Komatsu DUMP TRUCK 730E Shop Manual (DG708) PDF

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Komatsu DUMP TRUCK 730E Shop Manual (DG708) – PDF DOWNLOAD

FILE DETAILS:

Komatsu DUMP TRUCK 730E Shop Manual (DG708) – PDF DOWNLOAD

Language : English
Pages :862
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu DUMP TRUCK 730E Shop Manual (DG708) – PDF DOWNLOAD

SERIAL SUFFIX AFE47-B thru AFE47-AL

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.

TABLE OF CONTENTS:

Komatsu DUMP TRUCK 730E Shop Manual (DG708) – PDF DOWNLOAD

SERIAL SUFFIX AFE47-B thru AFE47-AL

COVER 1
FOREWARD 5
CONTENTS 7
A GENERAL INFORMATION 9
CHARTS AND TABLES 47
STORAGE PROCEDURES 53
B STRUCTURES 73
STRUCTURAL COMPONENTS 75
GRILLE AND HOOD 75
LADDERS 76
DECKS 76
RIGHT DECK AND COMPONENTS 76
LEFT DECK 76
DUMP BODY 79
INSTALLATION 79
REMOVAL 79
BODY PADS 80
BODY GUIDE 81
BODY SLING 81
BODY POSITION INDICATOR 81
ROCK EJECTORS 82
HOIST LIMIT SWITCHES 82
FUEL TANK 83
REMOVAL 83
INSTALLATION 84
CLEANING 84
VENT 84
FUEL GAUGE SENDER 84
C ENGINE, FUEL, COOLING, AND AIR CLEANER 85
POWER MODULE 87
REMOVAL 87
INSTALLATION 91
COOLING SYSTEM 93
RADIATOR 93
REMOVAL 93
SERVICE 94
INSTALLATION 94
RADIATOR FILL PROCEDURE 95
COOLING SYSTEM TROUBLESHOOTING 96
POWER TRAIN 97
ALTERNATOR REMOVAL AND INSTALLATION PROCEDURE 97
REMOVAL 97
ENGINE / ALTERNATOR MATING 99
ALTERNATOR MEASUREMENT 99
ENGINE END PLAY MEASUREMENT100
DETERMINING SHIM REQUIREMENTS100
INSTALLATION101
ENGINE103
REMOVAL103
INSTALLATION103
AIR CLEANERS105
FILTER ELEMENT REPLACEMENT105
MAIN FILTER ELEMENT CLEANING107
PRECLEANER SECTION108
E ELECTRIC PROPULSION AND CONTROL 0
E02011C1pdf 0
ELECTRICAL PROPULSION COMPONENTS151
GENERAL SYSTEM DESCRIPTION151
CONTROL SYSTEM151
System Operation152
17FL275 PANEL153
CARD REPLACEMENT154
Removal154
Installation154
Card Repair154
PANEL WIRING154
COMPUTER DESCRIPTION155
Microprocessor155
Download Capability155
SOFTWARE155
Base Monitor Program155
Runtime Monitor Program – OBJ Running Code155
Configuration Software – CFG156
PTU – Portable Test Unit Code156
System Regulation156
Propulsion156
Retarding157
2-DIGIT DISPLAY PANEL158
The Coded Number158
Events158
Frames159
Windows159
System Categories159
Limits On Resetting Faults159
Na Faults160
Event Sequence160
Resetting Events160
Event Descriptions160
Subcode Descriptions160
2-DIGIT DISPLAY PANEL CODES161
PORTABLE TEST UNIT (PTU)170
DESCRIPTION170
OPERATIONAL HINTS170
SOFTWARE INSTALLATION PREPARATION171
Deleting Prior Software Versions171
Computer Boot File Editing171
SOFTWARE INSTALLATION ON PTU172
THE MAIN MENU173
CONFIGURATION (CFG) FILE CONVERSION175
Conversion Procedure175
STATEX CONFIGURATION FILES181
“Change Ptu Password”191
PROGRAMMING THE TRUCK192
Connect PTU to the Truck192
Select Configuration File192
Activate The PTU Mode192
Check Object Code Version193
Download Configuration Files194
Date And Time195
Event Data196
STATISTICAL DATA198
“View Counters”198
“View Profiles”198
“Upload Statistical Data To A File”198
Statistical Data Codes – Counters199
STATISTICAL DATA CODES – PROFILES205
Truck Specific Information209
Temporary Truck Settings210
MISCELLANEOUS FEATURES211
Saving Data211
Ptu Abbreviations211
OTHER MENU SELECTIONS211
E02011C2pdf 0
MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS213
ALTERNATOR213
ELECTRIC WHEEL MOTORS213
RETARDING GRIDS213
AIR THROTTLE/ELECTRONIC RETARD CONTROL214
Acceleration Switch [AS]214
Range Adjustment214
Differential Adjustment214
Removal214
Installation214
Disassembly and Assembly215
Adjustment Procedure (On Bench)215
Adjustment Procedure (On Truck)215
PROPEL/RETARD INTERFACE PANELS (Non-Fuel Saver Only)215
ACC Panel Operation215
RET Panel Operation215
ELECTRONIC ACCELERATOR AND RETARD PEDALS216
Removal216
Installation216
Disassembly216
Assembly216
COOLING BLOWER WARNING SYSTEM217
Operation217
Test217
Removal217
Installation217
ELECTRICAL CONTROL CABINET218
ABBREVIATIONS FOR STATEX III ELECTRIC DRIVE COMPONENTS224
CARD IDENTIFICATION LIST GE17FL275 PANEL, STATEX III225
DETROIT DIESEL ELECTRONIC ENGINE CONTROLS ABBREVIATIONS225
ELECTRICAL CHECKOUT PROCEDURE227
G DRIVE AXLE, SPINDLES AND WHEELS279
TIRES AND RIMS (G02012)281
FRONT TIRES AND RIMS282
REMOVAL282
INSTALLATION283
REAR TIRES AND RIMS283
REMOVAL283
INSTALLATION284
RIM285
TIRE REMOVAL285
TIRE INSTALLATION286
FRONT WHEEL HUB AND SPINDLE ASSEMBLY (G03012)287
WHEEL HUB AND SPINDLE ASSEMBLY287
REMOVAL287
INSTALLATION289
DISASSEMBLY289
CLEANING AND INSPECTION290
ASSEMBLY290
WHEEL BEARING ADJUSTMENT (TIRE REMOVED)292
WHEEL BEARING ADJUSTMENT (TIRE MOUNTED)293
STEERING CYLINDERS AND TIE ROD295
REMOVAL295
INSTALLATION295
BEARING REPLACEMENT295
TOE-IN ADJUSTMENT297
REAR AXLE HOUSING ATTACHMENT (G04010)299
PIVOT PIN299
REMOVAL299
INSTALLATION299
DISASSEMBLY300
ASSEMBLY300
ANTI-SWAY BAR302
REMOVAL302
INSTALLATION302
DISASSEMBLY302
CLEANING AND INSPECTION302
ASSEMBLY302
REAR AXLE HOUSING (G05004)303
REAR AXLE HOUSING303
REMOVAL303
INSTALLATION303
WHEEL MOTOR303
REMOVAL303
CLEANING AND INSPECTION304
INSTALLATION304
J BRAKE CIRCUIT327
BRAKE CIRCUIT329
SERVICE BRAKE CIRCUIT OPERATION329
SECONDARY BRAKING AND AUTOMATIC APPLY331
PARKING BRAKE CIRCUIT331
BRAKE LOCK CIRCUIT332
WARNING CIRCUIT332
BRAKE VALVE CUT-AWAY333
BRAKE CIRCUIT COMPONENT SERVICE335
BRAKE VALVE335
REMOVAL335
INSTALLATION337
DISASSEMBLY338
CLEANING AND INSPECTION340
ASSEMBLY340
BENCH TEST AND ADJUSTMENT344
INSTALLATION OF BRAKE PEDAL ACTUATOR ASSEMBLY TO BRAKE VALVE347
INSTALLATION OF RETARD PEDAL (IF EQUIPPED) TO BRAKE VALVE348
HYDRAULIC BRAKE ACCUMULATORS349
REMOVAL349
INSTALLATION349
DISASSEMBLY349
CLEANING AND INSPECTION350
ASSEMBLY351
CHARGING PROCEDURE352
BRAKE CIRCUIT CHECKOUT PROCEDURE353
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING359
HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDURE DATA SHEET363
FRONT BRAKES (ROCKWELL)365
BRAKE CALIPER365
BRAKE LINING369
BRAKE PAD CONDITIONING (BURNISHING) PROCEDURE370
TEMPORARY BRAKE DISCONNECT (DISABLE) PROCEDURE370
BRAKE BLEEDING PROCEDURE372
REAR BRAKES (ROCKWELL)373
BRAKE CALIPER, DISC AND PARKING BRAKE373
CALIPER PISTON ASSEMBLY378
BENCH TEST384
BRAKE LINING385
BRAKE PAD CONDITIONING (BURNISHNG) PROCEDURE387
BRAKE BLEEDING PROCEDURE388
PARKING BRAKE (ROCKWELL)391
CALIPER STYLE IDENTIFICATION (SCL15 VS SCL70)391
REMOVAL392
INSTALLATION392
PARKING BRAKE ADJUSTMENT (SCL 70)392
PARKING BRAKE ADJUSTMENT (SCL 15)394
PARK BRAKE CALIPER DISASSEMBLY395
CLEANING AN INSPECTION396
PARK BRAKE CALIPER ASSEMBLY397
PARK BRAKE LINING397
REPLACEMENT397
CONDITIONING (BURNISHING PROCEDURE)397
BRAKE BLEEDING PROCEDURE397
M OPTIONS AND SPECIAL TOOLS519
FIRE CONTROL SYSTEMS521
ANSUL FIRE CONTROL PNEUMATIC SYSTEM521
ANSUL FIRE CONTROL ELECTRIC SYSTEM527
ANSUL FIRE CONTROL SYSTEM MANUAL521
OPERATION521
INSPECTION AND MAINTENANCE521
RECHARGING PROCEDURES522
ALTERNATOR AND WHEEL MOTOR COOLING AIR FILTER SYSTEM539
SYSTEM ADJUSTMENT539
PUMP539
BLOWER DRIVE MOTOR542
BLOWER BEARING REPAIR545
AIR CLEANER546
WIGGINS QUICK FILL FUEL SYSTEM547
TANK BREATHER VALVE548
FUEL RECEIVER549
FAN DRIVE CLUTCH – HYDRAULIC ACTUATED551
GENERAL DESCRIPTION551
MAINTENANCE554
TROUBLESHOOTING556
FIELD CHECK DIAGNOSIS557
THERMAL SENSOR AND SOLENOID VALVE558
TROUBLESHOOTING CHART561
DISASSEMBLY565
REASSEMBLY572
INSPECTION OF PARTS583
REBUILD TOOLS587
ENGINE COOLANT HEATER SYSTEM – HOT START – 220 VOLT589
HEATING ELEMENT589
THERMOSTAT590
ENGINE OIL HEATERS – HOT START – 220 VOLT591
TROUBLESHOOTING591
HEATING ELEMENT591
ENGINE AND COOLANT HEATERS – 440 VOLT593
TROUBLESHOOTING594
COOLANT HEATING ELEMENT595
OIL HEATING ELEMENT595
SPECIAL TOOL GROUP599
HEATER / AIR CONDITIONING SYSTEM607
ENVIRONMENTAL IMPACT607
OPERATOR CAB CONDITIONING608
PRINCIPLES OF REFRIGERATION608
MAJOR SYSTEM COMPONENTS610
SYSTEM SERVICING614
EVACUATING THE SYSTEM631
SYSTEM TROUBLESHOOTING633
24 VDC ELECTRIC SUPPLY SYSTEM643
ELECTRICAL SYSTEM DESCRIPTION643
BATTERY – MAINTENANCE AND SERVICE643
BATTERY CHARGING SYSTEM645
GENERAL DESCRIPTION645
TROUBLESHOOTING PROCEDURES645
NIEHOFF 250 AMP ALTERNATOR OVERHAUL MANUAL653
DIMENSIONS654
SPECIFICATIONS655
SERVICE PARTS LIST656
EXPLODED VIEW657
ON VEHICLE TEST658
BENCH TEST660
STATIC TESTS661
ALTERNATOR DISASSEMBLY664
ALTERNATOR ASSEMBLY669
SERVICE TOOL INSTRUCTIONS678
FUEL – WATER SEPARATOR681
INSTALLATION681
OPERATION681
FILTER SERVICE682
PAYLOAD METER II – OBWS683
TABLE OF CONTENTS683
GENERAL INFORMATION686
HAUL CYCLES686
LIGHTS, SWITCHES, AND COMPONENTS687
TIPS FOR OPERATION688
EXTERNAL DISPLAY LIGHTS688
THEORY OF OPERATION689
BASIC DESCRIPTION689
INCLINOMETER689
LINKAGE FACTOR689
GAIN FACTOR690
BRAKE FACTOR690
SOURCES OF ERROR690
TYPICAL DATA FROM SERVICE CHECK MODE690
EXAMPLE CALCULATION OF PAYLOAD691
VIEWING PAYLOAD CALCULATION INPUTS691
CHECKING THE GAIN692
ADJUSTING THE GAIN692
TYPES OF DATA STORED693
CYCLE DATA693
ENGINE ON / OFF DATA694
FAULT CODES AND WARNING DATA694
ENGINE OPERATION695
TOTAL PAYLOAD AND TOTAL NUMBER OF CYCLES695
OTHER DATA695
OPERATOR FUNCTIONS696
USING THE OPERATOR CHECK MODE696
VIEWING THE OPERATOR LOAD COUNTER696
CLEARING THE OPERATOR LOAD COUNTER696
DIMMING THE LIGHTS ON THE DISPLAY696
INITIAL SETUP OF PAYLOAD METER697
SWITCH SETTINGS697
CHECKING THE OPERATOR CHECK MODE698
CHECKING THE SERVICE CHECK MODE698
SETTING “UP:XX”698
SETTING “PL:00″698
CHECKING THE Gt SETTING699
CHECKING THE INCLINOMETER SETTING699
CALIBRATING A TRUCK699
DISPLAYS AT START-UP700
SET-UP AND MAINTENANCE701
SETTING THE SPEED LIMIT701
SETTING THE OPTION CODE701
SETTING THE MACHINE ID702
SETTING THE OPERATOR ID702
SETTING THE TIME AND DATE702
DOWNLOAD OF INFORMATION703
DISPLAY OF FAULT CODES703
CHARTS OF FAULT CODES AND OTHER INFORMATION705
MONITORING INPUT SIGNALS707
SERVICE CHECK MODE707
UP FACTOR – PAYLOAD CALCULATION GAIN708
PL MODE – LOAD CALCULATION TIMING708
FINAL GEAR RATIO SELECTION709
BATTERY REPLACEMENT PROCEDURE710
REPLACING THE BATTERY710
AFTER REPLACING THE BATTERY711
SUSPENSION PRESSURE SENSOR711
REMOVAL711
INSTALLATION712
INCLINOMETER712
REMOVAL712
INSTALLATION712
ADJUSTMENT712
PAYLOAD METER BACK PANEL713
CONNECTIONS (AMP PIN ID)714
PAYLOAD METER 2 REINITIALIZATION PROCEDURE715
PAYLOAD CIRCUIT NUMBERS716
TROUBLESHOOTING SECTION717
COMMON PROBLEMS717
SUSPENSION CHARGING717
SYMPTOM TABLE718
MISSING BODY-UP SIGNAL718
MISSING SPEED SIGNAL719
F-18: R-TERMINAL, OIL PRESSURE SIGNALS719
SHORTED 18V SENSOR POWER SUPPLY (930E)719
FAULT TREE DIAGNOSIS720
PAYLOAD LIGHTS WON’T ILLUMINATE720
RED, AMBER, OR GREEN PAYLOAD LIGHTS DON’T ILLUMINATE721
CANNOT DOWNLOAD – PC COMMUNICATIONS722
PC COMMUNICATIONS CONFIGURATION723
FCAL: PAYLOAD METER WON’T CALIBRATE724
F-20: SENSOR POWER FAULT725
F-21 THRU F-28 PRESSURE SENSOR FAULTS727
F-31, F-32: INCLINOMETER729
BODY UP INPUT731
BRAKE LOCK INPUT732
SPEED SIGNAL733
CONNECTORS AND PRESSURE SENSORS735
REAL-TIME PAYLOAD METER 2 MONITOR PROGRAM738
DATA DEFINITIONS AND COMMENTS739
TRUCK STATUS AND INPUTS740
MENU FUNCTIONS741
USING SCOPE741
LOG FILE INFORMATION741
CONNECTIONS TO PAYLOAD METER 2742
USING SCOPE743
MONITORING INPUTS USING SCOPE743
MONITORING SUSPENSION CHARGING USING SCOPE743
PRESSURE SENSOR DUMMY LOADS746
GAIN ADJUSTMENT WORKSHEET747
N OPERATOR’S CAB749
TRUCK CAB751
DESCRIPTION751
REMOVAL752
INSTALLATION753
CAB DOOR754
REMOVAL754
INSTALLATION754
DOOR ADJUSTMENT754
DOOR GLASS REPLACEMENT757
DOOR HANDLE OR LATCH REPLACEMENT761
DOOR AND DOOR HINGE SEAL REPLACEMENT762
GLASS REPLACEMENT763
ADHESIVE BONDED WINDOWS763
WINDSHIELD AND REAR GLASS REPLACEMENT764
CAB COMPONENTS765
WINDSHIELD WIPER765
WINDSHIELD WASHER766
OPERATOR COMFORT767
OPERATOR SEAT767
Adjustment767
Removal767
Installation767
HEATER/AIR CONDITIONER768
Operation768
HEATER COMPONENTS769
Circuit Breakers769
Heater Control Components769
Heater Coil769
Fan Motor And Speed Control770
Actuators770
Filter770
AIR CONDITIONER COMPONENTS770
P LUBRICATION AND SERVICE791
LUBRICATION AND SERVICE793
LINCOLN AUTOMATIC LUBRICATION SYSTEM801
MOTORIZED WHEEL MAINTENANCE SCHEDULE815
Q ALPHABETICAL INDEX819
R SYSTEM SCHEMATICS823

IMAGES PREVIEW OF THE MANUAL:

S.M 26/12/24