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Komatsu 730E-10 Rigid Dump Truck Shop Manual (CEBM041901)

Format: PDF (Printable Document)

File Language: English

File Pages: 1117

File Size: 46.49 MB (Speed Download Link)

Brand: Komatsu

Model: 730E-10 Rigid Dump Truck

Book No: CEBM041901

Serial No: SN A50066-UP

Type of Document: Shop Manual

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Komatsu 730E-10 Rigid Dump Truck Shop Manual (CEBM041901)

The Komatsu 730E-10 Rigid Dump Truck is a big mine truck that spends its life hauling rock on rough haul roads, running long shifts, and getting hammered by heat, dust, and heavy braking. The people who reach for the Komatsu 730E-10 Rigid Dump Truck Shop Manual (CEBM041901) are usually shop mechanics, field techs, and rebuild guys who actually have to tear into systems, not just top off fluids. They’re trying to track down intermittent faults, rebuild major components, and put the truck back to work without repeat comebacks. This isn’t a “how to drive it” book; it’s the workshop playbook.

What this manual helps you do

  • Trace electrical faults using wiring information and step‑by‑step diagnostic routines that these manuals usually include.
  • Check and adjust engine, braking, and drivetrain systems the way Komatsu expects you to in a proper workshop setting.
  • Follow disassembly and assembly sequences for major components like final drives, suspension, and steering gear so you don’t break expensive castings.
  • Diagnose hydraulic and electric drive complaints with the kind of test points and logic trees you’d expect in a factory shop manual.
  • Handle calibration and setup procedures after component replacement so sensors and controls talk to each other correctly.

Who this is for

This is aimed at field techs, shop mechanics, and fleet maintenance supervisors who already have tools, test gear, and basic Komatsu experience. Operators or new trainees looking for daily checks and driving instructions should be looking for the Operation & Maintenance Manual instead.

FAQ

Q: Is this a PDF I can download and search?

A: Yes, it’s a digital PDF you can download, search by keyword, and print selected pages for use in the shop.

Q: Is this deep enough for full overhauls, or just light service?

A: This kind of shop manual is written for workshop‑level repairs, including diagnostics, removal/installation, and overhaul‑type work on the 730E‑10.

Q: How do I know if it matches my exact truck build or variant?

A: Check your truck’s model designation and match it to Komatsu 730E‑10, then confirm the book reference CEBM041901 against your maintenance documentation or dealer.

Bottom line: if you’re the person actually fixing a Komatsu 730E‑10 in a mine or heavy shop, this is the right manual; if you only need operating tips or basic service intervals, keep looking for the O&M book instead.

📘 Show Index

Table of Contents:

  • COVER
  • 00 CONTENTS AND FOREWORD
    • Foreword
      • How to Read the Shop Manual
      • Safety Alert Symbol and Signal Words
    • General Precautions Common to Operation and Maintenance
      • Preparations for Safe Operation
      • Fire and Explosion Prevention
      • Precautions When Getting On or Off the Machine
      • Precautions for Cab and Working Around Machine
      • Precautions for Diesel Exhaust Fluid (DEF)
    • Operation Precautions
      • Precautions at Jobsite
      • Precautions in Starting Engine
      • Precautions During Operation
    • Maintenance Precautions
      • Precautions Before Inspection and Maintenance
      • Precautions During Inspection and Maintenance
      • Precautions for Electrical Equipment
        • Primary Causes of Wiring Harness Failure
      • Control Cabinet Capacitor Discharge
      • Hydraulic Equipment Precautions
  • 01 SPECIFICATIONS
    • Specifications
      • Specifications: 730E-10
      • Recommended Fuel, Coolant, and Lubricant
        • Wheel Motor Oil Specifications
        • Suspension Cylinder Oil and Nitrogen Specifications
  • 10 STRUCTURE AND FUNCTION
    • Steering System
      • Steering System Layout
      • Steering System Operation
      • Steering Bleeddown Manifold
      • Steering Control Unit
      • Steering Accumulators (Piston Type)
      • Steering/Brake Pump Operation
      • Flow Amplifier Operation
    • Hoist System
      • Hoist System Layout
      • Hoist System Operation
      • Hoist Control Valve
      • Overcenter Manifold
      • Hoist Pilot Valve
    • Brake System
      • Service Brake System Layout
      • Hydraulic Brake Cabinet Layout
      • Service Brake Operation
      • Parking Brake Operation
      • Brake Lock Operation
      • Secondary Braking and Auto Apply
    • Electrical System, 24V
      • Battery Power Supply
        • Battery Disconnect Switches
      • Engine Starting System
      • Auxiliary Control Cabinet Components
      • Body-Up Switch
      • Hoist Limit Switch
    • Automatic Lubrication (Auto Lube) System
      • Automatic Lubrication (Auto Lube) Grease Pump and Reservoir
      • Automatic Lubrication (Auto Lube) System Operation
    • Suspensions
    • Engine Emissions After-Treatment System Operations
  • 20 STANDARD VALUE TABLE
    • Standard Value Table
  • 30 TEST AND ADJUST
    • Hydraulic Systems
      • Hydraulic System Checkout Procedures
        • Hydraulic System Checkout Sheet
      • Steering System Leakage Check
      • Toe-In Adjustment
      • Hoist Cylinder Leakage Test
      • Steering Cylinder Leakage Test
      • Checking the Steering/Brake Pump Control Pressures
      • Adjusting the Steering/Brake Pump Control Pressures
      • High Altitude Steering/Brake Pump Adjustment
    • Brake System
      • Brake System Checkout Procedures
        • Brake System Checkout Sheet
      • Service Brake Conditioning (Burnishing)
        • Front Brake Conditioning
        • Rear Brake Conditioning
      • Parking Brake Adjustment Procedure
      • Brake Bleeding Procedure
      • Piston Assembly Return Spring Force and Built-in Clearance (BIC)
        • Piston Assembly Adjuster Grip Force
        • Adjuster Force
        • Piston Return Spring
    • Accumulators and Suspensions
      • Bladder Accumulator Charging Procedure
      • Bladder Accumulator Leakage Test
      • Bladder Accumulator Storage
      • Piston Accumulator Charging Procedure
      • Piston Accumulator Leakage Test
      • Piston Accumulator Storage
      • Check for Improper Suspension Charge
      • Suspension Oiling and Charging Procedures
        • Oiling and Charging Tools and Support Blocks
        • Nitrogen Charging Kit Installation
        • Nitrogen Charging Kit Removal
        • Front Suspension Oiling and Charging
        • Rear Suspension Oiling and Charging
      • Suspension Pressure Test
    • Automatic Lubrication (Auto Lube) System
      • Prime the Auto Lube Pump
      • Prime the Auto Lube Grease Lines
      • Auto Lube System Checkout
      • Adjust the Auto Lube Cycle Timing
    • Cab Air Conditioning
      • Refrigerant Leak Detection
      • A/C System Performance Test
      • Check the A/C System Oil
      • A/C System Flushing Procedure
      • Manifold Gauge Set Installation
      • Refrigerant: Recycled vs Reclaimed
      • Refrigerant Recovery Procedure
      • Evacuate the A/C System
      • Charge the A/C System
    • Electrical Systems
      • Shutdown Procedure for Drive System Service
      • Electrical System Checkout Procedures
        • Visual Checks
        • Resistance Checks
        • Voltage Checks
        • Truck Function Checks
        • Interface Module (IM) Checks
        • KOMTRAX Plus II Checks
        • Payload Meter (PLM) Checks
        • Drive System Checks
        • Engine Delayed Shutdown Smart Timer Check
        • Hoist Limit Switch Check
        • Electrical System Checkout Sheet
    • Interface Module 2 (IM2)
      • Interface Module 2 Software and Tools
      • Program the IM2 Controller
      • Interface Module 2 Checkout Procedures
        • Check for IM Fault Codes
        • Checking Digital Inputs to the IM2
        • Checking Analog Inputs to the IM2
        • Checking Serial Communication to the IM
        • Checking Outputs from the IM2
        • Interface Module 2 Checkout Sheet
    • Payload Meter IV
      • Payload Meter IV Software and Tools
      • Payload Meter IV System Configuration
        • Configuring a Static IP Address
      • Payload Meter IV Software Installation
      • Payload Meter IV Data Downloading
      • Payload Meter IV Checkout Procedure
        • Payload Meter IV Checkout Sheet
    • KOMTRAX Plus II
      • KOMTRAX Plus II Software and Tools
      • Komtrax Plus II Controller Ethernet Connection
      • KOMTRAX Plus II Configuration
      • GPS Connection Test
      • Satellite Connection Test
      • Komtrax Plus II System Initialization
    • KomVision
      • KomVision Setup and Calibration Requirements
      • KomVision Initial Setup and Checkout Procedure
        • KomVision Checkout Sheet
      • KomVision Calibration Sheets
        • Calibration Sheet Layout
        • Unfold and Fold Calibration Sheet
        • Calibration Sheet Placement
      • KomVision Camera Calibration Procedures
        • Automatic 6 Camera Calibration
        • Manual 6 Camera Calibration
        • 1 Camera Calibration
      • KomVision Radar Setting Procedure
    • Komatsu Wireless Bridge (KWB)
      • Komatsu Wireless Bridge Software and Tools
      • Bullet Wireless Radio Configuration
      • Bullet Wireless Radio Installation
      • NanoStation Access Point Configuration
      • NanoStation Access Point Connection Test
    • Tire Monitoring System
      • Tire Monitoring System Software and Tools
      • Tire Monitoring System Software Installation
      • Tire Monitoring System Configuration
        • Connecting to the Tire Monitoring System Web Server
        • Configuring a Static IP Address
      • Tire Monitoring System Reset
      • Tire Monitoring System Checkout Procedure
        • Tire Monitoring System Checkout Sheet
  • 40 TROUBLESHOOTING
    • Fuses, Diodes and Relays
    • Standard Truck Fault Codes
      • A001
      • A002
      • A003
      • A004
      • A005
      • A006
      • A007
      • A008
      • A011
      • A013
      • A014
      • A016
      • A017
      • A018
      • A019
      • A022
      • A101
      • A103
      • A104
      • A105
      • A109
      • A111
      • A115
      • A117
      • A118
      • A123
      • A124
      • A125
      • A126
      • A127
      • A128
      • A139
      • A145
      • A146
      • A152
      • A153
      • A154
      • A155
      • A158
      • A166
      • A167
      • A168
      • A169
      • A170
      • A171
      • A172
      • A173
      • A184
      • A190
      • A193
      • A194
      • A195
      • A196
      • A197
      • A198
      • A199
      • A200
      • A201
      • A202
      • A203
      • A204
      • A205
      • A206
      • A207
      • A213
      • A214
      • A215
      • A216
      • A223
      • A230
      • A231
      • A233
      • A235
      • A236
      • A237
      • A240
      • A242
      • A243
      • A244
      • A245
      • A246
      • A247
      • A248
      • A249
      • A250
      • A251
      • A252
      • A253
      • A256
      • A257
      • A258
      • A260
      • A261
      • A262
      • A264
      • A265
      • A266
      • A267
      • A268
      • A270
      • A272
      • A273
      • A274
      • A275
      • A277
      • A278
      • A279
      • A280
      • A281
      • A282
      • A283
      • A284
      • A285
      • A286
      • A292
      • A303
      • A304
      • A305
      • A307
      • A309
      • A310
      • A311
      • A312
      • A313
      • A315
      • A316
      • A317
      • A318
      • A328
      • A332
      • A333
      • A334
      • A335
      • A337
      • A338
      • A339
      • A340
      • A341
      • A342
      • A343
      • A344
      • A345
      • A346
      • A347
      • A348
      • A349
      • A350
      • A351
      • A352
      • A353
      • A354
      • A355
      • A356
      • A357
      • A358
      • A359
      • A360
      • A361
      • A362
      • A363
      • A364
      • A365
      • A366
      • A400
      • A401
      • A402
      • A403
      • A404
      • A405
      • A406
      • A407
      • A408
      • A409
      • A410
      • A411
      • A412
      • A413
      • A414
      • A415
      • A416
      • A417
      • A418
      • A419
      • A420
      • A421
      • A422
      • A423
      • A424
      • A425
      • A426
      • A427
      • A428
      • A429
      • A430
      • A431
      • A432
      • A433
      • A434
      • A435
      • A436
      • A437
      • A438
      • A439
      • A440
      • A441
      • A442
      • A443
      • A444
      • A445
      • A446
      • A447
    • Aftertreatment System Fault Codes
      • CA256
      • CA1677
      • CA1678
      • CA1682
      • CA1683
      • CA1684
      • CA1685
      • CA1686
      • CA1695
      • CA1712
      • CA1713
      • CA1714
      • CA1715
      • CA1887
      • CA2771
      • CA3142
      • CA3143
      • CA3146
      • CA3147
      • CA3232
      • CA3497
      • CA3498
      • CA3547
      • CA3558
      • CA3559
      • CA3562
      • CA3563
      • CA3567
      • CA3571
      • CA3572
      • CA3573
      • CA3574
      • CA3575
      • CA3712
      • CA3713
      • CA3714
      • CA3867
      • CA3868
      • CA3878
      • CA3988
      • CA3995
      • CA4113
      • CA4114
      • CA4119
      • CA4121
      • CA4152
      • CA4164
      • CA4165
      • CA4166
      • CA4168
      • CA4169
      • CA4174
      • CA4175
      • CA4233
      • CA4234
      • CA4243
      • CA4277
      • CA4456
      • CA4457
      • CA4458
      • CA4459
      • CA4461
      • CA4462
      • CA4464
      • CA4465
      • CA4466
      • CA4467
      • CA4474
      • CA4475
      • CA4572
      • CA4677
      • CA4679
      • CA4682
      • CA4731
      • CA4732
      • CA4736
      • CA4737
      • CA4738
      • CA4739
      • CA4745
      • CA4768
      • CA4769
      • CA4842
      • CA4863
      • CA5115
      • CA5116
      • CA5117
      • CA5247
      • CA5653
      • CA5654
      • CA5725
      • CA5727
      • CA5728
      • CA5729
      • CA5748
      • CA5749
      • CA5751
      • CA5753
      • CA5755
      • CA5756
      • CA5758
      • CA5768
      • CA5769
      • CA5771
      • CA5772
      • CA5773
      • CA5774
      • CA5775
      • CA5776
      • CA5778
      • CA5779
      • CA5887
      • CA5888
      • CA5889
      • CA5891
      • CA5892
      • CA5893
      • CA6692
      • CA6693
      • CA6694
      • CA6695
      • CA6696
      • CA6697
      • CA6855
      • CA6856
    • KomVision Fault Codes
    • Troubleshoot the Steering System
      • Steering System Troubleshooting Guide
      • Basic Hydraulic System Checks
      • Steering/Brake Pump Troubleshooting Guide
      • Steering/Brake Pump Troubleshooting Checks
        • Steering/Brake Pump Fails to Unload
        • Steering/Brake Pump Fails to Develop Pressure
        • Steering/Brake Pump Slow to Develop Pressure
        • Steering/Brake Pump Control Valve Inspection
        • Steering/Brake Pump Case Drain Check
    • Troubleshoot the Auto Lube System
    • Troubleshoot the HVAC System
      • Control Panel Configurations
      • Diagnostics Mode
        • Error Codes
        • Advanced Diagnostics
        • Firmware Version
      • Additional HVAC Troubleshooting Chart
      • Voltage Levels
    • Troubleshoot the Electronic Fan Clutch
  • 50 DISASSEMBLY AND ASSEMBLY
    • Special Tools List
    • Wheels, Spindles and Rear Axle
      • General Precautions for Tires and Rims
      • Lubricants for Tire and Rim Service
      • Tire Inflation
      • Rim Components
      • Wheel Stud Maintenance
      • Rear Outer Wheel Stud Installation
      • Front Wheel Removal
      • Front Wheel Installation
      • Rear Wheel Removal
      • Rear Wheel Installation
      • Lock Ring Removal
      • Lock Ring Installation
      • Tire Removal (Front 5-Piece Rim)
      • Tire and Rim Preparation
      • Tire Installation (Front 5-Piece Rim)
      • Tire Installation (Rear Inner 5-Piece Rim)
      • Front Wheel Hub and Spindle Removal
      • Spindle Removal While Off the Truck
      • Front Wheel Hub and Spindle Installation
      • Spindle, Hub and Brake Assembly Cross-Section View
      • Front Wheel Hub and Spindle Disassembly
      • Front Wheel Hub and Spindle Cleaning and Inspection
      • Front Wheel Hub and Spindle Assembly
      • Floating Seal Installation (CPS or Goetze)
      • Rear Axle Removal
      • Rear Axle Cleaning and Inspection
      • Rear Axle Installation
      • Anti-Sway Bar Removal
      • Anti-Sway Bar Installation
      • Pivot Pin Removal
      • Pivot Pin Installation
      • Pivot Eye Bearing Wear Inspection
      • Pivot Eye Bearing Replacement
      • Pivot Eye Removal
      • Pivot Eye Installation
      • Wheel Motor Removal
      • Wheel Motor Cleaning and Inspection
      • Wheel Motor Installation
    • Steering System
      • Steering Control Unit Removal
      • Steering Control Unit Installation
      • Steering Control Unit Disassembly
      • Steering Control Unit Assembly
      • Steering Column Removal
      • Steering Column Installation
      • Steering Wheel Removal
      • Steering Wheel Installation
      • Bleeddown Manifold Removal
      • Bleeddown Manifold Installation
      • Flow Amplifier Removal
      • Flow Amplifier Installation
      • Steering Pin Joint Wear Inspection
      • Tie Rod Removal
      • Tie Rod Installation
      • Steering Cylinder Removal
      • Steering Cylinder Installation
      • Steering Cylinder Disassembly
      • Steering Cylinder Cleaning and Inspection
      • Steering Cylinder Assembly
      • Steering/Brake Pump Removal
      • Steering/Brake Pump Installation
      • Piston Steering Accumulator Removal
      • Piston Steering Accumulator Installation
      • Piston Steering Accumulator Disassembly
      • Piston Accumulator Cleaning and Inspection
      • Piston Seal Replacement
      • Piston Steering Accumulator Assembly
    • Brake System
      • Brake Treadle Valve Removal
      • Brake Treadle Valve Installation
      • Brake Valve/Pedal Disassembly
      • Brake Valve/Pedal Assembly
      • Brake Bladder Accumulator Removal
      • Brake Bladder Accumulator Installation
      • Brake Manifold Removal
      • Brake Manifold Installation
      • Brake Manifold Component Replacement
      • Front Brake Caliper Removal
      • Front Brake Caliper Installation
      • Front Brake Caliper Disassembly
      • Front Brake Caliper Cleaning and Inspection
      • Front Brake Caliper Assembly
      • Rear Brake Caliper Removal
      • Rear Brake Caliper Installation
      • Rear Brake Caliper Disassembly
      • Rear Brake Caliper Cleaning and Inspection
      • Rear Brake Caliper Assembly
    • Hoist System
      • Hoist Pump Removal
      • Hoist Pump Installation
      • Hoist Pump Disassembly
      • Hoist Pump Inspection
      • Hoist Pump Assembly
      • Hoist Control Valve Removal
      • Hoist Control Valve Installation
      • Hoist Control Valve Service
        • Hoist Control Valve O-Ring Replacement
        • Inlet Section Disassembly
        • Inlet Section Assembly
        • Spool Section Assembly
        • Spool Section Disassembly
        • Overcenter Manifold Service
      • Hoist Pilot Valve Removal
      • Hoist Pilot Valve Installation
      • Hoist Pilot Valve Disassembly
      • Hoist Pilot Valve Cleaning and Inspection
      • Hoist Pilot Valve Assembly
      • Hoist Cylinder Removal
      • Hoist Cylinder Installation
      • Hoist Cylinder Disassembly
      • Hoist Cylinder Cleaning and Inspection
      • Quill Installation
      • Quill Check Ball and Plug Installation
      • Hoist Cylinder Assembly
    • Suspensions
      • Front Suspension Removal
      • Front Suspension Cleaning and Inspection
      • Front Suspension Installation
      • Front Suspension Bolted Joint Inspection
      • Front Suspension Charging Valve Replacement
      • Front Suspension Disassembly
      • Front Suspension Assembly
      • Rear Suspension Removal
      • Rear Suspension Installation
      • Rear Suspension Disassembly
      • Rear Suspension Cleaning and Inspection
      • Rear Suspension Assembly
    • Dump Body and Structures
      • Dump Body Removal
      • Dump Body Inspection
      • Dump Body Installation
      • Body Pads Removal
      • Body Pads Installation
      • Body Pad Shimming Procedure
      • Diagonal Ladder Removal
      • Diagonal Ladder Installation
      • Grille and Hood Assembly Removal
      • Grille and Hood Assembly Installation
      • Egress Gate Adjustment
      • RH Deck Removal
      • RH Deck Installation
      • LH Deck Removal
      • LH Deck Installation
      • Fuel Tank Removal
      • Fuel Tank Cleaning and Inspection
      • Fuel Tank Installation
      • Fuel Gauge Sender Removal
      • Fuel Gauge Sender Installation
      • Hydraulic Tank Removal
      • Hydraulic Tank Installation
      • Hydraulic Tank Strainers Removal
      • Hydraulic Tank Strainers Cleaning and Inspection
      • Hydraulic Tank Strainers Installation
    • Operator Cab
      • Operator Cab Removal
      • Operator Cab Installation
      • Cab Door Removal
      • Cab Door Installation
      • Window Regulator Removal
      • Window Regulator Installation
      • Door Glass Removal
      • Door Glass Installation
      • Inner Door Seal Replacement
      • Outer Door Seal Replacement
      • Interior Door Handle and Door Latch Removal
      • Interior Door Handle and Door Latch Installation
      • Door Jamb Bolt Adjustment
        • Poor Seal When Door Is Closed
        • Door Springs Back Open
      • Exterior Door Handle Release Button Adjustment
      • Side Window Glass Removal
      • Side Window Glass Installation
      • Windshield and Rear Window Glass Removal
      • Windshield and Rear Window Glass Installation
      • Windshield Wiper Motor Removal
      • Windshield Wiper Motor Installation
      • Windshield Wiper Arm and Linkage Removal
      • Windshield Wiper Arm and Linkage Installation
      • Cab Seat Removal
      • Cab Seat Servicing
      • Cab Seat Installation
      • Seat Belt Removal
      • Seat Belt Installation
    • Power Module
      • Power Module General Information
      • Power Module Removal
      • Power Module Installation
      • Exhaust Tube Installation
      • Exhaust Blanket Installation
      • Alternator Removal
      • Alternator Installation
        • Engine Flywheel Adapter Face Runout
        • Engine Crankshaft Endplay
        • Engine Flywheel to Flywheel Housing Adapter – Measurement “C”
        • Alternator Housing to Rotor – Measurement “A”
        • Measurements After Joining the Alternator and Engine
        • Flywheel Housing Face Runout
        • Flywheel Housing Radial Runout
        • Flywheel/Flexplate Face Runout
        • Flywheel/Flexplate Radial Runout
      • Radiator Removal
      • Radiator Installation
      • Radiator Internal Inspection
      • Radiator External Cleaning
      • Radiator Disassembly
      • Radiator Cleaning and Inspection
      • Radiator Assembly
      • Engine Removal
      • Engine Service
      • Engine Installation
      • Electronic Fan Clutch Removal
      • Electronic Fan Clutch Installation
      • Electronic Fan Clutch Speed Sensor Removal
      • Electronic Fan Clutch Speed Sensor Installation
  • 60 MAINTENANCE STANDARD
    • Rules for Maintenance
    • Torque Specifications
    • Hydraulic System Bleeddown Procedure
    • Hydraulic System Vacuum Procedure
    • Power Cable Inspection
    • Long Term Storage of Electric Dump Truck
    • Diesel Exhaust Fluid (DEF) Equipment De-Crystallizing Instructions
      • DEF Component Flushing Apparatus
      • DEF Nozzle De-Crystallizing Procedure
      • DEF Fast Fill Valve Flushing Procedure
      • DEF Receiver Flushing Procedure
    • Hydraulic Pumps
      • Steering/Brake Pump
      • Hoist Pump
    • Tie Rod
    • Tail Lights, Clearance Lights and Turn Signals
  • 90 CIRCUIT DIAGRAMS
    • CONTENTS: 730E-10

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