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KOMATSU 330M DUMP TRUCK SHOP MANUAL DG728 – PDF DOWNLOAD
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Description
KOMATSU 330M DUMP TRUCK SHOP MANUAL DG728 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU 330M DUMP TRUCK SHOP MANUAL DG728 – PDF DOWNLOAD
Language : English
Pages : 824
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU 330M DUMP TRUCK SHOP MANUAL DG728 – PDF DOWNLOAD
MAIN MENU............................................................................................................. 0 COVER................................................................................................................. 1 TABLE OF CONTENTS..................................................................................................... 5 A - GENERAL INFORMATION............................................................................................... 7 MAJOR COMPONENTS & SPECIFICATIONS................................................................................. 9 GENERAL SAFETY.................................................................................................... 13 WARNINGS & CAUTIONS............................................................................................... 43 CHARTS & TABLES................................................................................................... 51 STANDARD MAINTENANCE TABLES....................................................................................... 57 B - STRUCTURES........................................................................................................ 75 GRILL & HOOD...................................................................................................... 77 DECKS............................................................................................................. 77 LEFT DECK & CAB................................................................................................... 78 Removal....................................................................................................... 78 Installation.................................................................................................. 78 RIGHT DECK STRUCTURE.............................................................................................. 79 Removal....................................................................................................... 79 Installation.................................................................................................. 79 CENTER DECK STRUCTURE............................................................................................. 80 Removal....................................................................................................... 80 Installation.................................................................................................. 80 DUMP BODY - REMOVAL............................................................................................... 81 DUMP BODY - INSTALLATION.......................................................................................... 82 BODY PADS......................................................................................................... 83 Removal....................................................................................................... 83 Installation.................................................................................................. 83 Adjustment.................................................................................................... 83 BODY GUIDE........................................................................................................ 84 BODY PIN.......................................................................................................... 84 ROCK EJECTORS..................................................................................................... 85 Rock Ejectors - Inspection.................................................................................... 85 FUEL TANK......................................................................................................... 87 Removal....................................................................................................... 87 Installation.................................................................................................. 88 Cleaning...................................................................................................... 88 VENT.............................................................................................................. 88 QUICK FUEL OPTION................................................................................................. 88 C - ENGINE, RADIATOR & AIR CLEANER.................................................................................... 89 RADIATOR.......................................................................................................... 91 Removal....................................................................................................... 91 Service....................................................................................................... 93 Installation.................................................................................................. 93 BRAKE OIL COOLER.................................................................................................. 94 Removal....................................................................................................... 94 Installation.................................................................................................. 94 FAN............................................................................................................... 94 Removal....................................................................................................... 94 Installation.................................................................................................. 94 FAN BELT.......................................................................................................... 95 Removal....................................................................................................... 95 Installation.................................................................................................. 95 ENGINE............................................................................................................ 97 Removal....................................................................................................... 97 Installation..................................................................................................100 DRIVE LINE ADAPTER................................................................................................101 Removal.......................................................................................................101 Installation..................................................................................................102 Repair........................................................................................................103 AIR FILTRATION SYSTEM.............................................................................................105 AIR CLEANER.......................................................................................................105 Service Checks................................................................................................105 Filter Element Replacement....................................................................................105 MAIN FILTER ELEMENT...............................................................................................107 Main Filter Element Cleaning..................................................................................107 Air Intake Troubleshooting....................................................................................108 D - ELECTRICAL SYSTEM.................................................................................................109 24VDC ELECTRICAL SUPPLY SYSTEM....................................................................................111 Electrical System Description.................................................................................111 Battery.......................................................................................................111 Service...................................................................................................111 Storage...................................................................................................111 Maintenance & Troubleshooting.............................................................................112 Spillage..................................................................................................113 Battery Charging Alternator...................................................................................113 Operation.................................................................................................114 Engine Prelube System.........................................................................................115 Design....................................................................................................115 Operation.................................................................................................115 Troubleshooting...........................................................................................117 24VDC ELECTRICAL SYSTEM COMPONENTS................................................................................119 Vehicle Monitor System........................................................................................119 Vehicle Monitor Panel.....................................................................................122 Sensors & Switches........................................................................................122 Monitor Panel Displays .......................................................................................124 Instrument Panel Indicators, Test Switch......................................................................128 Electronic Accelerator Pedal System...........................................................................130 AISS..........................................................................................................131 Transmission Controller.......................................................................................132 Exhaust Brake.................................................................................................134 POINTS TO REMEMBER WHEN TROUBLESHOOTING...........................................................................137 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE..................................................................138 Points To Remember When Handling Electric Equipment...........................................................138 Handling Of Controller Boxes..................................................................................143 Precautions when performing arc welding on the truck..........................................................143 Points to remember when troubleshooting electric circuits.....................................................143 Points to remember when handling hydraulic equipment..........................................................144 CHECKS BEFORE TROUBLESHOOTING.....................................................................................146 TYPE OF CONNECTOR & POSITION OF INSTALLATION......................................................................148 FOR ARSC (AUTOMATIC RETARDER SPEED CONTROL).......................................................................153 CONNECTOR PIN ALLOCATION CHART....................................................................................154 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS........................................................................159 EXPLANATIONS OF FUNCTIONS (CONTROL MECHANISM) OF ELECTRICAL SYSTEM................................................169 Explanation of functions......................................................................................169 Explanation of self-diagnostic display functions..............................................................169 Checking operation of electrical system.......................................................................171 MONITOR PANEL ACTION CODES & SERVICE MODE.........................................................................175 Outline.......................................................................................................175 Action Code Display...........................................................................................175 Service Mode..................................................................................................176 Method of deleting data from memory...........................................................................184 Precautions when operating service mode.......................................................................184 Table 1 Bit Numbers...........................................................................................187 Brake Air Pressure Sensor.....................................................................................188 SELF-DIAGNOSTIC DISPLAY METHOD FOR MONITOR PANEL & CONTROLLERS....................................................189 Monitor Panel.................................................................................................189 Transmission Controller.......................................................................................189 Self-Diagnostic Display Code Table........................................................................189 Warning Display Table.....................................................................................190 Method of re-enacting fault displayed.....................................................................191 Operation of controller when fault is detected............................................................191 Transmission mode display.....................................................................................192 Saving self-diagnostic display to memory......................................................................192 Saving service code to memory.................................................................................193 TABLE OF SERVICE CODES & ACTION CODES.............................................................................194 Table of service codes & action codes related to monitor panel................................................194 Table of service codes & action codes related to transmission controller......................................195 Table of service codes & action codes related to suspension controller........................................198 Table of service codes & action codes related to PMC..........................................................199 METHOD OF USING TABLE.............................................................................................200 METHOD OF USING TROUBLESHOOTING CHARTS............................................................................201 Method of using troubleshooting chart for each troubleshooting fault..........................................201 ADJUSTING ELECTRONIC MONITOR (SPEEDOMETER, MODULE)................................................................203 SETTING ROTARY SWITCH (MODEL & NETWORK DATA) WHEN REPLACING TRANSMISSION CONTROLLER...............................204 METHOD OF DELETING DATA FROM TRANSMISSION CONTROLLER MEMORY.......................................................205 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM.................................................................209 Troubleshooting Charts........................................................................................209 Troubleshooting Index.....................................................................................209 Points to remember when carrying out troubleshooting of transmission controller system ...................212 Action taken by self-diagnostic device and problems on the truck .........................................214 Table for transmission controller, transmission related parts ............................................234 A-1 ( u.u ) a) (OFF) Controller self-diagnostic display LED does not light up ..........................236 b001(E. « 0.1) b) Drop in voltage of controller power source is displayed ................................237 b0dA(E. « d.A) c) Drop in voltage of battery direct power source is displayed.............................238 b0db(E. « d.b) d) Drop in voltage of main power source is displayed ......................................239 b002(E. « 0.2) e) Fault in transmission cut relay power source is displayed ..............................240 A-2 b003(E. « 0.3) Fault in neutral safety circuit is displayed ..........................................241 A-3 b005(E. « 0.5) Double engagement for clutch is displayed .............................................242 A-4 b006(E. « 0.6) Fault in transmission (cut relay) is displayed ........................................243 A-5 b008(E. « 0.8) Fault in rear brake solenoid is displayed .............................................244 A-6 b009(E. « 0.9) Fault in exhaust brake solenoid is displayed ..........................................245 A-7 b0C4(E. « C.4) a) Short circuit with ground in BCV rear solenoid is displayed.........................246 b0C6(E. « C.6) b) Short circuit in BCV rear solenoid is displayed ........................................246 b0C8(E. « C.8) c) Disconnection in BCV rear solenoid is displayed ........................................248 A-8 b010(E. « 1.0) or b060 (E. « 6.0) ....................................................................249 b011(E. « 1.1) or b061 (E. « 6.1) ........................................................................250 b012(E. « 1.2) or (E. « 6.2) .............................................................................251 b013(E. « 1.3) or (E. « 6.3)..............................................................................252 A-9 b022(E. « 2.2) or b023 (E. « 2.3) ....................................................................253 b024(E. « 2.4) or b028 (E. « 2.8).........................................................................254 A-10 b014(E. « 1.4) a) Fault in model selection (wiring harness) is displayed ............................255 b0A1(E. « A.1) b) Fault in model selection (rotary switch) is displayed ..................................256 A-11b007(E. « 0.7) a) Short circuit in shift lever assembly power source is displayed ....................257 b015(E. « 1.5) b) Shift lever position signal input for 2 or more circuit is displayed ...................258 b016(E. « 1.6) c) Shift lever position signal is not inputted ............................................260 A-12 b017(E. « 1.7) Fault in accelerator signal is displayed .............................................262 A-13b019(E. « 1.9) Fault in transmission oil temperature sensor is displayed .............................263 A-14b032(E. « 3.2) - b038 (E. « 3.8) ....................................................................264 b042(E. « 4.2) - b048 (E. « 4.8) ........................................................................266 b-1) Checking fill signal.................................................................................266 b042(E. « 4.2) - b043 (E. « 4.3) ........................................................................267 A-15b052(E. « 5.2) - b058 (E. « 5.8) ....................................................................268 A-16b071(E. « 7.1) - b078 (E. « 7.8) ....................................................................269 b091(E. « 9.1) - b098 (E. « 9.8) ........................................................................269 A-17b0A2(E. « A.2) a) Fault in torque converter oil temperature sensor is displayed ......................271 b0A3(E. « A.3) b) Fault in fuel level sensor is displayed ................................................272 b0b2(E. « b.2) c) Fault in cooling water temperature sensor is displayed .................................273 b0b3(E. « b.3) d) Fault in air pressure sensor is displayed ..............................................274 b0b4(E. « b.4) e) Fault in retarder brake oil temperature sensor is displayed ............................275 A-18 b0d1(E. « d.1) a) Transmission filter clogged warning is displayed ..................................276 b0d5(E. « d.5) b) Tilt warning is displayed ..............................................................277 b0d6(E. « d.6) c) Drop in radiator water level warning is displayed ......................................278 b0d7(E. « d.7) d) Battery charge level warning is displayed ..............................................279 b0E5(E. « E.5) e)Steering oil temperature overheat warning is displayed ..................................280 b0F5(E. « F.5) f) Drop in engine oil pressure warning is displayed .......................................281 b0F6(E. « F.6) g) Rear brake oil pressure warning is displayed ...........................................282 A-19b0B7(E. « B.7) Fault in engine oil pressure sensor is displayed ......................................283 A-20b0C1(E. « C.1) Fault in connector connection is displayed ............................................284 A-21b0d2(E. « d.2) a) Torque converter oil temperature overheat warning is displayed .....................285 b0d3(E. « d.3) b) Engine water temperature overheat warning is displayed .................................285 b0E9(E. « E.9) c) Air pressure drop warning is displayed .................................................285 b0F3(E. « F.3) d) Retarder brake oil temperature overheat warning is displayed ...........................285 b0d8(E. « d.8) e) Engine overrun actuated is displayed ...................................................286 b0d9(E. « d.9) f) Engine overshoot actuated is displayed .................................................286 MONITOR PANEL TROUBLESHOOTING.....................................................................................287 TROUBLESHOOTING CHARTS........................................................................................287 TROUBLESHOOTING INDEX.........................................................................................287 Method of self-diagnostic display for monitor panel and controllers . . ................................289 Action taken by self-diagnostic device and problems on truck (monitor panel)..............................289 P-1 Check pattern for wiring harnesses between modules ...................................................294 P-2 Nothing on monitor panel works........................................................................297 P-3 LH, RH module and fuel gauge do not operate...........................................................298 P-4 LH, RH module and fuel gauge do not operate...........................................................299 P-5 RH module does not operate............................................................................300 P-6 LH module does not operate............................................................................301 P-7 Travel calculator does not operate....................................................................302 P-8 Service meter display does not operate correctly......................................................303 P-9 Central warning lamp does not operate, or monitor panel detects fault code [A002].....................304 P-10 Central warning lamp stays on........................................................................305 P-11 Alarm buzzer does not operate , or monitor panel detects failure code [A003].........................306 P-12 Alarm buzzer continues to sound......................................................................307 P-13 All data from shift controller (speedometer, tachometer, shift indicator, etc.) are abnormal ........308 P-14 Suspension mode power/economy mode displays are abnormal.............................................309 P-15 Gauge displays are abnormal (nothing is displayed, or display does not change) . ....................310 P-16 Cooling water level drop caution lamp does not operate,..............................................311 P-17 Cooling water level drop caution lamp stays on.......................................................312 P-18 Emergency steering pilot lamp does not operate, or monitor panel detects service code [A001].........313 P-19 Emergency steering pilot lamp stays on...............................................................314 P-20 Engine oil pressure drop caution lamp does not operate...............................................315 P-21 Engine oil pressure drop caution lamp stays on.......................................................316 P-22 Exhaust brake pilot lamp does not operate, or monitor panel detects service code [A001]..............317 P-23 Exhaust brake pilot lamp (optional) stays on ........................................................318 P-24 Charging circuit fault caution lamp does not operate, or monitor panel detects service code [A001....319 P-25 Charging circuit fault caution lamp stays on.........................................................320 P-26 Transmission filter clogging caution lamp does not operate...........................................321 P-27 Transmission filter clogging caution lamp stays on...................................................322 P-28 Brake stroke caution lamp does not operate, or monitor panel detects service code [A001].............323 P-29 Brake stroke caution lamp stays on...................................................................324 P-30 Preheating switch pilot lamp does not operate, or monitor panel detects service code [A001] .........325 P-31 Preheating switch pilot lamp stays on................................................................326 P-32 Tilt warning lamp does not operate, or monitor panel detects service code [A001].....................327 P-33 Tilt warning lamp stays on...........................................................................328 P-34 Body FLOAT (except FLOAT) pilot lamp does not operate................................................329 P-35 Body FLOAT (except FLOAT) pilot lamp stays on........................................................330 P-36 Rear brake pilot lamp does not operate, or monitor panel detects service code [A001].................331 P-37 Rear brake pilot lamp stays on.......................................................................332 P-38 Parking brake pilot lamp does not operate, or monitor panel detects service code [A001]..............333 P-39 Parking brake pilot lamp stays on....................................................................334 P-40 Maintenance caution lamp does not operate, or monitor panel detects service code [A001]..............335 P-41 Maintenance caution lamp stays on....................................................................336 P-42 Steering oil temperature caution lamp does not operate...............................................337 P-43 Steering oil temperature caution lamp stays on.......................................................338 P-46 High beam display does not light up..................................................................339 P-47 Turn signal lamp (right) does not light up ..........................................................341 P-48 Turn signal lamp (left) does not light up............................................................342 P-49 Lamp check switch does not operate...................................................................343 P-50 AISS switch does not operate.........................................................................344 P-51 Exhaust brake switch (optional) does not operate.....................................................345 P-52 Mode change switch (1) does not operate..............................................................346 P-53 Mode change switch (2) does not operate..............................................................347 P-54 KPH/MPH speedometer unit selector does not operate...................................................348 P-55 Improper operation of all switch inputs..............................................................349 P-56 Monitor panel detects service codes [A014] or [A019] ................................................350 P-58 Monitor panel detects service code [A011.............................................................351 P-59 Monitor panel detects service code [A012]............................................................351 P-60 Monitor panel detects service code [A000] ..........................................................351 ENGINE ELECTRONIC DIAGNOSTIC SYSTEM...............................................................................353 Fault Code Information (T01-001)..............................................................................356 ELECTRICAL SPECIFICATIONS.........................................................................................359 HYDRAULIC & MECHANICAL SYSTEMS TROUBLESHOOTING....................................................................361 Troubleshooting Index.........................................................................................361 H-1 Truck does not move...................................................................................362 H-2 Truck does not travel smoothly........................................................................364 H-3 Lock-up clutch cannot be disengaged...................................................................364 H-4 Excessive shock when starting or shifting.............................................................364 H-5 Transmission does not shift up........................................................................365 H-6 Truck lacks power or speed when moving................................................................366 H-7 Time lag is excessive when starting or shifting gear .................................................370 H-8 Torque converter oil temperature is high..............................................................372 H-9 Torque converter oil pressure is high.................................................................373 H-10 Front brakes are ineffective, or effective only on one side..........................................374 H-11 Rear brakes are ineffective, or effective on one side only...........................................375 H-12 Steering wheel is difficult to turn..................................................................376 H-13 Steering wheel inoperative...........................................................................377 H-14 Steering wheel vibrates..............................................................................377 H-15 Hoist cylinder lacks lifting force (lifting speed) ..................................................378 H-16 Hoist cylinders do not operate.......................................................................380 H-17 Excessive dump body hydraulic drift..................................................................382 H-18 Air pressure does not increase ......................................................................383 F - TRANSMISSION......................................................................................................385 TORQUE CONVERTER OPERATION........................................................................................388 Main Relief Valve.............................................................................................393 Torque Converter Relief Valve.................................................................................393 Lockup Solenoid Valve.........................................................................................395 Testing Hydraulic Pressure of Torque Converter Valve..........................................................398 Torque Converter Stall Speed..................................................................................399 TRANSMISSION OPERATION............................................................................................401 ECMV (Electronic Control Modulation Valve)....................................................................405 Lubrication Relief Valve......................................................................................415 TRANSMISSION .....................................................................................................416 Removal.......................................................................................................416 Installation..................................................................................................418 TRANSMISSION FILTER...............................................................................................420 Service.......................................................................................................420 TRANSMISSION OIL COOLER...........................................................................................421 Removal.......................................................................................................421 Installation..................................................................................................421 TRANSMISSION OIL STRAINER.........................................................................................421 Removal.......................................................................................................421 Installation..................................................................................................421 TORQUE CONVERTER CONTROL VALVE....................................................................................422 Removal.......................................................................................................422 Installation..................................................................................................422 Disassembly...................................................................................................422 Assembly......................................................................................................423 DRIVELINES & U-JOINTS.............................................................................................425 Removal.......................................................................................................425 Installation..................................................................................................425 Disassembly...................................................................................................425 Assembly......................................................................................................425 AUTOMATIC SHIFT CONTROL SYSTEM....................................................................................427 General Information...........................................................................................427 Transmission Shift Controller.................................................................................427 Power Mode................................................................................................427 Braking Mode..............................................................................................427 Lock-Up & Engine Overspeed................................................................................427 Transmission Speeds Monitoring............................................................................427 Self Diagnostics..........................................................................................428 Range Selector Positions & Automatic Gear Shifting Ranges.....................................................430 Transmission Operation Modes.............................................................................430 Automatic Gear Shifting.......................................................................................431 Automatic Shifting Sequence...............................................................................431 Safety Functions..........................................................................................433 Transmission Range Selector...................................................................................434 Sensors, Switches.............................................................................................435 Transmission Troubleshooting Procedures.......................................................................438 G - WHEELS, SPINDLES & FINAL DRIVE....................................................................................443 TIRES & RIMS......................................................................................................445 General Information...........................................................................................445 FRONT TIRE & RIM..................................................................................................446 Removal.......................................................................................................446 Installation..................................................................................................447 REAR TIRE & RIM...................................................................................................447 Removal.......................................................................................................447 Installation..................................................................................................448 TIRE MATCHING.....................................................................................................450 FRONT WHEEL HUB & SPINDLES........................................................................................451 FRONT WHEEL HUB...................................................................................................451 Removal.......................................................................................................451 FRONT WHEEL BEARING & BRAKE DISC REPLACEMENT......................................................................452 FRONT WHEEL HUB INSTALLATION & BEARING ADJUSTMENT.................................................................453 A-FRAME...........................................................................................................454 Removal.......................................................................................................454 Installation..................................................................................................454 CENTER TIE ROD PIVOT..............................................................................................455 Removal.......................................................................................................455 Inspection....................................................................................................455 Installation..................................................................................................455 FINAL DRIVE ATTACHMENTS...........................................................................................457 Final Drive Lower Link........................................................................................457 Pin Removal...............................................................................................457 Pin Installation..........................................................................................458 Bearing Removal & Inspection..............................................................................458 Bearing Installation......................................................................................458 Diagonal Panhard Rod..........................................................................................458 Removal...................................................................................................458 Installation..............................................................................................459 Bearing Replacement.......................................................................................459 FINAL DRIVE ASSEMBLY..............................................................................................461 Complete Final Drive Assembly.................................................................................461 Removal...................................................................................................463 Installation..............................................................................................464 DIFFERENTIAL CARRIER ASSEMBLY.....................................................................................465 Removal.......................................................................................................465 Installation..................................................................................................466 Differential Cage Removal.....................................................................................466 Pinion Removal................................................................................................467 Differential Cage Disassembly.................................................................................467 Spider Gear Bearing Removal...................................................................................469 Spider Gear Bearing Installation..............................................................................471 Differential Cage Assembly....................................................................................471 Pinion Installation & Bearing Adjustment......................................................................473 Differential Cage Installation................................................................................474 Carrier Bearing & Backlash Adjustment.........................................................................476 FINAL DRIVE PLANETARIES & WHEEL HUBS..............................................................................479 Planetary Drive...............................................................................................479 Final Drive Carrier Removal...................................................................................480 Final Drive Carrier Installation..............................................................................481 Final Drive Carrier Disassembly...............................................................................481 Final Drive Carrier Assembly..................................................................................482 Final Drive Disassembly.......................................................................................482 Final Drive Assembly..........................................................................................485 H - SUSPENSIONS.......................................................................................................487 FRONT SUSPENSION..................................................................................................489 Operation.....................................................................................................489 Removal.......................................................................................................491 Installation..................................................................................................493 Disassembly...................................................................................................494 Inspection....................................................................................................495 Assembly......................................................................................................495 Attenuation Valve Repair......................................................................................496 REAR SUSPENSION...................................................................................................497 Operation.....................................................................................................497 Removal.......................................................................................................498 Installation..................................................................................................499 Disassembly...................................................................................................499 Assembly......................................................................................................500 Spherical Bearing Repair......................................................................................501 OILING & CHARGING PROCEDURES......................................................................................503 General.......................................................................................................503 Equipment List................................................................................................503 Front Suspension..............................................................................................503 Front Suspension Oiling...................................................................................504 Front Suspension Nitrogen Charging........................................................................505 Rear Suspension...............................................................................................507 Rear Suspension Oiling....................................................................................507 Rear Suspension Nitrogen Charging.........................................................................508 J - BRAKE SYSTEM......................................................................................................511 BRAKE CIRCUIT.....................................................................................................511 Component Description.........................................................................................513 Emergency Relay Valve (RE-6)..................................................................................514 Brake Circuit Operation.......................................................................................513 Hand Brake (Retarder).........................................................................................517 Parking Brake Pilot Valve.....................................................................................519 Parking Brake Relay Valve.....................................................................................520 Brake Chamber (Front).........................................................................................521 Brake Chamber (Rear)..........................................................................................521 Slack Adjuster................................................................................................522 Pressure Switch...............................................................................................524 Stop Lamp Switch..............................................................................................524 Parking Brake Switch..........................................................................................525 Automatic Retarder Valve......................................................................................525 Front Brake Cut-Off Valve.....................................................................................526 Brake Cooling Valve (BCV).....................................................................................527 Parking & Emergency Brake Valve...............................................................................528 Brake Valve (Treadle).........................................................................................530 BRAKE CIRCUIT COMPONENT SERVICE...................................................................................535 Service Brake Treadle Valve...................................................................................535 Pressure Converters (Front)...................................................................................538 Pressure Converters (Rear)....................................................................................542 Slack Adjuster................................................................................................546 BRAKE CIRCUIT CHECKOUT & ADJUSTMENT...............................................................................549 Checking Front Pad Wear.......................................................................................549 Checking Brake Pressure.......................................................................................549 Checking Rear Disc Wear.......................................................................................550 Brake Bleeding................................................................................................551 Brake Troubleshooting Charts..................................................................................552 FRONT BRAKES......................................................................................................555 Brake Pads....................................................................................................555 Removal...................................................................................................555 Installation..............................................................................................555 Brake Caliper Assembly........................................................................................555 Removal...................................................................................................555 Installation..............................................................................................556 Disassembly...............................................................................................556 Inspection Values.........................................................................................556 Assembly..................................................................................................557 REAR BRAKES.......................................................................................................559 Removal.......................................................................................................559 Installation..................................................................................................560 Disassembly...................................................................................................561 Inspection Values.............................................................................................562 Assembly......................................................................................................562 PARKING BRAKE.....................................................................................................565 Brake Pads....................................................................................................565 Removal...................................................................................................565 Installation..............................................................................................565 Parking Brake Caliper.........................................................................................565 Removal...................................................................................................565 Installation..............................................................................................566 Disassembly...............................................................................................566 Assembly..................................................................................................567 Parking Brake Spring Cylinder.................................................................................567 Removal...................................................................................................567 Installation..............................................................................................567 Disassembly...............................................................................................567 Assembly..................................................................................................568 Parking Brake Adjustment......................................................................................569 Parking Brake Disc............................................................................................570 Driveshaft Removal........................................................................................570 Parking Brake Disc Removal................................................................................570 Inspection Values.........................................................................................571 Parking Brake Disc Installation...........................................................................571 Driveshaft Installation...................................................................................571 PARKING BRAKE RELEASE AFTER EMERGENCY APPLY.......................................................................571 Release of Parking Brake......................................................................................571 Release of Emergency Brake....................................................................................572 K - AIR SYSTEM........................................................................................................573 AIR SYSTEM OPERATION..............................................................................................575 COMPONENT DESCRIPTION.............................................................................................575 Main Air Tank.................................................................................................575 Safety Valve..................................................................................................575 Air Govenor...................................................................................................575 Air Dryer.....................................................................................................576 Air Horn......................................................................................................578 AIR SYSTEM COMPONENT REPAIR.......................................................................................579 Air Compressor Service........................................................................................579 Air Governor..................................................................................................579 RETARDER VALVE....................................................................................................581 Removal.......................................................................................................581 Installation..................................................................................................581 Disassembly...................................................................................................583 Assembly......................................................................................................583 L - HYDRAULIC SYSTEM..................................................................................................585 HYDRAULIC SYSTEM OPERATION........................................................................................587 Component Description.........................................................................................587 HYDRAULIC SYSTEM COMPONENT REPAIR.................................................................................591 Hydraulic Pump................................................................................................591 Removal...................................................................................................591 Installation..............................................................................................592 Hydraulic Tank................................................................................................592 Filling Instructions (Hoist Oil Supply)...................................................................592 Filling Instructions (Rear Brake Cooling Oil Supply)......................................................592 Hydraulic Filters.............................................................................................593 Filter Replacement........................................................................................593 Hydraulic Tank Breather.......................................................................................593 Cleaning..................................................................................................593 High Pressure Hydraulic Filters...............................................................................594 Removal...................................................................................................594 Installation..............................................................................................594 Replacement...............................................................................................595 STEERING CIRCUIT..................................................................................................597 Steering Circuit Operation....................................................................................597 Demand Valve.................................................................................................598 Steering Control Valve........................................................................................598 Crossover Relief Valve........................................................................................599 Operation of Demand & Steering Control Valve..................................................................600 Emergency Steering System.....................................................................................608 Flow Switch...................................................................................................609 Relay Timer...................................................................................................609 Emergency Steering System Electrical Schematic................................................................610 STEERING VALVE ASSEMBLY...........................................................................................611 Removal.......................................................................................................611 Installation..................................................................................................611 Disassembly...................................................................................................612 Assembly......................................................................................................617 STEERING CIRCUIT COMPONENT REPAIR.................................................................................625 Emergency Steering Motor Pump Assembly........................................................................625 Removal...................................................................................................625 Installation..............................................................................................625 Steering Cylinder Assembly....................................................................................626 Removal...................................................................................................626 Installation..............................................................................................626 Disassembly...............................................................................................627 Assembly..................................................................................................629 Demand Valve Assembly.........................................................................................631 Removal...................................................................................................631 Installation..............................................................................................631 Disassembly...............................................................................................632 Assembly..................................................................................................632 Relief Valve Assembly.........................................................................................633 Disassembly...............................................................................................633 Assembly..................................................................................................633 HOIST CIRCUIT OPERATION & COMPONENT DESCRIPTION...................................................................635 Hoist Circuit Operation.......................................................................................635 Hoist Circuit Component Description...........................................................................635 HOIST CIRCUIT COMPONENT REPAIR....................................................................................641 Hoist Valve Assembly..........................................................................................641 Removal...................................................................................................641 Installation..............................................................................................641 Disassembly...............................................................................................642 Assembly..................................................................................................642 Hoist Cylinder................................................................................................644 Removal...................................................................................................644 Installation..............................................................................................645 Disassembly...............................................................................................646 Assembly..................................................................................................646 HYDRAULIC SYSTEM CHECKOUT.........................................................................................649 Dump Body Control.............................................................................................649 Adjusting Hoist Lever Linkage.................................................................................650 Adjusting Hoist Limiter.......................................................................................651 Testing & Adjusting Hydraulic Pressure in Steering & Hoist Circuit............................................652 Diagnostic Chart: Hoist System................................................................................655 Diagnostic Chart: Steering System.............................................................................658 M - OPTIONS & SPECIAL TOOLS...........................................................................................661 QUICK FUEL SYSTEM.................................................................................................663 SPECIAL TOOLS.....................................................................................................665 AIR CONDITIONING SYSTEM...........................................................................................673 PAYLOAD METER II..................................................................................................701 GENERAL INFORMATION...........................................................................................703 LIGHTS, SWITCHES, and COMPONENTS..............................................................................704 TIPS FOR OPERATION............................................................................................705 EXTERNAL DISPLAY LIGHTS.......................................................................................705 THEORY OF OPERATION...........................................................................................706 Linkage Factor............................................................................................706 Brake Lock................................................................................................707 Calculation Method .......................................................................................707 Sources of Error..........................................................................................707 Typical Data From Service Check Mode......................................................................707 Example Calculation of Payload............................................................................708 Calculation of the Calibration Load.......................................................................708 TYPES OF DATA STORED..........................................................................................709 Cycle data................................................................................................709 Engine ON/OFF Data........................................................................................710 Fault Codes and Warning Data..............................................................................710 Engine Operation..........................................................................................711 Total Payload and Total Number of Cycles..................................................................711 Other Data................................................................................................711 OPERATOR FUNCTIONS............................................................................................712 Using the Operator Load Counter...........................................................................712 Description...........................................................................................712 Viewing the Operator Load Counter.....................................................................712 Clearing the Operator Load Counter....................................................................712 Dimming the Lights on the Display.........................................................................712 INITIAL SETUP OF PAYLOAD METER................................................................................713 Switch Settings...........................................................................................713 Checking the Operator Check Mode..........................................................................713 Checking the Service Check Mode. .........................................................................714 Setting "UP:00".......................................................................................714 Setting "PL:00".......................................................................................714 Checking the Gt Setting...................................................................................714 Checking the Inclinometer Settings........................................................................714 Calibrating a Truck.......................................................................................715 DISPLAYS AT START-UP..........................................................................................716 SETUP AND MAINTENANCE.........................................................................................717 Setting the Speed Limit...................................................................................717 Setting the Option Code...................................................................................717 Setting The Machine I.D...................................................................................717 Setting The Operator I.D..................................................................................718 Setting The Time and Date.................................................................................718 DOWNLOAD OF PAYLOAD AND FAULT CODES...........................................................................718 DISPLAY OF FAULT CODES........................................................................................719 CHARTS OF ERROR CODES AND OTHER INFORMATION...................................................................720 SERVICE CHECK MODE............................................................................................722 Monitoring Input Signals..................................................................................722 UP Factor - Payload Calculation Gain......................................................................723 PL Mode - Load Calculation Timing.........................................................................723 FINAL GEAR RATIO SELECTION................................................................................724 BATTERY REPLACEMENT PROCEDURE.................................................................................725 Replacing the Battery.....................................................................................725 After Replacing the Battery...............................................................................726 SUSPENSION PRESSURE SENSOR....................................................................................726 Removal...................................................................................................726 Installation..............................................................................................727 INCLINOMETER..................................................................................................727 Removal...................................................................................................727 Installation..............................................................................................727 SCOREBOARD....................................................................................................728 Description...............................................................................................728 Making Connections........................................................................................728 Wiring Diagram............................................................................................729 Normal Operation of the Scoreboard........................................................................730 PAYLOAD METER BACK PANEL CONNECTIONS..........................................................................730 AMP Pin Identification....................................................................................731 PAYLOAD CIRCUIT NUMBER........................................................................................732 PAYLOAD METER II RE-INITIALIZATION PROCEDURE..................................................................733 N - OPERATOR'S CAB....................................................................................................735 TRUCK CAB.........................................................................................................737 Removal.......................................................................................................737 Installation..................................................................................................737 CAB COMPONENTS....................................................................................................739 Windshield Wiper..............................................................................................739 Operation.................................................................................................739 Removal...................................................................................................739 Installation..............................................................................................739 Windshield Washer.............................................................................................740 Service...................................................................................................740 Untitled..................................................................................................741 Air Cleaner Indicator Gauge...................................................................................741 OPERATOR COMFORT..................................................................................................743 Operator Seat.................................................................................................743 Adjustment Instructions...................................................................................743 Removal...................................................................................................744 Installation..............................................................................................744 Dash Panel....................................................................................................745 Removal...................................................................................................745 Installation..............................................................................................745 Heater & Air Conditioner Unit.................................................................................745 Removal...................................................................................................745 Installation..............................................................................................745 Disassembly...............................................................................................746 Assembly..................................................................................................746 Heater Controls...............................................................................................746 Removal...................................................................................................746 Installation..............................................................................................746 OPERATOR CAB & CONTROLS...........................................................................................747 Retarder Operation............................................................................................748 Center Console................................................................................................749 Engine Electronic Control System..............................................................................752 Hoist Control Lever...........................................................................................754 Dump Body Control Linkage.....................................................................................756 Steering Column Service.......................................................................................757 Instrument Panel..............................................................................................759 Instrument Panel (Upper Half).................................................................................761 Instrument Panel (Lower Half).................................................................................764 Heater / Air Conditioner Controls.............................................................................769 P - LUBRICATION & SERVICE.............................................................................................771 LUBRICATION & SERVICE.............................................................................................773 LUBRICATION SPECIFICATIONS CHARTS.................................................................................773 Service Capacities............................................................................................773 Anti-Freeze Specifications....................................................................................773 Lubrication Chart.............................................................................................774 10 HOUR (DAILY) LUBRICATION & MAINTENANCE CHECKS..................................................................775 250 HOUR LUBRICATION & MAINTENANCE CHECKS.........................................................................781 500 HOUR LUBRICATION & MAINTENANCE CHECKS.........................................................................783 1000 HOUR LUBRICATION & MAINTENANCE CHECKS........................................................................784 2000 HOUR LUBRICATION & MAINTENANCE CHECKS........................................................................785 HYDRAULIC TANK SERVICE & FILLING INSTRUCTIONS ....................................................................786 Hydraulic Tank Filter Replacement.............................................................................787 Hydraulic Tank Breather Service...............................................................................787 HIGH PRESSURE HYDRAULIC FILTER SERVICE............................................................................788 TRANSMISSION FILTER SERVICE.......................................................................................790 PERIODIC REPLACEMENT OF COMPONENT PARTS FOR SAFETY DEVICES........................................................791 Q - ALPHABETICAL INDEX................................................................................................793 R - SYSTEM SCHEMATICS.................................................................................................797 HA204 AIR CIRCUIT PIPING..........................................................................................799 HA203 AIR SYSTEM SCHEMATIC........................................................................................800 HH339 HYDRAULIC SYSTEM SCHEMATIC..................................................................................801 HH340 HYDRAULIC SYSTEM PIPING.....................................................................................802 KT-T01 TRANSMISSION CROSS SECTION VIEW............................................................................803 HE462 ELECTRICAL WIRING SCHEMATIC.................................................................................804 Sheet 1 (1-8).................................................................................................807 Sheet 2 (9-16)................................................................................................808 Sheet 3 (17-24)...............................................................................................809 Sheet 4 (25-32)...............................................................................................810 Sheet 5 (33-40)...............................................................................................811 Sheet 6 (41-48)...............................................................................................812 Sheet 7 (49-56)...............................................................................................813 Sheet 8 (57-64)...............................................................................................814 Sheet 9 (65-72)...............................................................................................815 Sheet 10 (73-80)..............................................................................................816 Sheet 11 (81-88)..............................................................................................817 Sheet 12 (89-96)..............................................................................................818 Sheet 13 (97-104).............................................................................................819 Sheet 14 (105-112)............................................................................................820 Sheet 15 (113-120)............................................................................................821 Sheet 16 (121-128)............................................................................................822
DESCRIPTION:
KOMATSU 330M DUMP TRUCK SHOP MANUAL DG728 – PDF DOWNLOAD
- This 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 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 HAULPAK® 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 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.
S.S 22/12/24
