Komatsu 730E Trolley Dump Truck Shop Manual DG726 – PDF DOWNLOAD

Description

Komatsu 730E Trolley Dump Truck Shop Manual DG726 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 730E Trolley Dump Truck Shop Manual DG726 – PDF DOWNLOAD

Language : English
Pages :900
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu 730E Trolley Dump Truck Shop Manual DG726 – PDF DOWNLOAD

SERIAL NUMBERS 32579-32582, 32588-32613, 32625,
32639-32641, 32683, 32684,
A30099-A30101, A30106-A30108

FOREWORD

• 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± 10% 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 Haulpak 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.

TABLE OF CONTENTS:

Komatsu 730E Trolley Dump Truck Shop Manual DG726 – PDF DOWNLOAD

SERIAL NUMBERS 32579-32582, 32588-32613, 32625,
32639-32641, 32683, 32684,
A30099-A30101, A30106-A30108

A01001pdf 0
MAJOR COMPONENTS & SPECIFICATIONS A2 9
GENERAL SAFETY AND OPERATION A3 9
WARNINGS AND CAUTIONS A4 9
STANDARD TORQUE CHARTS AND CONVERSION TABLES A5 9
STORAGE PROCEDURES A7 9
E02011C1pdf 0
ELECTRICAL PROPULSION COMPONENTS159
GENERAL SYSTEM DESCRIPTION159
CONTROL SYSTEM159
System Operation160
17FL275 PANEL161
CARD REPLACEMENT162
Removal162
Installation162
Card Repair162
PANEL WIRING162
COMPUTER DESCRIPTION163
Microprocessor163
Download Capability163
SOFTWARE163
Base Monitor Program163
Runtime Monitor Program – OBJ Running Code163
Configuration Software – CFG164
PTU – Portable Test Unit Code164
System Regulation164
Propulsion164
Retarding165
2-DIGIT DISPLAY PANEL166
The Coded Number166
Events166
Frames167
Windows167
System Categories167
Limits On Resetting Faults167
Na Faults168
Event Sequence168
Resetting Events168
Event Descriptions168
Subcode Descriptions168
2-DIGIT DISPLAY PANEL CODES169
PORTABLE TEST UNIT (PTU)178
DESCRIPTION178
OPERATIONAL HINTS178
SOFTWARE INSTALLATION PREPARATION179
Deleting Prior Software Versions179
Computer Boot File Editing179
SOFTWARE INSTALLATION ON PTU180
THE MAIN MENU181
CONFIGURATION (CFG) FILE CONVERSION183
Conversion Procedure183
STATEX CONFIGURATION FILES189
“Change Ptu Password”199
PROGRAMMING THE TRUCK200
Connect PTU to the Truck200
Select Configuration File200
Activate The PTU Mode200
Check Object Code Version201
Download Configuration Files202
Date And Time203
Event Data204
STATISTICAL DATA206
“View Counters”206
“View Profiles”206
“Upload Statistical Data To A File”206
Statistical Data Codes – Counters207
STATISTICAL DATA CODES – PROFILES213
Truck Specific Information217
Temporary Truck Settings218
MISCELLANEOUS FEATURES219
Saving Data219
Ptu Abbreviations219
OTHER MENU SELECTIONS219
E02011C2pdf 0
MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS221
ALTERNATOR221
ELECTRIC WHEEL MOTORS221
RETARDING GRIDS221
AIR THROTTLE/ELECTRONIC RETARD CONTROL222
Acceleration Switch [AS]222
Range Adjustment222
Differential Adjustment222
Removal222
Installation222
Disassembly and Assembly223
Adjustment Procedure (On Bench)223
Adjustment Procedure (On Truck)223
PROPEL/RETARD INTERFACE PANELS (Non-Fuel Saver Only)223
ACC Panel Operation223
RET Panel Operation223
ELECTRONIC ACCELERATOR AND RETARD PEDALS224
Removal224
Installation224
Disassembly224
Assembly224
COOLING BLOWER WARNING SYSTEM225
Operation225
Test225
Removal225
Installation225
ELECTRICAL CONTROL CABINET226
ABBREVIATIONS FOR STATEX III ELECTRIC DRIVE COMPONENTS232
CARD IDENTIFICATION LIST GE17FL275 PANEL, STATEX III233
DETROIT DIESEL ELECTRONIC ENGINE CONTROLS ABBREVIATIONS233
M09010pdf 0
AIR CONDITIONING SYSTEM641
Environmental Impact641
OPERATOR CAB AIR CONDITIONING642
PRINCIPLES OF REFRIGERATION642
Air Conditioning642
Refrigeration – The Act Of Cooling643
The Refrigeration Cycle643
AIR CONDITIONER SYSTEM COMPONENTS644
Compressor (Refrigerant Pump)644
Service Valves644
Condenser644
Expansion Block Valve645
Evaporator645
ELECTRICAL CIRCUIT646
Thermostat646
Compressor Clutch646
Trinary™ Switch647
SYSTEM SERVICING648
SYSTEM OIL649
Handling and Reusing PAG Oil649
Oil Quantity649
Replacing Oil After Servicing the System649
Setting Up a New Compressor649
REFRIGERANT650
Recycled Refrigerant650
Reclaimed Refrigerant650
Refrigerant Quantity650
R-134a Refrigerant Containers650
SERVICE TOOLS AND EQUIPMENT651
Recovery/Recycle Station651
Leak Detector651
Service Valves652
Vacuum Pump652
Manifold Gauge Set653
Installing Manifold Gauge Set654
Purging Air From Service Hoses655
Stabilizing the AC System656
SYSTEM PERFORMANCE TEST656
SYSTEM LEAK TESTING657
Electronic leak detector657
Tracer dyes657
Soap and water657
SYSTEM REPAIR658
System Cleaning658
Hoses and Fittings658
Lines658
Expansion Valve658
Receiver-Drier659
Thermostat659
Compressor659
Clutch659
Servicing the Compressor Clutch660
Pulley Removal662
Clutch Coil Check662
Pulley Installation662
Clutch Assembly Installation663
RECOVERING AND RECYCLING THE REFRIGERANT664
Performing the Recovery Cycle664
Performing the Recycling Procedure664
Evacuating and Charging the AC System664
EVACUATING THE SYSTEM665
CHARGING THE AC SYSTEM666
TROUBLESHOOTING667
Pre-Diagnosis Checks667
Preparing For Diagnosis667
Preliminary Steps667
System Performance Test667
Diagnosis Of Gauge Readings And System Performance668
PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM675
M20007pdf 0
SECTION M20717
PAYLOAD METER II – ON BOARD WEIGHING SYSTEM717
INDEX717
GENERAL INFORMATION719
Haul Cycles719
LIGHTS, SWITCHES AND COMPONENTS720
TIPS FOR OPERATION721
EXTERNAL DISPLAY LIGHTS721
THEORY OF OPERATION722
Basic Description722
Inclinometer722
Linkage Factor722
Gain Factor723
Brake Lock723
Sources of Error723
Typical Data From Service Check Mode723
Example Calculation of Payload724
Viewing Payload Calculation Inputs724
Checking the Gain725
Adjusting the Gain725
TYPES OF DATA STORED726
Cycle Data726
Engine ON/OFF Data727
Fault Codes and Warning Data727
Engine Operation728
Total Payload and Total Number of Cycles728
Other Data728
OPERATOR FUNCTIONS729
Using the Operator Load Counter729
Viewing the Operator Load Counter729
Clearing the Operator Load Counter729
Dimming the Lights on the Display729
INITIAL SETUP OF PAYLOAD METER730
Switch Settings730
Checking the Operator Check Mode731
Checking the Service Check Mode731
Checking the Gt setting:732
Checking the Inclinometer Settings732
Calibrating a Truck732
DISPLAYS AT START-UP733
Normal Operation733
SETUP AND MAINTENANCE734
Setting The Speed Limit734
Setting the Option Code734
Setting The Machine ID Code735
Setting The Operator ID Code735
Setting The Time and Date735
DOWNLOAD OF INFORMATION736
DISPLAY OF FAULT CODES736
Monitoring Input Signals740
Service Check Mode740
UP FACTOR – PAYLOAD CALCULATION GAIN741
PL MODE -LOAD CALCULATION TIMING741
FINAL GEAR RATIO SELECTION742
BATTERY REPLACEMENT PROCEDURE743
Replacing the Battery743
After Replacing the Battery744
SUSPENSION PRESSURE SENSOR744
Removal744
Installation745
INCLINOMETER745
Removal745
Installation745
Adjustment745
PAYLOAD METER BACK PANEL746
CONNECTIONS747
PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE748
PAYLOAD CIRCUIT NUMBERS749
TROUBLESHOOTING750
COMMON PROBLEMS750
Suspension Charging750
Symptom Table751
Missing Body-Up Signal751
Missing Speed Signal752
F-18: Alternator R-Terminal, Oil Pressure Signals752
Shorted 18v Sensor Power Supply (930E)752
FAULT TREE DIAGNOSIS753
Payload Lights Won’t Illuminate753
Red, Amber or Green Payload Light Does Not Illuminate754
Cannot Download – PC Communications755
PC Communications Configuration756
FCAL: Payload Meter Won’t Calibrate757
F-20: Sensor Power Fault758
F-21, F-25: Left Front Pressure Sensor760
F-22, F-26: Right Front Pressure Sensor760
F-23, F-27: Left Rear Pressure Sensor760
F-24, F-28: Right Rear Pressure Sensor760
F-31, F-32: Inclinometer762
Body Up Input764
Brake Lock Input765
Speed Signal766
Adjusting the Speed Sensor766
CONNECTORS AND PRESSURE SENSORS768
REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM771
Menu Functions774
Using Scope774
Log File Information774
Connections to Payload Meter II™775
USING SCOPE776
Monitoring Inputs Using Scope776
Monitoring Suspension Charging Using Scope776
Pressure Sensor Dummy Loads779
GAIN ADJUSTMENT WORKSHEET780
N04015pdf 0
OPERATOR COMFORT801
OPERATOR SEAT801
Adjustment801
Removal801
Installation801
HEATER/AIR CONDITIONER802
Operation802
HEATER COMPONENTS803
Circuit Breakers803
Heater Control Components803
Heater Coil803
Fan Motor And Speed Control804
Actuators804
Filter804
AIR CONDITIONER COMPONENTS804

IMAGES PREVIEW OF THE MANUAL:

S.M 24/12/24