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Komatsu 330M Dump Truck Shop Manual SN A10212-A10223 – PDF DOWNLOAD
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Komatsu 330M Dump Truck Shop Manual
SERIAL NUMBERS A10212 – A10223
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Description
Komatsu 330M Dump Truck Shop Manual
FILE DETAILS:
Komatsu 330M Dump Truck Shop Manual
Brands: Komatsu
Equipment Type: Dump Truck
Manuals Type: Shop Manual
Machine Model: 330M
Serial Number: A10212-A10223
Book Code: DG744
Language: English
Pages: 922
File Format: Portable Document Format (PDF)
TABLE OF CONTENTS:
Komatsu 330M Dump Truck Shop Manual
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 Installation.........................................................................101 Drive Line Adapter...................................................................102 Removal..........................................................................102 Installation.....................................................................103 Repair...........................................................................104 AIR FILTRATION SYSTEM....................................................................106 AIR CLEANER..........................................................................106 Service Checks...................................................................106 Filter Element Replacement.......................................................106 MAIN FILTER ELEMENT..................................................................108 Main Filter Element Cleaning.....................................................108 Air Intake Troubleshooting.......................................................109 ELECTRICAL SYSTEM............................................................................110 24VDC ELECTRIC SUPPLY SYSTEM.............................................................112 ELECTRICAL SYSTEM DESCRIPTION........................................................112 BATTERY..............................................................................112 Service..........................................................................112 Storage..........................................................................112 Maintenance and Troubleshooting..................................................113 Spillage.........................................................................114 BATTERY CHARGING ALTERNATOR..........................................................115 Operation........................................................................116 ENGINE PRELUB SYSTEM.................................................................118 DESIGN...........................................................................118 OPERATION........................................................................118 TROUBLESHOOTING..................................................................121 24VDC ELECTRICAL SYSTEM COMPONENTS.......................................................124 VEHICLE MONITOR SYSTEM...............................................................124 VEHICLE MONITOR PANEL............................................................126 SENSORS, SWITCHES................................................................127 MONITOR PANEL DISPLAYS...............................................................129 INSTRUMENT PANEL INDICATORS,TEST SWITCH..............................................133 ELECTRONIC ACCELERATOR PEDAL.........................................................135 AISS.................................................................................136 TRANSMISSION CONTROLLER..............................................................137 POINTS TO REMEMBER WHEN TROUBLESHOOTING..................................................140 POINTS TO REMEMBER WHEN PERFORMING MAINTENANCE...........................................141 POINTS TO REMEMBER WHEN HANDLINGELECTRIC EQUIPMENT...................................141 HANDLING CONTROLLER BOXES............................................................146 Precautions when performing arc welding on the truck.................................146 Points to remember when troubleshooting electric circuits............................146 POINTS TO REMEMBER WHEN SERVICING HYDRAULIC EQUIPMENT................................147 CHECKS BEFORE TROUBLESHOOTING............................................................149 CONNECTOR TYPE AND LOCATION..............................................................150 ARSC ( AUTOMATIC RETARDER SPEED CONTROL).................................................156 CONNECTOR PIN ALLOCATION CHART...........................................................157 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...............................................162 EXPLANATIONS OF FUNCTIONS (CONTROL MECHANISM) OFELECTRICAL SYSTEM........................172 SYSTEM FUNCTION......................................................................172 SELF-DIAGNOSTIC DISPLAY FUNCTIONS....................................................172 CHECKING OPERATION OF ELECTRICAL SYSTEM (No System Faults)...........................174 MONITOR PANEL ACTION CODES AND SERVICE MODE..............................................178 OUTLINE..............................................................................178 ACTION CODE DISPLAY..................................................................178 SERVICE MODE.........................................................................179 Method of deleting trouble data from memory..........................................187 Precautions when operating service mode..............................................187 Table 1 Bit numbers..................................................................190 BRAKE AIR PRESSURE SENSOR............................................................191 SELF-DIAGNOSTIC DISPLAY METHOD FOR MONITOR PANEL ANDCONTROLLERS..........................192 MONITOR PANEL........................................................................192 TRANSMISSION CONTROLLER..............................................................192 Self-diagnostic Display Code Table...............................................192 Warning Display Table............................................................193 Method of re-enacting fault displayed............................................194 Operation of controller when fault is detected...................................194 Transmission mode display............................................................195 Saving self-diagnostic display to memory.............................................196 TABLE OF SERVICE CODES AND ACTION CODES..................................................197 TABLE OF SERVICE CODES AND ACTION CODES RELATED TO MONITOR PANEL.....................197 Table Of Service Codes And Action Codes Related To Transmission Controller...........198 Table Of Service Codes And Action Codes Related To Suspension Controller.............201 Table of service codes and action codes related to PMC...............................202 METHOD OF USING TABLE....................................................................203 METHOD OF USING TROUBLESHOOTING CHARTS...................................................204 Method of using troubleshooting chart for each troubleshooting fault.................204 ADJUSTING ELECTRONIC MONITOR (Speedometer Module)........................................206 SETTING ROTARY SWITCH(Model Data, Network Data) WHEN REPLACING TRANSMISSIONCONTROLLER....207 METHOD OF DELETING DATA FROM TRANSMISSION CONTROLLER MEMORY..............................208 TRANSMISSION CONTROLLER SYSTEM TROUBLESHOOTING...........................................212 TROUBLESHOOTING CHARTS...............................................................212 TROUBLESHOOTING INDEX............................................................212 MONITOR PANEL TROUBLESHOOTING............................................................290 TROUBLESHOOTING CHART................................................................290 TROUBLESHOOTING INDEX............................................................290 ENGINE ELECTRONIC DIAGNOSTIC SYSTEM......................................................356 Fault Code Information (T01-001).....................................................359 ELECTRICAL SPECIFICATIONS................................................................362 HYDRAULIC AND MECHANICAL SYSTEMS TROUBLESHOOTING.........................................364 Troubleshooting Index................................................................364 SUSPENSION CONTROLLER SYSTEM TROUBLESHOOTING.............................................388 TRANSMISSION.................................................................................408 TORQUE CONVERTER VALVE...................................................................411 MAIN RELIEF VALVE....................................................................416 TORQUE CONVERTER RELIEF VALVE........................................................416 LOCKUP VALVE.........................................................................418 HYDRAULIC PRESSURE OF TORQUE CONVERTER VALVE.........................................421 TORQUE CONVERTER STALL SPEED.........................................................423 TRANSMISSION OPERATION...................................................................424 ECMV (Electronic Control Modulation Valve)...........................................428 LUBRICATION RELIEF VALVE.............................................................438 TRANSMISSION.............................................................................439 Removal..............................................................................439 Installation.........................................................................441 TRANSMISSION FILTER......................................................................443 Service..............................................................................443 TRANSMISSION OIL COOLER..................................................................444 Removal And Installation.............................................................444 TRANSMISSION STRAINER................................................................444 Removal..........................................................................444 Installation.....................................................................444 TORQUE CONVERTER CONTROL VALVE.......................................................445 Removal..........................................................................445 Installation.....................................................................445 Disassembly......................................................................445 Assembly.........................................................................446 DRIVELINES & U-JOINTS....................................................................448 Removal..............................................................................448 Installation.........................................................................448 Disassembly..........................................................................448 Assembly.............................................................................448 AUTOMATIC SHIFT CONTROL SYSTEM...........................................................450 GENERAL INFORMATION..................................................................450 TRANSMISSION SHIFT CONTROLLER........................................................450 POWER MODE.......................................................................450 BRAKING MODE.....................................................................450 LOCK-UP AND ENGINE OVERSPEED.....................................................450 TRANSMISSION SPEEDS MONITORING...................................................450 SELF DIAGNOSTICS.................................................................451 RANGE SELECTOR POSITIONS AND AUTOMATIC GEAR SHIFTING RANGES..........................453 TRANSMISSION OPERATION MODES.....................................................453 AUTOMATIC GEAR SHIFTING..............................................................454 AUTOMATIC SHIFTING SEQUENCE......................................................454 SAFETY FUNCTIONS.................................................................456 TRANSMISSION RANGE SELECTOR..........................................................457 SENSORS, SWITCHES....................................................................458 TRANSMISSION TROUBLESHOOTING PROCEDURES..............................................463 WHEELS, SPINDLES AND FINAL DRIVE.............................................................468 TIRES AND RIMS...........................................................................470 TIRES AND RIMS.......................................................................470 General Information..............................................................470 FRONT TIRES AND RIMS.................................................................471 Removal..........................................................................471 Installation.....................................................................472 REAR TIRE AND RIM....................................................................472 Removal..........................................................................472 INSTALLATION OF REAR WHEEL ASSEMBLY..............................................473 TIRE MATCHING........................................................................475 FRONT WHEEL HUB AND SPINDLES.............................................................476 FRONT WHEEL HUB......................................................................476 Removal..........................................................................476 Front Wheel Bearing and Brake Disc Replacement...................................477 Front Wheel Hub Installation and Bearing Adjustment..............................478 A-FRAME..............................................................................479 Removal..........................................................................479 Installation.....................................................................479 FINAL DRIVE ATTACHMENTS..................................................................482 FINAL DRIVE LOWER LINK...............................................................482 Pin Removal......................................................................482 Pin Installation.................................................................483 DIAGONAL PANHARD ROD.................................................................483 Removal..........................................................................483 Installation.....................................................................484 FINAL DRIVE CENTER CASE ASSEMBLY.........................................................486 Specifications.......................................................................488 REAR AXLE............................................................................488 Removal..........................................................................488 Installation.....................................................................489 DIFFERENTIAL ASSEMBLY................................................................490 Removal..........................................................................490 Installation.....................................................................491 Disassembly......................................................................491 Disassembly of Pinion Carrier Assembly...........................................492 Differential Gear Unit...........................................................493 Disassembly Of Differential Gear Unit............................................493 ASSEMBLY of DIFFERENTIAL.........................................................496 Differential Bearing.............................................................496 Assembly Of Differential Gear Assembly...........................................496 Installation Of Differential Assembly............................................497 Input Pinion and Carrier Assembly................................................498 Adjusting Tooth Contact, Backlash................................................501 FINAL DRIVE PLANETARIES AND WHEEL HUBS...................................................504 FINAL DRIVE..........................................................................504 CARRIER ASSEMBLY.....................................................................505 Removal..........................................................................505 Installation.....................................................................506 FINAL DRIVE CARRIER..................................................................506 Disassembly......................................................................506 Assembly.........................................................................507 FINAL DRIVE ASSEMBLY.................................................................507 Disassembly......................................................................507 Assembly.........................................................................510 SUSPENSIONS..................................................................................512 FRONT SUSPENSION.........................................................................515 Operation............................................................................515 Removal..........................................................................516 Installation.....................................................................518 Disassembly......................................................................519 Inspection.......................................................................520 Assembly.........................................................................520 Attenuation Valve Repair.........................................................521 REAR SUSPENSIONS.........................................................................522 Operation............................................................................522 Removal..........................................................................523 Installation.....................................................................524 Disassembly......................................................................524 Assembly.........................................................................525 Spherical Bearing Repair.........................................................526 OILING AND CHARGING PROCEDURES...........................................................528 GENERAL..............................................................................528 EQUIPMENT LIST.......................................................................528 FRONT SUSPENSION.....................................................................528 Front Suspension Oiling..........................................................529 Front Suspension Nitrogen Charging...............................................530 REAR SUSPENSION......................................................................532 Rear Suspension Oiling...........................................................532 Rear Suspension Nitrogen Charging................................................533 BRAKE SYSTEM.................................................................................536 BRAKE CIRCUIT............................................................................538 BRAKE CIRCUIT OPERATION..............................................................538 COMPONENT DESCRIPTION................................................................538 EMERGENCY RELAY (RE-6) VALVE.........................................................539 HAND BRAKE (Retarder)................................................................542 PARKING BRAKE PILOT VALVE............................................................544 PARKING BRAKE RELAY VALVE............................................................545 BRAKE CHAMBER FRONT..................................................................546 BRAKE CHAMBER REAR...................................................................546 SLACK ADJUSTER.......................................................................547 PRESSURE SWITCH......................................................................549 STOP LIGHT SWITCH....................................................................549 PARKING BRAKE SWITCH.................................................................550 AUTOMATIC RETARDER VALVE.............................................................550 FRONT BRAKE CUT-OFF VALVE............................................................551 BRAKE COOLING VALVE (BCV)............................................................552 Parking Brake Valve..................................................................553 EMERGENCY BRAKE CONTROL VALVE........................................................554 BRAKE VALVE..........................................................................558 BRAKE CIRCUIT COMPONENT SERVICE..........................................................562 SERVICE BRAKE TREADLE VALVE..........................................................562 BRAKE CHAMBERS (PRESSURE CONVERTERS).................................................565 FRONT............................................................................565 REAR.............................................................................569 SLACK ADJUSTER.......................................................................573 EMERGENCY BRAKE CONTROL VALVE........................................................576 BRAKE CIRCUIT CHECKOUT AND ADJUSTMENT....................................................580 CHECKING FRONT BRAKE PAD WEAR........................................................580 TESTING BRAKE PRESSURE...............................................................580 CHECKING WEAR OF REAR BRAKE DISCS....................................................581 BRAKE BLEEDING.......................................................................582 FRONT BRAKES.............................................................................586 BRAKE PADS...........................................................................586 Removal..........................................................................586 Installation.....................................................................586 Brake Caliper Assembly...............................................................586 Removal..........................................................................586 Installation.....................................................................587 Disassembly......................................................................587 Inspection Values............................................................587 Assembly.........................................................................588 REAR BRAKES..............................................................................590 Removal..............................................................................590 Installation.........................................................................591 Disassembly..........................................................................592 Inspection...........................................................................593 Assembly.............................................................................593 PARKING BRAKE............................................................................596 BRAKE PAD............................................................................596 Pad Removal......................................................................596 Pad Installation.................................................................596 PARKING BRAKE CALIPER................................................................596 Caliper Removal..................................................................596 Caliper Installation.............................................................597 Caliper Disassembly..............................................................597 Caliper Assembly.................................................................598 PARKING BRAKE SPRING CYLINDER........................................................598 Removal..........................................................................598 Installation.....................................................................598 Disassembly......................................................................598 Assembly.........................................................................599 PARKING BRAKE ADJUSTMENT.............................................................600 PARKING BRAKE DISC...................................................................601 Driveshaft Removal...............................................................601 Parking Brake Disc Removal.......................................................601 Inspection Values................................................................602 Parking Brake Disc Installation..................................................602 Driveshaft Installation..........................................................602 PARKING BRAKE RELEASE AFTER EMERGENCY APPLY..............................................602 RELEASE OF PARKING BRAKE.............................................................602 RELEASE OF EMERGENCY BRAKE...........................................................603 AIR SYSTEM...................................................................................604 AIR SYSTEM COMPONENT REPAIR..............................................................610 AIR COMPRESSOR SERVICE...............................................................610 AIR GOVERN0R.........................................................................610 AIR SYSTEM OPERATION.....................................................................606 COMPONENT DESCRIPTION....................................................................606 Main Air Tank........................................................................606 Safety Valve.........................................................................606 Air Governor.........................................................................606 Air Dryer............................................................................607 Air Horn.............................................................................609 RETARDER VALVE...........................................................................612 Removal..............................................................................612 Installation.........................................................................612 Disassembly..........................................................................614 Assembly.............................................................................614 HYDRAULIC SYSTEM.............................................................................616 HYDRAULIC SYSTEM.........................................................................616 HYDRAULIC SYSTEM OPERATION...........................................................618 COMPONENT DESCRIPTION................................................................618 HYDRAULIC SYSTEM COMPONENT REPAIR........................................................622 HYDRAULIC PUMP.......................................................................622 Removal..........................................................................622 Installation.....................................................................623 HYDRAULIC TANK.......................................................................623 HYDRAULIC TANK FILTERS...............................................................624 Filter Replacement...............................................................624 HYDRAULIC TANK BREATHER..............................................................624 Cleaning.........................................................................624 BRAKE COOLING OIL STRAINER...........................................................625 Cleaning.........................................................................625 HIGH PRESSURE HYDRAULIC FILTERS......................................................625 Removal..........................................................................625 Installation.....................................................................626 Replacement......................................................................626 STEERING CIRCUIT.........................................................................628 STEERING CIRCUIT OPERATION...........................................................628 DEMAND VALVE.........................................................................629 STEERING CONTROL VALVE...............................................................629 CROSSOVER RELIEF VALVE...............................................................630 OPERATION OF DEMAND AND STEERING CONTROL VALVE...................................631 EMERGENCY STEERING SYSTEM............................................................639 FLOW SWITCH..........................................................................640 Relay Timer..........................................................................640 EMERGENCY STEERING SYSTEM ELECTRICAL SCHEMATIC...................................641 STEERING VALVE ASSEMBLY..................................................................642 Removal..............................................................................642 Installation.........................................................................642 Disassembly..........................................................................643 Assembly.............................................................................648 STEERING CIRCUIT COMPONENT REPAIR........................................................656 STEERING CIRCUIT COMPONENT REPAIR....................................................656 Removal..........................................................................656 Installation.....................................................................656 STEERING CYLINDER ASSEMBLY...........................................................657 Removal..........................................................................657 Installation.....................................................................657 Disassembly......................................................................658 Assembly.........................................................................660 DEMAND VALVE ASSEMBLY................................................................662 Removal..........................................................................662 Installation.....................................................................662 Disassembly......................................................................663 Assembly.........................................................................663 RELIEF VALVE ASSEMBLY................................................................664 Disassembly......................................................................664 Assembly.........................................................................664 HOIST CIRCUIT............................................................................666 CIRCUIT OPERATION....................................................................666 COMPONENT DESCRIPTION................................................................666 HOIST CIRCUIT COMPONENT REPAIR...........................................................672 HOIST VALVE ASSEMBLY.................................................................672 Removal..........................................................................672 Installation.....................................................................672 Disassembly......................................................................673 Assembly.........................................................................673 HOIST CYLINDER.......................................................................675 Removal..........................................................................675 Installation.....................................................................676 Disassembly......................................................................677 Assembly.........................................................................677 HYDRAULIC SYSTEM CHECKOUT................................................................680 DUMP BODY CONTROL....................................................................680 ADJUSTING HOIST LEVER LINKAGE........................................................681 ADJUSTING HOIST LIMITER..............................................................682 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING,HOIST CIRCUIT...................683 HOIST CYLINDER LACKS LIFTING FORCE (LIFTING SPEED)...................................686 HOIST CYLINDER DOES NOT MOVE.........................................................687 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY...............................................688 STEERING FEEL IS HEAVY...............................................................689 STEERING DOES NOT FUNCTION...........................................................690 STEERING WHEEL VIBRATES..............................................................691 OPTIONS AND SPECIAL TOOLS....................................................................692 WIGGINS QUICK FILL FUEL SYSTEM...........................................................694 SPECIAL TOOLS............................................................................696 AIR CONDITIONING SYSTEM..................................................................706 PAYLOAD METER II - ON BOARD WEIGHING SYSTEM..............................................754 PAYLOAD METER II - ON BOARD WEIGHING SYSTEM..........................................754 GENERAL INFORMATION..............................................................756 Haul Cycles..................................................................756 LIGHTS, SWITCHES AND COMPONENTS..................................................757 TIPS FOR OPERATION...............................................................758 EXTERNAL DISPLAY LIGHTS..........................................................758 THEORY OF OPERATION..............................................................759 Basic Description............................................................759 Inclinometer.................................................................759 Linkage Factor...............................................................759 Gain Factor..................................................................760 Brake Lock...................................................................760 Sources of Error.............................................................760 Typical Data From Service Check Mode.........................................760 Example Calculation of Payload...............................................761 Viewing Payload Calculation Inputs...........................................761 Checking the Gain............................................................762 Adjusting the Gain...........................................................762 TYPES OF DATA STORED.............................................................763 Cycle Data...................................................................763 Engine ON/OFF Data...........................................................764 Fault Codes and Warning Data.................................................764 Engine Operation.............................................................765 Total Payload and Total Number of Cycles.....................................765 Other Data...................................................................765 OPERATOR FUNCTIONS...............................................................766 Using the Operator Load Counter..............................................766 Viewing the Operator Load Counter............................................766 Clearing the Operator Load Counter...........................................766 Dimming the Lights on the Display............................................766 INITIAL SETUP OF PAYLOAD METER...................................................767 Switch Settings..............................................................767 Checking the Operator Check Mode.............................................768 Checking the Service Check Mode..............................................768 Checking the Gt setting......................................................769 Checking the Inclinometer Settings...........................................769 Calibrating a Truck..........................................................769 DISPLAYS AT START-UP.............................................................770 Normal Operation.............................................................770 SETUP AND MAINTENANCE............................................................771 Setting The Speed Limit......................................................771 Setting the Option Code......................................................771 Setting The Machine I.D. Code................................................772 Setting The Operator I.D. Code...............................................772 Setting The Time and Date....................................................772 DOWNLOAD OF INFORMATION..........................................................773 DISPLAY OF FAULT CODES...........................................................773 Monitoring Input Signals.....................................................777 Service Check Mode...........................................................777 UP FACTOR - PAYLOAD CALCULATIONGAIN..............................................778 PL MODE -LOAD CALCULATION TIMING.................................................778 FINAL GEAR RATIO SELECTION.......................................................779 BATTERY REPLACEMENT PROCEDURE....................................................780 Replacing the Battery........................................................780 After Replacing the Battery..................................................781 SUSPENSION PRESSURE SENSOR.......................................................781 Removal......................................................................781 Installation.................................................................782 INCLINOMETER.....................................................................782 Removal......................................................................782 Installation.................................................................782 Adjustment...................................................................782 PAYLOAD METER BACK PANEL.........................................................783 CONNECTIONS......................................................................784 PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE........................................785 PAYLOAD CIRCUIT NUMBERS..............................................................786 TROUBLESHOOTING......................................................................787 COMMON PROBLEMS..................................................................787 Suspension Charging..........................................................787 Symptom Table................................................................788 Missing Body-Up Signal.......................................................788 Missing Speed Signal.........................................................789 F-18: Alternator R-Terminal, Oil Pressure Signals............................789 Shorted 18v Sensor Power Supply (930E).......................................789 FAULT TREE DIAGNOSIS.............................................................790 Payload Lights Won't Illuminate..............................................790 Red, Amber or Green Payload Light Does Not Illuminate........................791 Cannot Download - PC Communications..........................................792 PC Communications Configuration..............................................793 F.CAL: Payload Meter Won't Calibrate.........................................794 F-20: Sensor Power Fault.....................................................795 F-21, F-25: Left Front Pressure Sensor.......................................797 F-22, F-26: Right Front Pressure Sensor......................................797 F-23, F-27: Left Rear Pressure Sensor........................................797 F-24, F-28: Right Rear Pressure Sensor.......................................797 F-31, F-32: Inclinometer.....................................................799 Body Up Input................................................................801 Brake Lock Input.............................................................802 Speed Signal.................................................................803 Adjusting the Speed Sensor...............................................803 CONNECTORS AND PRESSURE SENSORS..................................................805 REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM..........................................808 Menu Functions...................................................................811 Using Scope......................................................................811 Log File Information.............................................................811 Connections to Payload Meter II™.................................................812 USING SCOPE..........................................................................813 Monitoring Inputs Using Scope....................................................813 Monitoring Suspension Charging Using Scope.......................................813 Pressure Sensor Dummy Loads......................................................816 GAIN ADJUSTMENT WORKSHEET............................................................817 EXHAUST BRAKE............................................................................818 OPERATOR'S CAB...............................................................................826 TRUCK CAB................................................................................828 Removal..............................................................................828 Installation.........................................................................828 CAB COMPONENTS...........................................................................830 WINDSHIELD WIPER ....................................................................830 Operation........................................................................830 Removal..........................................................................830 Installation.....................................................................830 WINDSHIELD WASHER....................................................................831 Service..........................................................................831 AIR CLEANER INDICATOR GUILDE.........................................................832 OPERATOR COMFORT.........................................................................836 OPERATOR SEAT........................................................................836 Adjustment Instructions..........................................................836 Removal..........................................................................837 Installation.....................................................................837 HEATER AND AIR CONDITIONER...........................................................839 Removal..........................................................................839 Installation.....................................................................839 HEATER AND AIR CONDITIONER COREREPLACEMENT...........................................839 Disassembly......................................................................839 Assembly.........................................................................839 FILTER MAINTENANCE...................................................................841 Cab Fresh Air Filter.............................................................841 Heater/Air Conditioner Air Filter................................................841 HEATER CONTROLS......................................................................842 Removal..........................................................................842 Installation.....................................................................842 DASH PANEL...........................................................................842 Removal..........................................................................842 Installation.....................................................................842 OPERATOR CAB AND CONTROLS................................................................844 OPERATOR CONTROLS....................................................................844 Retard Operation.................................................................845 Center Console...................................................................846 ENGINE ELECTRONIC CONTROL SYSTEM.................................................849 Hoist Control Lever..............................................................851 DUMP BODY CONTROL LINKAGE........................................................853 STEERING COLUMN SERVICE..........................................................854 INSTRUMENT PANEL.....................................................................856 INSTRUMENT PANEL (Upper Half)........................................................858 INSTRUMENT PANEL (Lower Half)........................................................862 HEATER/AIR CONDITIONER CONTROLS......................................................867 LUBRICATION AND SERVICE......................................................................870 LUBRICATION AND SERVICE..................................................................872 LUBRICATION SPECIFICATIONS CHARTS........................................................874 SERVICE CAPACITIES...................................................................874 ANTI-FREEZE SPECIFICATIONS...........................................................874 LUBRICATION CHART....................................................................875 10 HOUR (DAILY) INSPECTION...............................................................876 250 HOUR LUBRICATION AND MAINTENANCE CHECKS..............................................882 500 HOUR LUBRICATION AND MAINTENANCE CHECKS..............................................884 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................885 2000 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................886 5000 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................887 HYDRAULIC TANK SERVICE...................................................................888 Filling Instructions (Hoist Oil Supply)..............................................888 Filling Instructions (Rear Brake Cooling OilSupply)..................................888 HYDRAULIC FILTERS Filter Replacement.................................................889 HYDRAULIC TANK BREATHER Cleaning.....................................................889 HIGH PRESSURE HYDRAULIC FILTERS..........................................................890 TRANSMISSION FILTER......................................................................892 PERIODIC REPLACEMENT OF COMPONENT PARTS FOR SAFETY DEVICES...............................893 ALPHABETICAL INDEX...........................................................................894 SYSTEM SCHEMATICS............................................................................898 AIR SYSTEM PIPING........................................................................900 AIR SYSTEM SCHEMATIC.....................................................................901 HYDRAULIC SYSTEM SCHEMATIC...............................................................902 HYDRAULIC SYSTEM PIPING..................................................................903 TRANSMISSION CROSS SECTION VIEW..........................................................904 ELECTRICAL WIRING SCHEMATIC..............................................................905
KOMATSU 330M DUMP TRUCK SHOP MANUAL SN A10212-A10223 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu 330M Dump Truck Shop Manual
FOREWORD:
This Shop 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 æ10% tolerance unless otherwise specified.
- A Product Identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating.
- The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 330E). 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.
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
