Komatsu 330M DUMP TRUCK Shop Manual DG744 PDF

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Komatsu 330M DUMP TRUCK Shop Manual DG744 – PDF DOWNLOAD

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Komatsu 330M DUMP TRUCK Shop Manual DG744 – PDF DOWNLOAD

Language : English
Pages :922
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu 330M DUMP TRUCK Shop Manual DG744 – PDF DOWNLOAD

SERIAL NUMBERS A10212 – A10223

FOREWORD
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.

TABLE OF CONTENTS:

Komatsu 330M DUMP TRUCK Shop Manual DG744 – PDF DOWNLOAD

SERIAL NUMBERS A10212 – A10223

MAIN MENU 0
COVER 1
FOREWORD 4
TABLE OF CONTENTS 6
GENERAL INFORMATION 8
MAJOR COMPONENTS AND SPECIFICATIONS 10
GENERAL SAFETY AND OPERATING INSTRUCTIONS 14
WARNINGS AND CAUTIONS 44
STANDARD CHARTS AND TABLES 52
STANDARD VALUE TABLES 58
STRUCTURES 76
STRUCTURAL COMPONENTS 78
GRILLE AND HOOD 78
DECKS 78
LEFT DECK STRUCTURE 79
Removal 79
Installation 79
RIGHT DECK STRUCTURE 80
Removal 80
Installation 80
CENTER DECK STRUCTURE 81
Removal 81
Installation 81
DUMP BODY 82
Removal 82
Installation 83
BODY PAD 84
Removal 84
Installation 84
Adjustment 84
BODY GUIDE 85
BODY PIN 85
Installation 85
ROCK EJECTORS 86
Inspection 86
FUEL TANK 88
Removal 88
Installation 89
Cleaning 89
VENT 89
QUICK FUEL INSTALLATION (OPTION) 89
ENGINE, RADIATOR & AIR CLEANER 90
COOLING SYSTEM 92
RADIATOR 92
Removal 92
Service 94
Installation 94
BRAKE OIL COOLER 95
Removal 95
Installation 95
FAN 95
Removal 95
Installation 95
FAN BELT 96
Removal 96
Installation 96
ENGINE 98
Removal 98
Installation101
Drive Line Adapter102
Removal102
Installation103
Repair104
AIR FILTRATION SYSTEM106
AIR CLEANER106
Service Checks106
Filter Element Replacement106
MAIN FILTER ELEMENT108
Main Filter Element Cleaning108
Air Intake Troubleshooting109
ELECTRICAL SYSTEM110
24VDC ELECTRIC SUPPLY SYSTEM112
ELECTRICAL SYSTEM DESCRIPTION112
BATTERY112
Service112
Storage112
Maintenance and Troubleshooting113
Spillage114
BATTERY CHARGING ALTERNATOR115
Operation116
ENGINE PRELUB SYSTEM118
DESIGN118
OPERATION118
TROUBLESHOOTING121
24VDC ELECTRICAL SYSTEM COMPONENTS124
VEHICLE MONITOR SYSTEM124
VEHICLE MONITOR PANEL126
SENSORS, SWITCHES127
MONITOR PANEL DISPLAYS129
INSTRUMENT PANEL INDICATORS,TEST SWITCH133
ELECTRONIC ACCELERATOR PEDAL135
AISS136
TRANSMISSION CONTROLLER137
POINTS TO REMEMBER WHEN TROUBLESHOOTING140
POINTS TO REMEMBER WHEN PERFORMING MAINTENANCE141
POINTS TO REMEMBER WHEN HANDLINGELECTRIC EQUIPMENT141
HANDLING CONTROLLER BOXES146
Precautions when performing arc welding on the truck146
Points to remember when troubleshooting electric circuits146
POINTS TO REMEMBER WHEN SERVICING HYDRAULIC EQUIPMENT147
CHECKS BEFORE TROUBLESHOOTING149
CONNECTOR TYPE AND LOCATION150
ARSC ( AUTOMATIC RETARDER SPEED CONTROL)156
CONNECTOR PIN ALLOCATION CHART157
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS162
EXPLANATIONS OF FUNCTIONS (CONTROL MECHANISM) OFELECTRICAL SYSTEM172
SYSTEM FUNCTION172
SELF-DIAGNOSTIC DISPLAY FUNCTIONS172
CHECKING OPERATION OF ELECTRICAL SYSTEM (No System Faults)174
MONITOR PANEL ACTION CODES AND SERVICE MODE178
OUTLINE178
ACTION CODE DISPLAY178
SERVICE MODE179
Method of deleting trouble data from memory187
Precautions when operating service mode187
Table 1 Bit numbers190
BRAKE AIR PRESSURE SENSOR191
SELF-DIAGNOSTIC DISPLAY METHOD FOR MONITOR PANEL ANDCONTROLLERS192
MONITOR PANEL192
TRANSMISSION CONTROLLER192
Self-diagnostic Display Code Table192
Warning Display Table193
Method of re-enacting fault displayed194
Operation of controller when fault is detected194
Transmission mode display195
Saving self-diagnostic display to memory196
TABLE OF SERVICE CODES AND ACTION CODES197
TABLE OF SERVICE CODES AND ACTION CODES RELATED TO MONITOR PANEL197
Table Of Service Codes And Action Codes Related To Transmission Controller198
Table Of Service Codes And Action Codes Related To Suspension Controller201
Table of service codes and action codes related to PMC202
METHOD OF USING TABLE203
METHOD OF USING TROUBLESHOOTING CHARTS204
Method of using troubleshooting chart for each troubleshooting fault204
ADJUSTING ELECTRONIC MONITOR (Speedometer Module)206
SETTING ROTARY SWITCH(Model Data, Network Data) WHEN REPLACING TRANSMISSIONCONTROLLER207
METHOD OF DELETING DATA FROM TRANSMISSION CONTROLLER MEMORY208
TRANSMISSION CONTROLLER SYSTEM TROUBLESHOOTING212
TROUBLESHOOTING CHARTS212
TROUBLESHOOTING INDEX212
MONITOR PANEL TROUBLESHOOTING290
TROUBLESHOOTING CHART290
TROUBLESHOOTING INDEX290
ENGINE ELECTRONIC DIAGNOSTIC SYSTEM356
Fault Code Information (T01-001)359
ELECTRICAL SPECIFICATIONS362
HYDRAULIC AND MECHANICAL SYSTEMS TROUBLESHOOTING364
Troubleshooting Index364
SUSPENSION CONTROLLER SYSTEM TROUBLESHOOTING388
TRANSMISSION408
TORQUE CONVERTER VALVE411
MAIN RELIEF VALVE416
TORQUE CONVERTER RELIEF VALVE416
LOCKUP VALVE418
HYDRAULIC PRESSURE OF TORQUE CONVERTER VALVE421
TORQUE CONVERTER STALL SPEED423
TRANSMISSION OPERATION424
ECMV (Electronic Control Modulation Valve)428
LUBRICATION RELIEF VALVE438
TRANSMISSION439
Removal439
Installation441
TRANSMISSION FILTER443
Service443
TRANSMISSION OIL COOLER444
Removal And Installation444
TRANSMISSION STRAINER444
Removal444
Installation444
TORQUE CONVERTER CONTROL VALVE445
Removal445
Installation445
Disassembly445
Assembly446
DRIVELINES & U-JOINTS448
Removal448
Installation448
Disassembly448
Assembly448
AUTOMATIC SHIFT CONTROL SYSTEM450
GENERAL INFORMATION450
TRANSMISSION SHIFT CONTROLLER450
POWER MODE450
BRAKING MODE450
LOCK-UP AND ENGINE OVERSPEED450
TRANSMISSION SPEEDS MONITORING450
SELF DIAGNOSTICS451
RANGE SELECTOR POSITIONS AND AUTOMATIC GEAR SHIFTING RANGES453
TRANSMISSION OPERATION MODES453
AUTOMATIC GEAR SHIFTING454
AUTOMATIC SHIFTING SEQUENCE454
SAFETY FUNCTIONS456
TRANSMISSION RANGE SELECTOR457
SENSORS, SWITCHES458
TRANSMISSION TROUBLESHOOTING PROCEDURES463
WHEELS, SPINDLES AND FINAL DRIVE468
TIRES AND RIMS470
TIRES AND RIMS470
General Information470
FRONT TIRES AND RIMS471
Removal471
Installation472
REAR TIRE AND RIM472
Removal472
INSTALLATION OF REAR WHEEL ASSEMBLY473
TIRE MATCHING475
FRONT WHEEL HUB AND SPINDLES476
FRONT WHEEL HUB476
Removal476
Front Wheel Bearing and Brake Disc Replacement477
Front Wheel Hub Installation and Bearing Adjustment478
A-FRAME479
Removal479
Installation479
FINAL DRIVE ATTACHMENTS482
FINAL DRIVE LOWER LINK482
Pin Removal482
Pin Installation483
DIAGONAL PANHARD ROD483
Removal483
Installation484
FINAL DRIVE CENTER CASE ASSEMBLY486
Specifications488
REAR AXLE488
Removal488
Installation489
DIFFERENTIAL ASSEMBLY490
Removal490
Installation491
Disassembly491
Disassembly of Pinion Carrier Assembly492
Differential Gear Unit493
Disassembly Of Differential Gear Unit493
ASSEMBLY of DIFFERENTIAL496
Differential Bearing496
Assembly Of Differential Gear Assembly496
Installation Of Differential Assembly497
Input Pinion and Carrier Assembly498
Adjusting Tooth Contact, Backlash501
FINAL DRIVE PLANETARIES AND WHEEL HUBS504
FINAL DRIVE504
CARRIER ASSEMBLY505
Removal505
Installation506
FINAL DRIVE CARRIER506
Disassembly506
Assembly507
FINAL DRIVE ASSEMBLY507
Disassembly507
Assembly510
SUSPENSIONS512
FRONT SUSPENSION515
Operation515
Removal516
Installation518
Disassembly519
Inspection520
Assembly520
Attenuation Valve Repair521
REAR SUSPENSIONS522
Operation522
Removal523
Installation524
Disassembly524
Assembly525
Spherical Bearing Repair526
OILING AND CHARGING PROCEDURES528
GENERAL528
EQUIPMENT LIST528
FRONT SUSPENSION528
Front Suspension Oiling529
Front Suspension Nitrogen Charging530
REAR SUSPENSION532
Rear Suspension Oiling532
Rear Suspension Nitrogen Charging533
BRAKE SYSTEM536
BRAKE CIRCUIT538
BRAKE CIRCUIT OPERATION538
COMPONENT DESCRIPTION538
EMERGENCY RELAY (RE-6) VALVE539
HAND BRAKE (Retarder)542
PARKING BRAKE PILOT VALVE544
PARKING BRAKE RELAY VALVE545
BRAKE CHAMBER FRONT546
BRAKE CHAMBER REAR546
SLACK ADJUSTER547
PRESSURE SWITCH549
STOP LIGHT SWITCH549
PARKING BRAKE SWITCH550
AUTOMATIC RETARDER VALVE550
FRONT BRAKE CUT-OFF VALVE551
BRAKE COOLING VALVE (BCV)552
Parking Brake Valve553
EMERGENCY BRAKE CONTROL VALVE554
BRAKE VALVE558
BRAKE CIRCUIT COMPONENT SERVICE562
SERVICE BRAKE TREADLE VALVE562
BRAKE CHAMBERS (PRESSURE CONVERTERS)565
FRONT565
REAR569
SLACK ADJUSTER573
EMERGENCY BRAKE CONTROL VALVE576
BRAKE CIRCUIT CHECKOUT AND ADJUSTMENT580
CHECKING FRONT BRAKE PAD WEAR580
TESTING BRAKE PRESSURE580
CHECKING WEAR OF REAR BRAKE DISCS581
BRAKE BLEEDING582
FRONT BRAKES586
BRAKE PADS586
Removal586
Installation586
Brake Caliper Assembly586
Removal586
Installation587
Disassembly587
Inspection Values587
Assembly588
REAR BRAKES590
Removal590
Installation591
Disassembly592
Inspection593
Assembly593
PARKING BRAKE596
BRAKE PAD596
Pad Removal596
Pad Installation596
PARKING BRAKE CALIPER596
Caliper Removal596
Caliper Installation597
Caliper Disassembly597
Caliper Assembly598
PARKING BRAKE SPRING CYLINDER598
Removal598
Installation598
Disassembly598
Assembly599
PARKING BRAKE ADJUSTMENT600
PARKING BRAKE DISC601
Driveshaft Removal601
Parking Brake Disc Removal601
Inspection Values602
Parking Brake Disc Installation602
Driveshaft Installation602
PARKING BRAKE RELEASE AFTER EMERGENCY APPLY602
RELEASE OF PARKING BRAKE602
RELEASE OF EMERGENCY BRAKE603
AIR SYSTEM604
AIR SYSTEM COMPONENT REPAIR610
AIR COMPRESSOR SERVICE610
AIR GOVERN0R610
AIR SYSTEM OPERATION606
COMPONENT DESCRIPTION606
Main Air Tank606
Safety Valve606
Air Governor606
Air Dryer607
Air Horn609
RETARDER VALVE612
Removal612
Installation612
Disassembly614
Assembly614
HYDRAULIC SYSTEM616
HYDRAULIC SYSTEM616
HYDRAULIC SYSTEM OPERATION618
COMPONENT DESCRIPTION618
HYDRAULIC SYSTEM COMPONENT REPAIR622
HYDRAULIC PUMP622
Removal622
Installation623
HYDRAULIC TANK623
HYDRAULIC TANK FILTERS624
Filter Replacement624
HYDRAULIC TANK BREATHER624
Cleaning624
BRAKE COOLING OIL STRAINER625
Cleaning625
HIGH PRESSURE HYDRAULIC FILTERS625
Removal625
Installation626
Replacement626
STEERING CIRCUIT628
STEERING CIRCUIT OPERATION628
DEMAND VALVE629
STEERING CONTROL VALVE629
CROSSOVER RELIEF VALVE630
OPERATION OF DEMAND AND STEERING CONTROL VALVE631
EMERGENCY STEERING SYSTEM639
FLOW SWITCH640
Relay Timer640
EMERGENCY STEERING SYSTEM ELECTRICAL SCHEMATIC641
STEERING VALVE ASSEMBLY642
Removal642
Installation642
Disassembly643
Assembly648
STEERING CIRCUIT COMPONENT REPAIR656
STEERING CIRCUIT COMPONENT REPAIR656
Removal656
Installation656
STEERING CYLINDER ASSEMBLY657
Removal657
Installation657
Disassembly658
Assembly660
DEMAND VALVE ASSEMBLY662
Removal662
Installation662
Disassembly663
Assembly663
RELIEF VALVE ASSEMBLY664
Disassembly664
Assembly664
HOIST CIRCUIT666
CIRCUIT OPERATION666
COMPONENT DESCRIPTION666
HOIST CIRCUIT COMPONENT REPAIR672
HOIST VALVE ASSEMBLY672
Removal672
Installation672
Disassembly673
Assembly673
HOIST CYLINDER675
Removal675
Installation676
Disassembly677
Assembly677
HYDRAULIC SYSTEM CHECKOUT680
DUMP BODY CONTROL680
ADJUSTING HOIST LEVER LINKAGE681
ADJUSTING HOIST LIMITER682
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING,HOIST CIRCUIT683
HOIST CYLINDER LACKS LIFTING FORCE (LIFTING SPEED)686
HOIST CYLINDER DOES NOT MOVE687
EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY688
STEERING FEEL IS HEAVY689
STEERING DOES NOT FUNCTION690
STEERING WHEEL VIBRATES691
OPTIONS AND SPECIAL TOOLS692
WIGGINS QUICK FILL FUEL SYSTEM694
SPECIAL TOOLS696
AIR CONDITIONING SYSTEM706
PAYLOAD METER II – ON BOARD WEIGHING SYSTEM754
PAYLOAD METER II – ON BOARD WEIGHING SYSTEM754
GENERAL INFORMATION756
Haul Cycles756
LIGHTS, SWITCHES AND COMPONENTS757
TIPS FOR OPERATION758
EXTERNAL DISPLAY LIGHTS758
THEORY OF OPERATION759
Basic Description759
Inclinometer759
Linkage Factor759
Gain Factor760
Brake Lock760
Sources of Error760
Typical Data From Service Check Mode760
Example Calculation of Payload761
Viewing Payload Calculation Inputs761
Checking the Gain762
Adjusting the Gain762
TYPES OF DATA STORED763
Cycle Data763
Engine ON/OFF Data764
Fault Codes and Warning Data764
Engine Operation765
Total Payload and Total Number of Cycles765
Other Data765
OPERATOR FUNCTIONS766
Using the Operator Load Counter766
Viewing the Operator Load Counter766
Clearing the Operator Load Counter766
Dimming the Lights on the Display766
INITIAL SETUP OF PAYLOAD METER767
Switch Settings767
Checking the Operator Check Mode768
Checking the Service Check Mode768
Checking the Gt setting769
Checking the Inclinometer Settings769
Calibrating a Truck769
DISPLAYS AT START-UP770
Normal Operation770
SETUP AND MAINTENANCE771
Setting The Speed Limit771
Setting the Option Code771
Setting The Machine ID Code772
Setting The Operator ID Code772
Setting The Time and Date772
DOWNLOAD OF INFORMATION773
DISPLAY OF FAULT CODES773
Monitoring Input Signals777
Service Check Mode777
UP FACTOR – PAYLOAD CALCULATIONGAIN778
PL MODE -LOAD CALCULATION TIMING778
FINAL GEAR RATIO SELECTION779
BATTERY REPLACEMENT PROCEDURE780
Replacing the Battery780
After Replacing the Battery781
SUSPENSION PRESSURE SENSOR781
Removal781
Installation782
INCLINOMETER782
Removal782
Installation782
Adjustment782
PAYLOAD METER BACK PANEL783
CONNECTIONS784
PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE785
PAYLOAD CIRCUIT NUMBERS786
TROUBLESHOOTING787
COMMON PROBLEMS787
Suspension Charging787
Symptom Table788
Missing Body-Up Signal788
Missing Speed Signal789
F-18: Alternator R-Terminal, Oil Pressure Signals789
Shorted 18v Sensor Power Supply (930E)789
FAULT TREE DIAGNOSIS790
Payload Lights Won’t Illuminate790
Red, Amber or Green Payload Light Does Not Illuminate791
Cannot Download – PC Communications792
PC Communications Configuration793
FCAL: Payload Meter Won’t Calibrate794
F-20: Sensor Power Fault795
F-21, F-25: Left Front Pressure Sensor797
F-22, F-26: Right Front Pressure Sensor797
F-23, F-27: Left Rear Pressure Sensor797
F-24, F-28: Right Rear Pressure Sensor797
F-31, F-32: Inclinometer799
Body Up Input801
Brake Lock Input802
Speed Signal803
Adjusting the Speed Sensor803
CONNECTORS AND PRESSURE SENSORS805
REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM808
Menu Functions811
Using Scope811
Log File Information811
Connections to Payload Meter II™812
USING SCOPE813
Monitoring Inputs Using Scope813
Monitoring Suspension Charging Using Scope813
Pressure Sensor Dummy Loads816
GAIN ADJUSTMENT WORKSHEET817
EXHAUST BRAKE818
OPERATOR’S CAB826
TRUCK CAB828
Removal828
Installation828
CAB COMPONENTS830
WINDSHIELD WIPER 830
Operation830
Removal830
Installation830
WINDSHIELD WASHER831
Service831
AIR CLEANER INDICATOR GUILDE832
OPERATOR COMFORT836
OPERATOR SEAT836
Adjustment Instructions836
Removal837
Installation837
HEATER AND AIR CONDITIONER839
Removal839
Installation839
HEATER AND AIR CONDITIONER COREREPLACEMENT839
Disassembly839
Assembly839
FILTER MAINTENANCE841
Cab Fresh Air Filter841
Heater/Air Conditioner Air Filter841
HEATER CONTROLS842
Removal842
Installation842
DASH PANEL842
Removal842
Installation842
OPERATOR CAB AND CONTROLS844
OPERATOR CONTROLS844
Retard Operation845
Center Console846
ENGINE ELECTRONIC CONTROL SYSTEM849
Hoist Control Lever851
DUMP BODY CONTROL LINKAGE853
STEERING COLUMN SERVICE854
INSTRUMENT PANEL856
INSTRUMENT PANEL (Upper Half)858
INSTRUMENT PANEL (Lower Half)862
HEATER/AIR CONDITIONER CONTROLS867
LUBRICATION AND SERVICE870
LUBRICATION AND SERVICE872
LUBRICATION SPECIFICATIONS CHARTS874
SERVICE CAPACITIES874
ANTI-FREEZE SPECIFICATIONS874
LUBRICATION CHART875
10 HOUR (DAILY) INSPECTION876
250 HOUR LUBRICATION AND MAINTENANCE CHECKS882
500 HOUR LUBRICATION AND MAINTENANCE CHECKS884
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS885
2000 HOUR LUBRICATION AND MAINTENANCE CHECKS886
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS887
HYDRAULIC TANK SERVICE888
Filling Instructions (Hoist Oil Supply)888
Filling Instructions (Rear Brake Cooling OilSupply)888
HYDRAULIC FILTERS Filter Replacement889
HYDRAULIC TANK BREATHER Cleaning889
HIGH PRESSURE HYDRAULIC FILTERS890
TRANSMISSION FILTER892
PERIODIC REPLACEMENT OF COMPONENT PARTS FOR SAFETY DEVICES893
ALPHABETICAL INDEX894
SYSTEM SCHEMATICS898
AIR SYSTEM PIPING900
AIR SYSTEM SCHEMATIC901
HYDRAULIC SYSTEM SCHEMATIC902
HYDRAULIC SYSTEM PIPING903
TRANSMISSION CROSS SECTION VIEW904
ELECTRICAL WIRING SCHEMATIC905

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S.M 24/12/24