Komatsu 330M Dump Truck Operation & Maintenance Manual SERIAL NUMBERS A10212-A10223 – PDF Download

Description

Komatsu 330M Dump Truck Operation & Maintenance Manual SERIAL NUMBERS A10212-A10223

Description:

• Komatsu 330M Dump Truck Operation & Maintenance Manual
• SERIAL NUMBERS A10212-A10223
• The first section is an Introduction to the manual and contains a Table of Contents to locate specific areas of interest. Other sections include Safety, Operation, Maintenance, Specifications, and Optional Equipment.
• The illustrations used in this manual are TYPICAL of the component shown and may not be an exact reproduction of what is found on the truck. This manual shows dimensioning of metric and (U.S. standard) units throughout. All references to “Right”, “Left”, “Front”, or “Rear” aremade with respect to the operator’s normal seated position, unless specifically stated otherwise.
• Standard torque requirements are shown in torque charts in the Introduction section and individual torques are provided in the text in bold face type, such as 723 kg.m (100 ft.lbs.) torque.
• All torque specifications have ±10% tolerance unless otherwise specified. A Product Identification plate is normally located on the truck frame upright in front of the left 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. 330M). The three numbers represent the basic truck model. The letter “M” designates a Mechanical drive and the letter “E” designates an Electrical wheelmotor drive system.
• The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill ofmaterial for this unit. This complete number will be necessary for proper ordering ofmany service parts and/or warranty consideration. The Gross VehicleWeight (GVW) is what determines the load on the drive train, frame, tires, and other components.
• The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight (GVW) and this means the TOTAL WEIGHT: the Empty Vehicle Weight + the fuel & lubricants + the payload.

Table Of Contents:

• Komatsu 330M Dump Truck Operation & Maintenance Manual
• SERIAL NUMBERS A10212-A10223

• MAIN MENU.........................................................  0
  COVER.............................................................  1
  INTRODUCTION......................................................  3
  	FOREWORD......................................................  3
  	ALERTS Page - DANGER, WARNING, CAUTION........................  4
  	TABLE OF CONTENTS.............................................  5
  	TRUCK MODEL ILLUSTRATION......................................  8
  	About This Manual.............................................  9
  	STANDARD TABLES............................................... 11
  SAFETY............................................................ 17
  	GENERAL SAFETY................................................ 17
  	PRECAUTIONS DURING OPERATION.................................. 21
  		OPERATING THE MACHINE..................................... 22
  		TOWING.................................................... 25
  		BATTERY................................................... 26
  	PRECAUTIONS FOR MAINTENANCE................................... 27
  		BEFORE CARRYING OUT MAINTENANCE........................... 27
  		DURING MAINTENANCE........................................ 28
  		TIRES..................................................... 31
  	WARNINGS AND CAUTIONS, and Instruction Plates / Decals........ 32
  OPERATION......................................................... 41
  	OPERATING INSTRUCTIONS........................................ 41
  		PREPARING FOR OPERATION................................... 41
  		SAFETY IS THINKING AHEAD.................................. 41
  		At The Truck - Ground Level Walk AroundInspection......... 41
  	ENGINE START-UP SAFETY PRACTICES.............................. 45
  	AFTER ENGINE HAS STARTED...................................... 47
  	MACHINE OPERATION SAFETY PRECAUTIONS.......................... 48
  	LOADING....................................................... 48
  	HAULING....................................................... 49
  	PASSING....................................................... 51
  	DUMPING....................................................... 51
  	SAFE PARKING PROCEDURES....................................... 52
  	SHUTDOWN PROCEDURE............................................ 52
  	TOWING........................................................ 53
  	BRAKE RELEASE................................................. 54
  	RELEASE OF PARKING BRAKE...................................... 54
  	RELEASE OF EMERGENCY BRAKE.................................... 54
  	OPERATOR CAB AND CONTROLS..................................... 55
  		Steering Wheel And Controls............................... 55
  		Retarder Control Lever.................................... 56
  		Service Brake Pedal....................................... 56
  		Throttle Pedal............................................ 56
  		Center Console and Controls............................... 56
  		ENGINE ELECTRONIC CONTROL SYSTEM.......................... 60
  			DETERMINING "FAULT" CODES............................. 61
  			EXITING THE DIAGNOSTICS MODE.......................... 61
  		Differential Lock Pedal................................... 61
  		Hoist Control Valve....................................... 62
  			SAFETY LOCK........................................... 62
  		OPERATOR SEAT............................................. 63
  	INSTRUMENT PANEL AND INDICATORS............................... 65
  	GAUGE AND MONITOR PANEL....................................... 67
  	INDICATORS AND CONTROL PANEL.................................. 70
  	INDICATORS AND CONTROL PANEL.................................. 70
  	INSTRUMENT PANEL - RIGHT SIDE................................. 75
  MAINTENANCE....................................................... 77
  	LUBRICATION AND SERVICE....................................... 77
  		Lubrication Chart......................................... 78
  		10 HOUR (SHIFT) Lubrication and Maintenance Checks........ 79
  		250 HOUR Lubrication and Maintenance Checks............... 85
  		500 HOUR Lubrication and Maintenance Checks............... 87
  		1000 HOUR Lubrication and Maintenance Checks.............. 88
  		2000 HOUR Lubrication and Maintenance Checks.............. 89
  		5000 HOUR Lubrication and Maintenance Checks.............. 90
  	HYDRAULIC TANK SERVICE........................................ 91
  	HIGH PRESSURE HYDRAULIC FILTERS............................... 93
  	TRANSMISSION FILTER SERVICE................................... 95
  	PERIODIC REPLACEMENT OF COMPONENT PARTS FOR SAFETY DEVICES.... 96
  	BRAKE CIRCUIT CHECKOUT AND ADJUSTMENT......................... 97
  		CHECKING FRONT BRAKE PAD WEAR............................. 97
  		TESTING BRAKE PRESSURE.................................... 97
  		CHECKING REAR BRAKE DISC WEAR............................. 98
  		BRAKE SYSTEM BLEEDING..................................... 99
  		PARKING BRAKE INSPECTION & ADJUSTMENT.....................100
  SPECIFICATIONS....................................................103
  	MAJOR COMPONENTS AND SPECIFICATIONS...........................103
  	SPECIFICATIONS................................................105
  OPTIONAL EQUIPMENT................................................107
  PAYLOAD METER II™ INDEX...........................................107
  PAYLOAD METER II™.................................................110
  	PAYLOAD METER II ON BOARD WEIGHING SYSTEM (OBWS)..............110
  	GENERAL INFORMATION...........................................110
  		Haul Cycles...............................................110
  	LIGHTS, SWITCHES, and COMPONENTS..............................111
  	TIPS FOR OPERATION............................................112
  	EXTERNAL DISPLAY LIGHTS.......................................112
  	THEORY OF OPERATION...........................................113
  		Basic Description.........................................113
  		Inclinometer..............................................113
  		Linkage Factor............................................113
  		Gain Factor...............................................114
  		Brake Lock................................................114
  		Sources of Error..........................................114
  		Typical Data From Service Check Mode......................114
  		Example Calculation of Payload............................115
  		Viewing Payload Calculation Inputs........................115
  		Checking the Gain.........................................116
  		Adjusting the Gain........................................116
  	TYPES OF DATA STORED..........................................117
  		Cycle Data................................................117
  		Engine ON/OFF Data........................................118
  		Fault Codes and Warning Data..............................118
  		Engine Operation..........................................119
  		Total Payload and Total Number of Cycles..................119
  		Other Data................................................119
  	OPERATOR FUNCTIONS............................................120
  		Using the Operator Load Counter...........................120
  		Viewing the Operator Load Counter.........................120
  		Clearing the Operator Load Counter........................120
  		Dimming the Lights on the Display.........................120
  	INITIAL SETUP OF PAYLOAD METER................................121
  		Switch Settings...........................................121
  		Checking the Operator Check Mode..........................122
  		Checking the Service Check Mode...........................122
  		Checking the Gt setting...................................123
  		Checking the Inclinometer Settings........................123
  		Calibrating a Truck.......................................123
  	DISPLAYS AT START-UP..........................................124
  	NORMAL OPERATION..............................................124
  	SETUP AND MAINTENANCE.........................................125
  		Setting The Speed Limit...................................125
  		Setting the Option Code...................................125
  		Setting The Machine I.D. Code.............................126
  		Setting The Operator I.D. Code............................126
  		Setting The Time and Date.................................126
  	DOWNLOAD OF INFORMATION.......................................127
  	DISPLAY OF FAULT CODES........................................127
  	Monitoring Input Signals......................................131
  	Service Check Mode............................................131
  	UP Factor - Payload Calculation Gain..........................132
  	PL Mode - Load Calculation Timing.............................132
  	FINAL GEAR RATIO SELECTION....................................133
  	BATTERY REPLACEMENT PROCEDURE.................................134
  		Replacing the Battery.....................................134
  		After Replacing the Battery...............................135
  	SUSPENSION PRESSURE SENSOR....................................135
  		Removal...................................................135
  		Installation..............................................136
  	INCLINOMETER..................................................136
  		Removal...................................................136
  		Installation..............................................136
  		Adjustment................................................136
  	PAYLOAD METER BACK PANEL......................................137
  	CONNECTIONS...................................................138
  	PAYLOAD METER 2 RE-INITIALIZATION PROCEDURE...................139
  	PAYLOAD CIRCUIT NUMBERS.......................................140
  

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KOMATSU 330M DUMP TRUCK OPERATION & MAINTENANCE MANUAL SERIAL NUMBERS A10212-A10223 – PDF DOWNLOAD:

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