOARD 2 (PAYLOAD METER)...................................144 RELAY BOARD 3 (STOP LIGHTS).....................................144 RELAY BOARD 4 (PARKING BRAKE)...................................144 RELAY BOARD 5 (HEADLIGHTS)......................................145 RELAY BOARD 6 (AUXILIARY PANEL).................................145 DIODE BOARD 1...................................................146 CIRCUIT BREAKER CHART...........................................147 E. ELECTRIC PROPULSION AND CONTROL..........................................148 ELECTRICAL PROPULSION COMPONENTS........................................150 GENERAL SYSTEM DESCRIPTION..........................................150 CONTROL SYSTEM......................................................150 FL275 PANEL.........................................................152 COMPUTER DESCRIPTION............................................154 SOFTWARE........................................................154 2-DIGIT DISPLAY PANEL...............................................157 EVENTS..........................................................157 FRAMES..........................................................158 WINDOWS.........................................................158 EVENT CODE DESCRIPTIONS (TABLE I)...........................160 SUBCODE DESCRIPTIONS (TABLE II).............................167 PORTABLE TEST UNIT (PTU)............................................170 DESCRIPTION.....................................................170 SOFTWARE INSTALLATION PREPARATION...............................171 THE MAIN MENU...............................................173 PTU SOFTWARE MENU TREE......................................174 CONFIGURATION (CFG) FILE CONVERSION.........................175 STATEX CONFIGURATION FILES......................................179 PROGRAMMING THE TRUCK...........................................190 PTU HOOKUP..................................................190 DOWNLOAD CONFIGURATION FILES................................192 EVENT DATA......................................................194 STATISTICAL DATA................................................196 STATISTICAL DATA CODES - COUNTERS (TABLE III)...............198 STATISTICAL DATA CODES - PROFILES (TABLE IV)................203 TRUCK SPECIFIC INFORMATION......................................207 TEMPORARY TRUCK SETTINGS........................................208 MISCELLANEOUS SOFTWARE FEATURES.................................209 SAVING DATA.................................................209 PTU ABBREVIATIONS...........................................210 MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS..........................211 ALTERNATOR..........................................................211 ELECTRIC WHEEL MOTORS...............................................211 RETARDING GRIDS.....................................................211 ELECTRONIC ACCELERATOR AND RETARD CONTROL...........................211 COOLING BLOWER WARNING SYSTEM.......................................213 ELECTRICAL CONTROL CABINET..........................................214 STATEX III ELECTRIC DRIVE COMPONENTS ABBREVIATIONS..................219 ELECTRICAL CHECKOUT PROCEDURE...........................................222 G. DRIVE AXLE, SPINDLES AND WHEELS..........................................274 TIRES AND RIMS (G02012).................................................276 FRONT TIRES AND RIMS................................................277 REMOVAL.........................................................277 INSTALLATION....................................................278 REAR TIRES AND RIMS.................................................278 REMOVAL.........................................................278 INSTALLATION....................................................279 RIM.................................................................280 TIRE REMOVAL....................................................280 TIRE INSTALLATION...............................................281 FRONT WHEEL HUB AND SPINDLE ASSEMBLY (G03012)...........................282 WHEEL HUB AND SPINDLE ASSEMBLY......................................282 REMOVAL.........................................................282 INSTALLATION....................................................284 DISASSEMBLY.....................................................284 CLEANING AND INSPECTION.........................................285 ASSEMBLY........................................................285 WHEEL BEARING ADJUSTMENT (TIRE REMOVED).........................287 WHEEL BEARING ADJUSTMENT (TIRE MOUNTED).........................288 STEERING CYLINDERS AND TIE ROD......................................290 REMOVAL.........................................................290 INSTALLATION....................................................290 BEARING REPLACEMENT.............................................290 TOE-IN ADJUSTMENT...................................................292 REAR AXLE HOUSING ATTACHMENT (G04010)...................................294 PIVOT PIN...........................................................294 REMOVAL.........................................................294 INSTALLATION....................................................294 DISASSEMBLY.....................................................295 ASSEMBLY........................................................295 ANTI-SWAY BAR.......................................................297 REMOVAL.........................................................297 INSTALLATION....................................................297 DISASSEMBLY.....................................................297 CLEANING AND INSPECTION.........................................297 ASSEMBLY........................................................297 REAR AXLE HOUSING (G05004)..............................................298 REAR AXLE HOUSING...................................................298 REMOVAL.........................................................298 INSTALLATION....................................................298 WHEEL MOTOR.........................................................298 REMOVAL.........................................................298 CLEANING AND INSPECTION.........................................299 INSTALLATION....................................................299 H. HYDRAIR II SUSPENSIONS...................................................300 FRONT SUSPENSION........................................................302 REMOVAL.............................................................302 INSTALLATION........................................................303 DISASSEMBLY.....................................................306 ASSEMBLY (BEARING RETAINER ONLY)................................307 ASSEMBLY (COMPLETE).............................................308 SUSPENSION PRESSURE TEST............................................309 REAR SUSPENSION.........................................................310 REMOVAL.............................................................310 INSTALLATION........................................................312 DISASSEMBLY.....................................................313 ASSEMBLY........................................................313 SUSPENSION PRESSURE TEST............................................315 OILING AND CHARGING PROCEDURES.......................................... 0 GENERAL............................................................. 0 EQUIPMENT LIST...................................................... 0 FRONT SUSPENSION.................................................... 0 FRONT SUSPENSION OILING......................................... 0 FRONT SUSPENSION NITROGEN CHARGING.............................. 0 REAR SUSPENSION..................................................... 0 REAR SUSPENSION OILING.......................................... 0 REAR SUSPENSION NITROGEN CHARGING............................... 0 OIL AND NITROGEN SPECIFICATIONS......................................... 0 J. BRAKE CIRCUIT............................................................324 BRAKE CIRCUIT...........................................................326 SERVICE BRAKE CIRCUIT OPERATION.....................................326 SECONDARY BRAKING AND AUTOMATIC APPLY...............................328 PARKING BRAKE CIRCUIT...............................................328 BRAKE LOCK CIRCUIT..................................................329 WARNING CIRCUIT.....................................................329 BRAKE VALVE CUT-AWAY................................................330 BRAKE CIRCUIT COMPONENT SERVICE.........................................332 BRAKE VALVE.........................................................332 REMOVAL.........................................................332 INSTALLATION....................................................334 DISASSEMBLY.....................................................336 CLEANING AND INSPECTION.........................................338 ASSEMBLY........................................................338 BENCH TEST AND ADJUSTMENT.......................................342 INSTALLATION OF BRAKE PEDAL ACTUATOR ASSEMBLY TO BRAKE VALVE....346 INSTALLATION OF RETARD PEDAL (IF EQUIPPED) TO BRAKE VALVE.......348 HYDRAULIC BRAKE ACCUMULATORS........................................349 REMOVAL.........................................................349 INSTALLATION....................................................349 DISASSEMBLY.....................................................349 CLEANING AND INSPECTION.........................................351 ASSEMBLY........................................................351 CHARGING PROCEDURE..............................................352 BRAKE CIRCUIT CHECKOUT PROCEDURE........................................354 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING...........................360 HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDURE DATA SHEET...................364 FRONT BRAKES (ROCKWELL).................................................366 BRAKE CALIPER.......................................................366 BRAKE LINING........................................................370 BRAKE PAD CONDITIONING (BURNISHING) PROCEDURE.......................371 TEMPORARY BRAKE DISCONNECT (DISABLE) PROCEDURE......................371 BRAKE BLEEDING PROCEDURE............................................373 REAR BRAKES (ROCKWELL)..................................................374 BRAKE CALIPER, DISC AND PARKING BRAKE...............................374 CALIPER PISTON ASSEMBLY.............................................379 BENCH TEST..........................................................385 BRAKE LINING........................................................386 BRAKE PAD CONDITIONING (BURNISHNG) PROCEDURE........................389 BRAKE BLEEDING PROCEDURE............................................391 PARKING BRAKE (ROCKWELL)................................................392 PARK BRAKE CALIPER..................................................392 REMOVAL.........................................................392 INSTALLATION....................................................393 PARKING BRAKE ADJUSTMENT .......................................393 PARKING BRAKE ADJUSTMENT................................................393 PARK BRAKE CALIPER DISASSEMBLY......................................395 CLEANING AN INSPECTION..............................................395 PARK BRAKE CALIPER ASSEMBLY.........................................396 PARK BRAKE LINING.......................................................397 REPLACEMENT......................................................... 0 CONDITIONING (BURNISHING PROCEDURE)................................. 0 BRAKE BLEEDING PROCEDURE................................................ 0 L. HYDRAULIC SYSTEM.........................................................398 HYDRAULIC SYSTEM........................................................402 HOIST CIRCUIT OPERATION.............................................402 STEERING CIRCUIT OPERATION..........................................403 AXLE BLOWER OPERATION...............................................405 HYDRAULIC COMPONENT REPAIR..............................................408 HOIST PUMP..........................................................408 REMOVAL.........................................................408 INSTALLATION....................................................409 DISASSEMBLY.....................................................410 INSPECTION......................................................412 ASSEMBLY........................................................413 TROUBLESHOOTING GUIDE...........................................417 PISTON PUMP.............................................................418 REMOVAL.............................................................418 INSTALLATION........................................................418 DISASSEMBLY.........................................................420 INSPECTION..........................................................426 ASSEMBLY............................................................428 AXLE BLOWER HYDRAULIC MOTOR.............................................432 REMOVAL.............................................................432 INSTALLATION........................................................432 REAR AXLE BLOWER HOUSING............................................432 DISASSEMBLY.....................................................432 ASSEMBLY........................................................432 DISASSEMBLY.........................................................434 INSPECTION..........................................................436 ASSEMBLY............................................................437 TROUBLESHOOTING.....................................................438 HAND WHEEL CONTROL..................................................439 DISASSEMBLY.....................................................439 ASSEMBLY........................................................439 HYDRAULIC TANK..........................................................441 FILLING INSTRUCTIONS................................................441 REMOVAL.............................................................442 INSTALLATION........................................................442 STRAINER AND DIFFUSER...............................................442 STEERING CIRCUIT........................................................444 STEERING CIRCUIT OPERATION..........................................444 COMPONENT DESCRIPTION...............................................445 STEERING CONTROL VALVE..........................................445 UNLOADER VALVE..................................................445 BLEED DOWN MANIFOLD VALVE.......................................446 FLOW AMPLIFIER..................................................450 STEERING PUMP...................................................459 ACCUMULATORS....................................................459 STEERING CONTROL VALVE..............................................460 REMOVAL.........................................................460 INSTALLATION....................................................460 REBUILD PROCEDURE...............................................461 DISASSEMBLY.................................................461 CLEANING AND INSPECTION.....................................462 ASSEMBLY....................................................464 STEERING PUMP...................................................467 REMOVAL.....................................................467 INSTALLATION................................................467 DISASSEMBLY.................................................469 INSPECTION..................................................469 ASSEMBLY....................................................469 STEERING CIRCUIT COMPONENT REPAIR...................................472 BLEEDDOWN MANIFOLD VALVE........................................472 STEERING ACCUMULATORS...........................................473 STEERING ACCUMULATORS CHARGING PROCEDURE........................477 FLOW AMPLIFIER..................................................478 STEERING CYLINDERS..............................................482 HOIST CIRCUIT.......................................................484 HOIST CIRCUIT OPERATION.........................................484 COMPONENT DESCRIPTION...........................................485 HOIST CIRCUIT COMPONENT REPAIR......................................498 HOIST VALVE.....................................................498 HOIST PILOT VALVE...............................................506 HOIST-UP LIMIT SOLENOID VALVE...................................509 HOIST CYLINDERS.................................................509 HYDRAULIC SYSTEM FILTERS............................................518 HOIST CIRCUIT FILTER............................................518 STEERING CIRCUIT FILTER.........................................520 HYDRAULIC CHECKOUT PROCEDURES.......................................524 STEERING CIRCUIT TEST PROCEDURE.................................524 COMPONENT LEAKAGE TEST......................................526 TROUBLESHOOTING CHART.......................................528 CHECKING HOIST SYSTEM RELIEF VALVE PRESSURES....................531 POWER UP RELIEF PRESSURE TEST...............................531 POWER DOWN RELIEF PRESSURE TEST.............................532 HOIST COUNTERBALANCE VALVE ADJUSTMENT.......................533 DISABLED TRUCK DUMPING PROCEDURE................................534 HYDRAULIC SYSTEM FLUSHING PROCEDURE.............................535 HYDRAULIC SYSTEM TEST PROCEDURE.................................538 M. OPTIONS AND SPECIAL TOOLS................................................540 FIRE CONTROL SYSTEMS....................................................542 ANSUL FIRE CONTROL PNEUMATIC SYSTEM.................................542 ANSUL FIRE CONTROL ELECTRIC SYSTEM..................................548 ANSUL FIRE CONTROL SYSTEM MANUAL....................................558 OPERATION.......................................................558 INSPECTION AND MAINTENANCE......................................558 RECHARGING PROCEDURES...........................................559 ALTERNATOR AND WHEEL MOTOR COOLING AIR FILTER SYSTEM....................560 SYSTEM ADJUSTMENT...................................................560 PUMP................................................................560 BLOWER DRIVE MOTOR..................................................563 BLOWER BEARING REPAIR...............................................566 AIR CLEANER.........................................................567 WIGGINS QUICK FILL FUEL SYSTEM..........................................568 TANK BREATHER VALVE.................................................569 FUEL RECEIVER.......................................................568 FAN DRIVE CLUTCH - HYDRAULIC ACTUATED...................................572 GENERAL DESCRIPTION.................................................572 MAINTENANCE.........................................................575 TROUBLESHOOTING.....................................................577 FIELD CHECK DIAGNOSIS...............................................578 THERMAL SENSOR AND SOLENOID VALVE...............................579 TROUBLESHOOTING CHART...............................................582 DISASSEMBLY.........................................................586 REASSEMBLY..........................................................593 INSPECTION OF PARTS.................................................604 REBUILD TOOLS.......................................................608 ENGINE COOLANT HEATER SYSTEM - HOT START - 220 VOLT.....................610 HEATING ELEMENT.....................................................610 THERMOSTAT..........................................................611 ENGINE OIL HEATERS - HOT START - 220 VOLT...............................612 TROUBLESHOOTING.....................................................612 HEATING ELEMENT.....................................................612 ENGINE AND COOLANT HEATERS - 440 VOLT...................................614 TROUBLESHOOTING.....................................................615 COOLANT HEATING ELEMENT.............................................616 OIL HEATING ELEMENT.................................................617 SPECIAL TOOL GROUP......................................................620 HEATER / AIR CONDITIONING SYSTEM........................................ 0 ENVIRONMENTAL IMPACT................................................ 0 OPERATOR CAB CONDITIONING........................................... 0 PRINCIPLES OF REFRIGERATION......................................... 0 MAJOR SYSTEM COMPONENTS............................................. 0 SYSTEM SERVICING.................................................... 0 EVACUATING THE SYSTEM............................................... 0 SYSTEM TROUBLESHOOTING.............................................. 0 24 VDC ELECTRIC SUPPLY SYSTEM...........................................664 ELECTRICAL SYSTEM DESCRIPTION.......................................664 BATTERY - MAINTENANCE AND SERVICE...................................664 BATTERY CHARGING SYSTEM.............................................666 GENERAL DESCRIPTION.............................................666 TROUBLESHOOTING PROCEDURES......................................666 NIEHOFF 250 AMP ALTERNATOR OVERHAUL MANUAL..............................674 DIMENSIONS..........................................................675 SPECIFICATIONS......................................................676 SERVICE PARTS LIST..................................................677 EXPLODED VIEW.......................................................678 ON VEHICLE TEST.....................................................679 BENCH TEST..........................................................681 STATIC TESTS........................................................682 ALTERNATOR DISASSEMBLY..............................................685 ALTERNATOR ASSEMBLY.................................................690 SERVICE TOOL INSTRUCTIONS...........................................699 FUEL - WATER SEPARATOR..................................................702 INSTALLATION........................................................702 OPERATION...........................................................702 FILTER SERVICE......................................................703 PAYLOAD METER III.......................................................704 OPERATION SECTION...................................................707 INTRODUCTION........................................................707 DATA SUMMARY........................................................707 DATA GATHERING......................................................707 COMPONENT DESCRIPTION...............................................708 SYSTEM DIAGRAM..................................................708 SUSPENSION PRESSURE SENSORS.....................................708 INCLINOMETER....................................................708 OPERATOR DISPLAY................................................708 OPERATOR SWITCH.................................................709 SPEED INPUT.....................................................709 BODY - UP SWITCH................................................709 BRAKE LOCK SWITCH...............................................709 PAYLOAD METER...................................................709 COMMUNICATIONS PORT.............................................709 KEYSWITCH INPUT.................................................710 PAYLOAD METER POWER.............................................710 LOAD LIGHTS.....................................................710 WIRING AND TERMINATION..........................................711 TCI OUTPUTS.....................................................711 OPERATOR'S DISPLAY AND SWITCH.......................................712 READING THE SPEEDOMETER.........................................712 READING THE LOAD DISPLAY........................................712 USING THE OPERATOR ID...........................................712 USING THE LOAD AND TON COUNTER..................................712 TOTAL TON COUNTER...........................................712 TOTAL LOAD COUNTER..........................................713 CLEARING THE COUNTERS.......................................713 VIEWING LIVE SENSOR DATA........................................713 OTHER DISPLAY MESSAGES..........................................713 PAYLOAD OPERATION AND CALCULATION...................................714 DESCRIPTION OF HAUL CYCLE STATES................................714 STATES OF HAUL CYLCLE.......................................714 HAUL CYCLE DESCRIPTION......................................714 LOAD CALCULATION................................................715 CARRY BACK......................................................715 MEASUREMENT ACCURACY............................................715 SOURCES FOR PAYLOAD ERROR.......................................715 PAYLOAD ERROR...............................................715 LOADING CONDITIONS..........................................716 PRESSURE SENSORS............................................716 SWINGLOADS..................................................716 SPEED AND DISTANCE..........................................716 HAUL CYCLE DATA.....................................................717 HAUL CYCLE DATA.................................................717 HAUL CYCLE WARNING FLAGS........................................718 ALARM RECORDS...................................................719 FRAME TORQUE DATA...............................................719 SPRUNG WEIGHT DATA..............................................720 MAXIMUM SPEED DATA..............................................720 PC SOFTWARE OVERVIEW................................................720 PC OVERVIEW.....................................................720 SYSTEM CONFIGURATION............................................720 INSTALLING THE PAYLOAD METER III SOFTWARE.......................720 DOWNLOADING DATA....................................................721 PLM III SYSTEM CONFIGURATION........................................722 STARTING COMMUNICATIONS.........................................722 DISPLAYED PAYLOAD UNITS.....................................722 TIME UNITS..................................................722 CONNECTION MENU.................................................722 CONNECTING TO THE PAYLOAD METER.................................723 CONFIGURE THE PAYLOAD METER.....................................723 SETTING THE DATE AND TIME...................................723 SETTING THE TRUCK TYPE......................................724 SETTING THE GAUGE DISPLAY UNITS.............................724 SETTING THE FRAME SERIAL NUMBER.............................724 SETTING THE TRUCK NUMBER....................................724 SETTING THE KMS DISTRIBUTOR.................................724 SETTING THE KMS CUSTOMER....................................724 CLEAN TRUCK TARE................................................725 INCLINOMETER CALIBRATION........................................725 DATA ANALYSIS.......................................................726 CREATING A QUERY................................................726 SORTING ON TRUCK UNIT NUMBER................................726 SORTING ON TRUCK TYPE.......................................726 SORTING ON DATE RANGE.......................................727 SORTING ON TIME RANGE.......................................727 PAYLOAD DETAIL SCREEN...........................................728 CREATING REPORTS................................................728 SUMMARY - ONE PAGE REPORT...................................729 DETAILED - MULTI-PAGE REPORT................................729 CREATING GRAPHS.................................................730 EXPORTING DATA..................................................730 CSV EXPORT..................................................730 COMPRESSED..................................................731 IMPORTING DATA..................................................732 DELETING HAUL CYCLE RECORDS.....................................732 VIEWING ALARMS..................................................733 DELETING ALARM RECORDS..........................................733 TROUBLESHOOTING SECTION.............................................734 TROUBLESHOOTING.................................................734 VIEWING ACTIVE ALARMS...........................................734 REAL-TIME DATA DISPLAY..........................................734 TESTING THE PAYLOAD LIGHTS......................................734 CREATING LOG FILES OF INPUTS....................................735 DAILY INSPECTIONS...............................................735 PERIODIC MAINTENANCE............................................735 ABNORMAL DISPLAYS AT POWER UP...................................736 NO PAYLOAD DISPLAY WHEN KEYSWITCH IS ON.........................737 NO DISPLAY ON SPEEDOMETER.......................................738 NO DISPLAY ON OPERATOR DISPLAY..................................738 NO COMMUNICATIONS WITH PC.......................................739 LOAD LIGHTS DON'T LIGHT DURING LOADING..........................740 LOAD LIGHTS REMAIN ON...........................................741 LOAD LIGHTS REMAIN ON DURING DUMPING............................741 DISPLAY DOESN'T CLEAR WHEN THE LOAD IS DUMPED...................741 CALIBRATION PROBLEMS............................................742 ALARM 1 - LEFT FRONT PRESSURE HIGH..............................743 ALARM 2- LEFT FRONT PRESSURE LOW................................743 TROUBLESHOOT WIRING TO LEFT FRONT SUSPENSION....................743 ALARM 3 - RIGHT FRONT PRESSURE HIGH.............................744 ALARM 4 - RIGHT FRONT PRESSURE LOW..............................744 TROUBLESHOOT WIRING TO RIGHT FRONT SUSPENSION...................744 ALARM 5 - LEFT REAR PRESSURE HIGH...............................745 ALARM 6 - LEFT REAR PRESSURE LOW................................745 TROUBLESHOOT WIRING TO LEFT REAR SUSPENSION.....................745 ALARM 7 - RIGHT REAR PRESSURE HIGH..............................746 ALARM 8 - RIGHT REAR PRESSURE LOW...............................746 TROUBLESHOOT WIRING TO RIGHT REAR SUSPENSION....................746 ALARM 9 - INCLINOMETER HIGH.....................................747 ALARM 10 - INCLINOMETER LOW.....................................747 TROUBLESHOOTING INCLINOMETER WIRING.............................747 ALARM 13 - BODY UP INPUT FAILURE................................748 ALARM 15 - MEMORY WRITE FAILURE.................................749 ALARM 16 - MEMORY READ FAILURE..................................749 ALARM 24 - SYSTEM KEY-ON STATUS.................................749 OPERATOR SWITCH DOESN'T WORK....................................750 ALARM 26 - USER SWITCH FAULT - SELECT...........................750 ALARM 27 - USER SWITCH FAULT - SET..............................750 CONNECTOR MAP...................................................751 CONNECTORS......................................................752 CHECKOUT PROCEDURE SECTION..........................................754 PLM III CHECKOUT PROCEDURE......................................754 GENERAL DESCRIPTION.........................................754 TOOLS REQUIRED..............................................754 CHECKOUT PROCEDURE..........................................754 PLM III CHECKOUT PROCEDURE CONFIRMATION.........................758 1.1 FLASHBURN PROGRAMMING - GENERAL INSTRUCTIONS............758 CONFIRMATION CHECKLIST......................................760 COMPONENTS AND SCHEMATICS SECTION...................................761 PAYLOAD METER III - COMPONENTS..................................761 PRESSURE SENSOR.............................................761 CONTROLLER..................................................761 SPEEDOMETER.................................................761 PAYLOAD METER III - SCHEMATICS......................................704 ELECTRICAL HOOK - UP DRAWING FOR 730E, 830E, 930E...............880 ELECTRICAL SCHEMATIC FOR 730E AND 830E..........................881 N. OPERATOR'S CAB...........................................................762 TRUCK CAB...............................................................764 DESCRIPTION.........................................................764 REMOVAL.........................................................765 INSTALLATION....................................................766 CAB DOOR............................................................767 REMOVAL.........................................................767 INSTALLATION....................................................767 DOOR ADJUSTMENT.................................................767 DOOR GLASS REPLACEMENT..........................................770 DOOR HANDLE OR LATCH REPLACEMENT................................774 DOOR AND DOOR HINGE SEAL REPLACEMENT............................775 GLASS REPLACEMENT...................................................776 ADHESIVE BONDED WINDOWS.........................................776 WINDSHIELD AND REAR GLASS REPLACEMENT...........................777 CAB COMPONENTS..........................................................778 WINDSHIELD WIPER....................................................778 WINDSHIELD WASHER...................................................779 OPERATOR COMFORT........................................................780 OPERATOR SEAT.......................................................780 ADJUSTMENT......................................................780 REMOVAL.........................................................780 INSTALLATION....................................................780 HEATER / AIR CONDITIONER................................................781 OPERATION...........................................................781 HEATER COMPONENTS.......................................................782 CIRCUIT BREAKERS....................................................783 HEATER CONTROL COMPONENTS...........................................783 HEATER COIL.........................................................783 FAN MOTOR AND SPEED CONTROL.........................................784 ACTUATORS...........................................................784 FILTER..............................................................784 OPERATOR CONTROLS.......................................................786 STEERING COLUMN.....................................................786 REMOVAL.........................................................786 INSTALLATION....................................................786 PEDAL CONTROLS......................................................788 SERVICE BRAKE PEDAL.............................................788 DUAL FUNCTION / SINGLE BRAKE PEDAL..............................788 DYNAMIC RETARDING PEDAL.........................................788 THROTTLE PEDAL..................................................788 CONSOLE CONTROLS........................................................789 OVERHEAD CONTROLS, GAUGES...............................................792 INSTRUMENT PANEL........................................................793 INDICATOR LIGHTS........................................................797 CENTRY FUEL SYSTEM......................................................805 DIAGNOSTICS.........................................................805 DETERMINING FAULT CODES.............................................806 P. LUBRICATION AND SERVICE..................................................808 LUBRICATION AND SERVICE.................................................810 SERVICE CAPACITIES..................................................810 HYDRAULIC TANK SERVICE..............................................810 HYDRAULIC TANK SERVICE (FILLING INSTRUCTIONS).......................810 COOLANT LEVEL CHECK.................................................811 RADIATOR FILLING PROCEDURE..........................................811 COOLING SYSTEM RECOMMENDATIONS......................................811 LUBRICATION CHART...................................................812 10 HOURS........................................................813 50 HOURS........................................................815 100 HOURS.......................................................816 250 HOURS.......................................................817 500 HOURS.......................................................819 1000 HOURS......................................................820 5000 HOURS......................................................821 LINCOLN AUTOMATIC LUBRICATION SYSTEM....................................822 GENERAL DESCRIPTION.................................................822 SYSTEM COMPONENTS...................................................824 SYSTEM OPERATION....................................................827 GENERAL INSTRUCTIONS................................................828 SYSTEM PRIMING..................................................828 LUBRICANT PUMP..................................................828 FILTER AND RESERVOIR............................................829 INJECTORS.......................................................830 SYSTEM CHECK-OUT....................................................831 24 VDC SOLID STATE TIMER CHECK-OUT AND ADJUSTMENT...................831 PUMP REBUILD........................................................832 DISASSEMBLY.....................................................832 CLEANING AND INSPECTION.........................................832 ASSEMBLY........................................................834 PREVENTATIVE MAINTENANCE PROCEDURE..................................838 MOTORIZED WHEEL MAINTENANCE SCHEDULE....................................840 Q. ALPHABETICAL INDEX.......................................................844 R. SYSTEM SCHEMATICS........................................................848 HYDRAULIC BRAKE SYSTEM SCHEMATIC........................................850 HYDRAULIC SYSTEM SCHEMATIC (HUSCO VALVE)................................851 ELECTRICAL SCHEMATIC....................................................852 PAYLOAD METER III HOOK UP WIRING........................................880 PAYLOAD METER III ELECTRICAL SCHEMATIC..................................881
DESCRIPTION:
KOMATSU 730E Shop Manual DUMP TRUCK with TROLLEY ASSIST SL NOA30197 – A30200
- 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 mnning and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance andlor operational checks on the truck. All safety notices.
- wamings and cautions should be understood and followed when accompfishing repairs on the truck. The first section covers componentdescriptions. truck specifications and safework 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 US. standard and metric (SI) units throughout and all references to ‘Right’. ’Lefi’. ‘ant’. or ‘Rear’ are made with respect to the operator’ 5 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 i 10% tolerance unless otherwise specified.
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
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Dorian Mohammed –