Komatsu 730E DUMP Truck with TROLLEY ASSIST Service Shop Repair Manual (A30225 and A30226)
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๐ท๏ธ Basic Information Identification Make: Komatsu Model: 730E Description: Articulated Dump Truck with Trolley Assist Codes Manual Part Numbers: A30225, A30226 ๐ Introduction Market Position Segment: Large mining and heavy construction articulated dump trucks Target User: Maintenance personnel, service technicians, fleet managers in mining, quarrying, and heavy construction industries. Competitive Analysis Competitors: Caterpillar, Liebherr, Volvo Construction Equipment, Bell Equipment Key Features Vehicle Capability: High payload capacity, robust construction for extreme environments, advanced trolley assist for energy efficiency and reduced emissions on inclines. Manual Value Proposition: Provides essential, detailed technical information for effective maintenance and repair, ensuring maximum uptime and operational efficiency of the 730E with its specialized trolley assist system. ๐ Manual Details Coverage Areas Primary Focus: Service, Repair, Maintenance, Assembly, Disassembly Special Features Covered: Trolley Assist System Page Count Total Estimated Pages: High volume (typical for heavy equipment service manuals, likely over 1000 pages across both part numbers) Manual Type Type: Service Shop Repair Manual Language Language: English (presumed standard for Komatsu service documentation) Format Format: Likely digital (PDF) for easy searching and access, potentially also available in print. Specific format not detailed but common for such manuals. ๐ Manual Coverage Systems Covered Powertrain: Engine, transmission, drivetrain, axles, differentials, final drives, cooling system, exhaust system Hydraulics: Steering system, braking system, hoist system, auxiliary hydraulic systems Electrical: Starting and charging system, lighting, instrumentation, diagnostic systems, trolley assist control system, wiring diagrams Chassis And Body: Frame, suspension, steering linkage, braking system components, body panels, dump body, cab structure, access systems Trolley Assist: Specific components, operation, troubleshooting, and maintenance of the trolley assist system Procedures Included Maintenance: Scheduled maintenance, lubrication, fluid checks and changes, filter replacements Disassembly And Assembly: Complete procedures for all major components and systems Troubleshooting: Diagnostic procedures, fault codes, common problem identification and resolution Repair And Overhaul: Detailed instructions for component repair, rebuilding, and replacement Calibration And Adjustment: Procedures for system calibration and adjustments Technical Depth Depth: Comprehensive, covering from basic inspection to full component overhaul and system diagnostics. Suitable for certified technicians. Diagnostic Capabilities: Detailed diagnostic flowcharts, troubleshooting guides, and expected readings/values. Specialized Knowledge: Includes in-depth technical information specific to heavy-duty mining/construction equipment and advanced systems like trolley assist. ๐ Manual Specifications File Format Digital Format: Likely PDF, optimized for digital viewing and printing. Searchable text is a common feature in professional manuals. Print Quality Print Quality: High resolution images and diagrams for clarity. Professional printing standards if physical copy. Binding Type Binding Type: If printed: Spiral-bound or perfect-bound for durability and ease of use in a workshop environment. Paper Type Paper Type: If printed: Heavy-duty, possibly coated paper to withstand grease and workshop conditions. โ๏ธ Engine Specifications Primary Engine Make Model: Komatsu SSDA16V159E-1 (or similar Cummins QSK Series, common in large mining trucks) Configuration: V16, 4-stroke, turbocharged and aftercooled diesel engine Displacement: Approximately 60.5 liters (3,692 cubic inches) Power Output: Typically in the range of 1800-2200 HP (1342-1641 kW). Specific rating depends on configuration and emissions standards. Torque Output: Very high torque figures, often exceeding 7000 lb-ft (9490 Nm). Specific value is critical and found in manual. Fuel System Injection Type: High-pressure common rail direct injection Fuel Type: Diesel fuel Cooling System Type: Water-cooled, with large capacity radiator and fan system Emissions Control Features: Depending on model year and region: EGR (Exhaust Gas Recirculation), DOC (Diesel Oxidation Catalyst), DPF (Diesel Particulate Filter), SCR (Selective Catalytic Reduction) systems may be present. ๐ง Transmission Standard Type: Komatsu Advanced Automatic Transmission (or similar heavy-duty off-highway automatic transmission like Allison) Gears: Typically 7 or 8 forward gears and 1 or 2 reverse gears Features Electronic Control: Electronically controlled for optimized shifting and performance, integrated with trolley assist system logic. Retarder: Integrated engine and transmission retarder for downhill braking and speed control. Fluid Specification Transmission Oil Type: Specific heavy-duty automatic transmission fluid (e.g., CAT TO-4, Allison TES 295, or Komatsu specific fluids). Manual will specify exact type and viscosity. ๐ Dimensions Exterior Length: Approximately 9.8 - 10.5 meters (32 - 34.5 feet) Width: Approximately 4.5 - 5 meters (14.7 - 16.4 feet) Height: Approximately 4.5 - 5 meters (14.7 - 16.4 feet) to top of cab Cargo Body Capacity Heaped: Approximately 39 - 44 cubic meters (51 - 57.5 cubic yards) Weights Operating Weight: Approximately 100,000 - 120,000 kg (220,000 - 265,000 lbs) Payload Capacity: Approximately 100 - 110 US tons (90.7 - 99.8 metric tons) Tire Size Tire Size: Typically 33.00R51 or similar heavy-duty off-road tires. Wheel Bolt Pattern Bolt Pattern: Specific to wheel hub and brake assembly, requires manual verification. ๐ก๏ธ Safety Features Ratings Safety Standards: Designed to meet rigorous mining and construction safety standards. Manual will detail specific safety features and compliance. Active Features Braking System: Full hydraulic braking system with multiple independent circuits, fail-safe parking brake, retarder system. Steering System: Hydrostatic power steering with emergency steering capability. Passive...
Large mining and heavy construction articulated dump trucks
Target User:
Maintenance personnel, service technicians, fleet managers in mining, quarrying, and heavy construction industries.
Competitive Analysis
Competitors:
Caterpillar, Liebherr, Volvo Construction Equipment, Bell Equipment
Key Features
Vehicle Capability:
High payload capacity, robust construction for extreme environments, advanced trolley assist for energy efficiency and reduced emissions on inclines.
Manual Value Proposition:
Provides essential, detailed technical information for effective maintenance and repair, ensuring maximum uptime and operational efficiency of the 730E with its specialized trolley assist system.
High volume (typical for heavy equipment service manuals, likely over 1000 pages across both part numbers)
Manual Type
Type:
Service Shop Repair Manual
Language
Language:
English (presumed standard for Komatsu service documentation)
Format
Format:
Likely digital (PDF) for easy searching and access, potentially also available in print. Specific format not detailed but common for such manuals.
๐ Manual Coverage
Systems Covered
Powertrain:
Engine, transmission, drivetrain, axles, differentials, final drives, cooling system, exhaust system
Hydraulics:
Steering system, braking system, hoist system, auxiliary hydraulic systems
Electrical:
Starting and charging system, lighting, instrumentation, diagnostic systems, trolley assist control system, wiring diagrams
Chassis And Body:
Frame, suspension, steering linkage, braking system components, body panels, dump body, cab structure, access systems
Trolley Assist:
Specific components, operation, troubleshooting, and maintenance of the trolley assist system
Procedures Included
Maintenance:
Scheduled maintenance, lubrication, fluid checks and changes, filter replacements
Disassembly And Assembly:
Complete procedures for all major components and systems
Troubleshooting:
Diagnostic procedures, fault codes, common problem identification and resolution
Repair And Overhaul:
Detailed instructions for component repair, rebuilding, and replacement
Calibration And Adjustment:
Procedures for system calibration and adjustments
Technical Depth
Depth:
Comprehensive, covering from basic inspection to full component overhaul and system diagnostics. Suitable for certified technicians.
Diagnostic Capabilities:
Detailed diagnostic flowcharts, troubleshooting guides, and expected readings/values.
Specialized Knowledge:
Includes in-depth technical information specific to heavy-duty mining/construction equipment and advanced systems like trolley assist.
๐ Manual Specifications
File Format
Digital Format:
Likely PDF, optimized for digital viewing and printing. Searchable text is a common feature in professional manuals.
Print Quality
Print Quality:
High resolution images and diagrams for clarity. Professional printing standards if physical copy.
Binding Type
Binding Type:
If printed: Spiral-bound or perfect-bound for durability and ease of use in a workshop environment.
Paper Type
Paper Type:
If printed: Heavy-duty, possibly coated paper to withstand grease and workshop conditions.
โ๏ธ Engine Specifications
Primary Engine
Make Model:
Komatsu SSDA16V159E-1 (or similar Cummins QSK Series, common in large mining trucks)
Configuration:
V16, 4-stroke, turbocharged and aftercooled diesel engine
Displacement:
Approximately 60.5 liters (3,692 cubic inches)
Power Output:
Typically in the range of 1800-2200 HP (1342-1641 kW). Specific rating depends on configuration and emissions standards.
Torque Output:
Very high torque figures, often exceeding 7000 lb-ft (9490 Nm). Specific value is critical and found in manual.
Fuel System
Injection Type:
High-pressure common rail direct injection
Fuel Type:
Diesel fuel
Cooling System
Type:
Water-cooled, with large capacity radiator and fan system
Emissions Control
Features:
Depending on model year and region: EGR (Exhaust Gas Recirculation), DOC (Diesel Oxidation Catalyst), DPF (Diesel Particulate Filter), SCR (Selective Catalytic Reduction) systems may be present.
๐ง Transmission
Standard
Type:
Komatsu Advanced Automatic Transmission (or similar heavy-duty off-highway automatic transmission like Allison)
Gears:
Typically 7 or 8 forward gears and 1 or 2 reverse gears
Features
Electronic Control:
Electronically controlled for optimized shifting and performance, integrated with trolley assist system logic.
Retarder:
Integrated engine and transmission retarder for downhill braking and speed control.
Fluid Specification
Transmission Oil Type:
Specific heavy-duty automatic transmission fluid (e.g., CAT TO-4, Allison TES 295, or Komatsu specific fluids). Manual will specify exact type and viscosity.
๐ Dimensions
Exterior
Length:
Approximately 9.8 - 10.5 meters (32 - 34.5 feet)
Width:
Approximately 4.5 - 5 meters (14.7 - 16.4 feet)
Height:
Approximately 4.5 - 5 meters (14.7 - 16.4 feet) to top of cab
Approximately 100,000 - 120,000 kg (220,000 - 265,000 lbs)
Payload Capacity:
Approximately 100 - 110 US tons (90.7 - 99.8 metric tons)
Tire Size
Tire Size:
Typically 33.00R51 or similar heavy-duty off-road tires.
Wheel Bolt Pattern
Bolt Pattern:
Specific to wheel hub and brake assembly, requires manual verification.
๐ก๏ธ Safety Features
Ratings
Safety Standards:
Designed to meet rigorous mining and construction safety standards. Manual will detail specific safety features and compliance.
Active Features
Braking System:
Full hydraulic braking system with multiple independent circuits, fail-safe parking brake, retarder system.
Steering System:
Hydrostatic power steering with emergency steering capability.
Passive Features
Cab Design:
ROPS (Roll-Over Protective Structure) and FOPS (Falling Object Protective Structure) compliant cab with excellent visibility.
Fire Suppression:
Optional or integrated fire suppression systems (e.g., Ansul) may be specified. Manual will cover their maintenance.
Lighting And Visibility:
Comprehensive work lights, road lights, and safety beacons.
๐ก Technology Features
Infotainment
Cab Features:
While primarily a work machine, cabs are typically equipped with robust instrumentation, operational status displays, and potentially communication systems. Advanced infotainment is not a focus.
Driver Assistance
Trolley Assist:
Integrated system allowing the truck to draw power from overhead electrical lines on inclines, reducing diesel consumption and emissions, and potentially boosting power. This is a key technological feature.
Payload Monitoring:
On-board payload weighing systems are common for optimizing load cycles.
Connectivity
Telematics Capability:
Likely equipped with telematics systems for remote monitoring of performance, diagnostics, and operational data (e.g., Komatsu's KOMTRAX or similar). Manual will cover diagnostic interfaces.
๐ง Maintenance
Service Intervals
Engine Oil And Filter:
Typically 250-500 hours, depending on operating conditions and oil analysis. Manual will provide precise intervals and procedures.
Transmission Oil And Filter:
Typically 1000-2000 hours for fluid and filter changes. Crucial for longevity, manual will specify.
Hydraulic Fluid And Filter:
Similar to transmission, typically 1000-2000 hours. Contamination control is paramount.
Greasing Points:
Daily or weekly greasing of pivot points, suspension components, and articulation joints as per lubrication chart.
Fluid Specifications
Engine Oil Spec:
API CJ-4 or higher, SAE 15W-40 or 10W-30 (for cold weather). Exact Komatsu specification required.
Coolant Spec:
Heavy-duty diesel engine coolant with extended life additives (ELC), typically a 50/50 mix with de-ionized water.
Brake Fluid Spec:
DOT 3 or DOT 4 heavy-duty brake fluid, or specific hydraulic oil if system utilizes it. Manual will specify.
Known Issues
Common Wear Items:
Brake components, suspension bushings, articulation bearings, cooling system components, electrical connectors in harsh environments.
Trolley Assist Challenges:
Pantograph wear, electrical contact issues, control system sensitivity, inverter faults. Manual will detail troubleshooting.
๐ Vehicle History
Brand Heritage
Brand Specialization:
Komatsu is a leading global manufacturer of construction, mining, and industrial equipment, known for its durability and innovation.
Model Evolution
730E Development:
The 730E is a highly successful model in Komatsu's rigid and articulated dump truck line, representing their commitment to large-capacity haulage. The trolley assist variant addresses specific operational demands for reduced environmental impact and cost in certain applications.
Production
Manufacturing Locations:
Komatsu heavy equipment is manufactured globally, with significant production facilities in Japan, North America, and Europe. Specific model assembly location may vary.
๐ Awards & Recognition
Recognitions
Industry Acclaim:
Komatsu's large mining trucks are widely recognized for their reliability, productivity, and innovation in the heavy-duty sector. Specific awards for the 730E or its trolley assist variant are not publicly detailed but its market presence indicates strong industry acceptance.