Komatsu A10212 Operation & Maintenance Manual
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Komatsu A10212 Operation & Maintenance Manual

Komatsu A10212 Operation & Maintenance Manual

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DG745
Operation & Maintenance
Manual
DUMP TRUCK
A10212 - A10223
SERIAL NUMBERS
®

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Summary of Contents for Komatsu A10212

  • Page 1 DG745 Operation & Maintenance Manual DUMP TRUCK A10212 - A10223 SERIAL NUMBERS ®...

  • Page 3: Foreword

    Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating. The KOMATSU Haulpak Truck Model designation consists of three numbers and one letter (i.e. 330M). The three numbers represent the basic truck model. The letter “M” designates a Mechanical drive and the letter “E”...
  • Page 4 Introduction - Section 1 OM1018.1 11/00 Page 1-2 “ALERT” This symbol is used with the signal words, “CAUTION” “DANGER” “WARNING” , and in this man- ual to alert the reader to hazards arising from improper operating and maintenance practices. “DANGER” identifies a specific potential hazard WHICH WILL RESULT in either INJURY OR DEATH...

  • Page 5: Table Of Contents

    OM1018.1 11/00 Introduction - Section 1 Page 1-3 TABLE OF CONTENTS SUBJECT ........SECTION / PAGE INTRODUCTION .

  • Page 6: Table Of Contents

    Introduction - Section 1 OM1018.1 11/00 Page 1-4 TABLE OF CONTENTS (Continued) SUBJECT ........SECTION / PAGE OPERATION (Continued) .
  • Page 7 OM1018.1 11/00 Introduction - Section 1 Page 1-5 TABLE OF CONTENTS (Continued) SUBJECT ........SECTION / PAGE SPECIFICATIONS .
  • Page 8 Introduction - Section 1 OM1018.1 11/00 Page 1-6 KOMATSU 330M HAULPAK TRUCK...

  • Page 9: About This Manual

    The front cover of this manual includes a Form Number. This Form No. should be referenced when ordering additional copies of this manual, or for any other correspondence regarding the coverage in this manual. Direct all inquiries to: Komatsu Mining Systems, Inc. Peoria Operations, Service Publications P.O. Box 240 Peoria, IL 61650-0240 (309)-672-7072 –...
  • Page 10 Introduction - Section 1 OM1018.1 11/00 Page 1-8 NOTES...

  • Page 11: Standard Tables

    OM1018.2 11/00 Introduction - Section 1 Standard Charts and Tables Page 1-9 STANDARD TABLES This manual provides dual dimensioning for many specifications. Metric units are specified first, with U.S. standard units in parentheses. References throughout the manual to standard torques or other standard values will be to one of the following Tables.
  • Page 12 Introduction - Section 1 OM1018.2 11/00 Page 1-10 Standard Charts and Tables TABLE I STANDARD TIGHTENING TORQUE FOR METRIC HEX HEAD CAPSCREW AND NUT ASSEMBLY Kilogram.meters Newton.meters Foot Pounds Capscrew Thread Width (kg.m) (N.m) (ft.lbs.) Diameter Across Flat ± ± ±...
  • Page 13 OM1018.2 11/00 Introduction - Section 1 Standard Charts and Tables Page 1-11 TABLE IV TEMPERATURE CONVERSIONS ÷ FORMULA: F° – 32 1.8 = C° C° x 1.8 + 32 = F° CELSIUS FAHRENHEIT CELSIUS FAHRENHEIT CELSIUS FAHRENHEIT C° F° C° F°...
  • Page 14 Introduction - Section 1 OM1018.2 11/00 Page 1-12 Standard Charts and Tables TABLE VII PRESSURE CONVERSIONS kilograms/cm (kg/cm ) To pounds per sq. in. (psi) 1 kg/cm = 14.2231 psi kg/cm (psi) 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5...

  • Page 15: Sealants And Adhesives

    Used for protecting battery electrode terminals from corrosion. NOTE: The Part Numbers in this column are NOT KOMATSU numbers. These are vendor designations. (1) Used for threaded areas (for example, plug, nipple, elbow etc.) which are removable and a pressure of 20 kg/cm (285 psi) or less.
  • Page 16 Introduction - Section 1 OM1018.2 11/00 Page 1-14 Standard Charts and Tables NOTES...

  • Page 17: Safety

    UNAUTHORIZED MODIFICATION • Any modification made to this vehicle without authorization from Komatsu Mining Systems, Inc. can possibly create hazards. • Before making any modification, consult the authorized regional Komatsu Mining Systems, Inc. distributor.

  • Page 18: Leaving The Operator's Seat

    Safety - Section 2 11/98 OM2013 Page 2-2 General Safety LEAVING THE OPERATOR'S SEAT • When preparing to leave the operator's seat, do not touch any control lever that is not locked. To prevent accidental operations from occurring, always carry out the following: •...
  • Page 19 OM2013 11/98 Safety - Section 2 General Safety Page 2-3 PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURES • Immediately after operations, the engine cooling water, engine oil, and hydraulic oil are at high temperature and are under pressure. If the cap is removed, or the oil or water is drained, or the filters are replaced, there is danger of serious burns.
  • Page 20 Komatsu Mining Systems, Inc., or is damaged when the machine rolls over, the strength will drop and it will not be able to fulfill its function properly. It can only display its performance if it is repaired or modified in the specified way.

  • Page 21: Precautions During Operation

    In addition, know the proper use and care of all the safety equipment on the truck. Only qualified operators or technicians should attempt to operate or maintain the Komatsu Truck. Safe practices start before the operator gets to the equipment! SAFETY AT WORKSITE •...

  • Page 22: Operating Machine

    Safety - Section 2 11/98 OM2013 Page 2-6 General Safety IN OPERATOR'S CAB - BEFORE STARTING ENGINE • Do not leave tools or spare parts lying around in the operator's compartment or allow trash to accumulate in cab of truck. Keep all unauthorized reading material out of truck cab. •...
  • Page 23 OM2013 11/98 Safety - Section 2 General Safety Page 2-7 • Check for flat tires periodically during shift. If truck has been run on a “flat”, it must not be parked in a building until the tire cools. If tire must be changed, do not stand in front of rim and locking ring when inflating tire mounted on the machine.
  • Page 24 Safety - Section 2 11/98 OM2013 Page 2-8 General Safety TRAVELING ON SLOPES • Traveling on slopes could result in the machine tipping over or slipping. • Do not change direction on slopes. To ensure safety, go down to level ground before turning. •...
  • Page 25 OM2013 11/98 Safety - Section 2 General Safety Page 2-9 WHEN DUMPING • Before starting the dumping operation, check that there is no person or object behind the machine. • Stop the machine in the correct position, and check again that there is no person or object behind the machine. Give the determined signal, then slowly operate the dump body.

  • Page 26: Battery

    Safety - Section 2 11/98 OM2013 Page 2-10 General Safety BATTERY BATTERY HAZARD PREVENTION • Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If you spill acid on yourself, immediately flush the area with water. •...

  • Page 27: Precautions For Maintenance

    ALWAYS attach the WARNING TAG to the control lever in the operator's cab to alert others that you are working on the machine. Attach additional warning tags around the machine, if necessary. • These tags are available from your Komatsu distributor. (Part No. 09963-03000) PROPER TOOLS •...

  • Page 28: During Maintenance

    Safety - Section 2 11/98 OM2013 Page 2-12 General Safety SECURING THE DUMP BODY The body pin is located under the dump body at the rear of the truck. This pin is intended to be used as a safety to hold the body in the up position while the technicians work under it.
  • Page 29 OM2013 11/98 Safety - Section 2 General Safety Page 2-13 RULES TO FOLLOW WHEN ADDING FUEL OR OIL • Spilled fuel and oil may cause slipping. Always clean up spills immediately. • Always tighten the cap of the fuel and oil fillers securely. •...

  • Page 30: Waste Materials

    Safety - Section 2 11/98 OM2013 Page 2-14 General Safety PRECAUTIONS WITH HIGH PRESSURE OIL • Do not forget that the work equipment circuits are always under pressure. • Do not add oil, drain oil, or carry out maintenance or inspection before completely releasing the internal pressure.

  • Page 31: Tires

    If the proper procedure for carrying out maintenance or replacement of the wheel or tire is not used, the wheel or tire may burst and cause serious injury or damage. When carrying out such maintenance, please consult the authorized regional Komatsu Mining Systems, Inc. distributor, or the tire manufacturer. STORING TIRES AFTER REMOVAL •...

  • Page 32: Warnings And Cautions

    Safety - Section 2 11/98 OM2013 Page 2-16 General Safety WARNINGS AND CAUTIONS The following paragraphs give an explanation of the WARNING, CAUTION, Service Instruction plates, and decals attached to the truck. The plates and decals listed here are typical of this model, but because of customer options, individual trucks may have plates and decals that are different from those shown here.
  • Page 33 OM2013 11/98 Safety - Section 2 General Safety Page 2-17 This instruction plate contains (4) WARNINGS (See illustration above): • Inspection and Maintenance With Body In Raised Up Position • Emergency Steering System Operation • Engine Shut Down Procedure • Retarder Oil Temperature Warning Light These "WARNINGS"...
  • Page 34 Safety - Section 2 11/98 OM2013 Page 2-18 General Safety A Steering and Hoist Oil decal is located to the left of the left hand filler cap on left hand side of hydraulic tank. DANGER plates are mounted on each suspension cylinder.
  • Page 35 OM2013 11/98 Safety - Section 2 General Safety Page 2-19 A plate is located next to filler cap on fuel cap which specifies Diesel Fuel Only. Care should be taken to open cap slowly and bleed off pressure that may be This CAUTION plate is located on left hand side of in tank when removing filler cap.
  • Page 36 Safety - Section 2 11/98 OM2013 Page 2-20 General Safety A caution plate is located on the right hand inside door panel and also on the lid of the battery box. These instructions must be followed when welding is done on the truck to avoid damage to the electronic A plate is located on center deck floor next to radiator components.
  • Page 37 OM2013 11/98 Safety - Section 2 General Safety Page 2-21 Warning plates are mounted on the truck frame in front of and to the rear of both front tires to alert all persons to stay clear when the truck is being steered. A Caution plate is located next to the sight gauge on the radiator cooling water reserve tank on top of right hand deck just aft of battery box.
  • Page 38 Safety - Section 2 11/98 OM2013 Page 2-22 General Safety An informational plate (above) for the solenoid valve and relays is mounted to the inside lid of the electrical console behind the operator and passenger seats. The fuse table plate (below) is located to the left of the solenoid valve and relay plate, also mounted to the inside lid of the electrical console.
  • Page 39 OM2013 11/98 Safety - Section 2 General Safety Page 2-23 A Speed/Grade decal showing Retarding Capacities is applied to the lower left-hand corner of the cab windshield. This decal is designed to help the oper- ator maintain a safe vehicle speed while descending a grade with a loaded truck.
  • Page 40 Safety - Section 2 11/98 OM2013 Page 2-24 General Safety A product indentification plate is located at the base of the left-hand upright. This lists the vehicle model number, maximum G.V.W. and Product Identification Number. The Product Identification Number (vehicle serial number) contains information which will identify the original manufaturing bill of material for this unit.

  • Page 41: Operating Instructions

    OM3018 08/07 Operation - Section 3 Operating Instructions Page 3-1 OPERATING INSTRUCTIONS PREPARING FOR OPERATION Local work practices may prevent an operator from performing all tasks suggested here, but to the extent The safest trucks are those which have been prop- permitted, personnel should follow this or similar rou- erly prepared for operation.

  • Page 42: Start Here

    Operation - Section 3 08/07 OM3018 Page 3-2 Operating Instructions START HERE 330M “WALK-AROUND” INSPECTION NOTE: Transmission Oil level is checked most accurately when engine is running and all systems are at normal operating temperatures. Engine Oil is checked most accurately with the engine stopped, but after engine oil, coolant, and transmission oil are at normal operating temperature.
  • Page 43 OM3018 08/07 Operation - Section 3 Operating Instructions Page 3-3 9. Move 17. Inspect around the right dual tires. Inspect hydraulic tank between the tires for rocks, and for condition of and check the the rock ejector; inspect the tires for cuts or hydraulic fluid damage, and for correct inflation.
  • Page 44 Operation - Section 3 08/07 OM3018 Page 3-4 Operating Instructions 25. Move on around to the right front of the truck. 32. Check cleaner indica- 26. When moving in front of the radiator, inspect for tor (1). If the any debris that might be stuck in front of the area radiator and remove it.

  • Page 45: Engine Start-Up Safety Practices

    OM3018 08/07 Operation - Section 3 Operating Instructions Page 3-5 ENGINE START-UP SAFETY PRACTICES • Check that the Central Warning Lamp and all Safety rules must be observed upon engine start-up. monitor lamps and gauges, light up for approximately 3 seconds and that the alarm buzzer sounds...
  • Page 46 Operation - Section 3 08/07 OM3018 Page 3-6 Operating Instructions STARTING THE ENGINE • Rotate switch fully clockwise to "start" position (with Transmission Range Selector in "Neutral") and Electric starters and engine grid heaters can be a HOLD this position until significant electrical drain on vehicle batteries.

  • Page 47: After Engine Has Started

    OM3018 08/07 Operation - Section 3 Operating Instructions Page 3-7 AFTER ENGINE HAS STARTED 4. Check Parking Brake capacity. • After starting engine, operate engine approximately 1000 rpm, coolant temperature • With the machine on flat ground, check that the gauge is indicating "normal"...

  • Page 48: Machine Operation Safety Precautions

    Operation - Section 3 08/07 OM3018 Page 3-8 Operating Instructions 9. Do not use the fire extinguisher for any purpose 5. Observe all regulations pertaining to the job other than putting out a fire! If extinguisher is site's traffic pattern. Be alert to any unusual traf- discharged, report the occurrence so the used fic pattern.

  • Page 49: Hauling

    OM3018 08/07 Operation - Section 3 Operating Instructions Page 3-9 HAULING RETARDER OPERATION 1. Always stay alert! If unfamiliar with the road, During normal operation, the retarder control lever drive with extreme caution. should be used to control the speed of the truck and to stop the truck instead of using the foot-operated 2.

  • Page 50: Engine Overspeed

    Operation - Section 3 08/07 OM3018 Page 3-10 Operating Instructions The continuous numbers on the chart indicate the Continue this procedure to downshift to the required gear range to maintain engine speed at combination of speeds and grades which the vehicle 1800 - 2400 RPM and brake oil temperature can safely negotiate for unlimited time or distance.

  • Page 51: Passing

    OM3018 08/07 Operation - Section 3 Operating Instructions Page 3-11 PASSING To Raise dump body: 1. Do not pass another truck on a hill or blind curve! 2. Before passing, make sure the road ahead is clear. If a disabled truck is blocking your lane, The dumping of very large rocks (10% of payload, slow down and pass with extreme caution.

  • Page 52: Safe Parking Procedures

    Operation - Section 3 08/07 OM3018 Page 3-12 Operating Instructions To Lower Body: SAFE PARKING PROCEDURES 8. After material being The operator must continue the use of safety precau- dumped clears body, tions when preparing for parking and engine shut- move dump lever to the down.

  • Page 53: Towing

    OM3018 08/07 Operation - Section 3 Operating Instructions Page 3-13 TOWING 3. If the engine is NOT operable, never haul the truck over 800m (2,625 ft.). Prior to towing a truck, many factors must be care- fully considered. Serious personal injury and/or sig- If the towing distance surpasses that limit, be nificant property damage may result if important sure to remove the drive shaft between the...

  • Page 54: Brake Release

    Operation - Section 3 08/07 OM3018 Page 3-14 Operating Instructions BRAKE RELEASE 6. With parking brake disconnected, remove blocking and immediately move the truck to a Releasing Parking Brake And Emergency Brake safe place. Refer to INSTRUCTIONS FOR After Being Actuated In An Emergency TOWING THE MACHINE.

  • Page 55: Operator Cab And Controls

    OM3018 08/07 Operation - Section 3 Operating Instructions Page 3-15 OPERATOR CAB AND CONTROLS FIGURE 3-1. STEERING WHEEL AND CONTROLS 1. Steering Wheel 5. Windshield Wiper/Washer 9. Throttle Pedal 2. Tilt Lever Switch 10. Center Console 3. Turn Signals and Headlight 6.

  • Page 56: Service Brake Pedal

    Operation - Section 3 08/07 OM3018 Page 3-16 Operating Instructions (6) Headlights and Dimmer Switch (9) Throttle Pedal The headlights and dim- The Throttle Pedal (9) is a mer switch (6, Figure 3- foot operated treadle pedal 1) is part of the turn sig- which allows the operator to nal lever function.
  • Page 57 OM3018 08/07 Operation - Section 3 Operating Instructions Page 3-17 When moving the range selector lever from "N" to "R", or from "D" to 5, the Release Button on the end of the handle (operator side) must be pressed before the selector lever can be moved.
  • Page 58 Operation - Section 3 08/07 OM3018 Page 3-18 Operating Instructions Shift Limiter Switch (2, Figure 3-2) Emergency Steering Switch (4, Figure 3-2) This switch is used to limit the This switch (4) actuates highest speed range when the the emergency steering transmission shift lever is in "D"...
  • Page 59 OM3018 08/07 Operation - Section 3 Operating Instructions Page 3-19 Emergency Brake Lever (5, Figure 3-2) • Immediately after making an emergency stop, the parking brake disc will be at a high temperature. Do not make any parking brake adjustment until the disc has cooled.
  • Page 60 Operation - Section 3 08/07 OM3018 Page 3-20 Operating Instructions ENGINE ELECTRONIC CONTROL SYS- Engine Shutdown Light (Stop Engine) (7, Figure 3-2) When illuminated, this red The following items (7, 8, 9, 11, & 12, Figure 3-2) engine shutdown light indi- relate to the engine electronic fuel control system.

  • Page 61: Determining "Fault" Codes

    If active fault codes have been determined as described previously, refer 1. To determine an active "fault", turn the key- to the appropriate Komatsu engine manual. switch to the "OFF" position and wait until the engine completely stops. 2. Turn keyswitch to "ON" position (engine NOT...

  • Page 62: Hoist Control Valve

    Operation - Section 3 08/07 OM3018 Page 3-22 Operating Instructions (12) Hoist Control 5. After lowering the dump body a certain distance, The hoist control (12, Figure 3-1) is a four position, move dump lever to the hand operated control lever located to the left of the FLOAT position.

  • Page 63: Operator Seat (Figure 3-3)

    OM3018 08/07 Operation - Section 3 Operating Instructions Page 3-23 OPERATOR SEAT 4. The Front-To-Rear position of the seat is The operator's seat is a fully adjustable air ride seat adjusted by pulling up on the bar located at the with 5 mechanisms to adjust the height, firmness, base of the seat in the center ([E], Figure 3-3), backrest angle, front-to-rear position, and lumbar...
  • Page 64 Operation - Section 3 08/07 OM3018 Page 3-24 Operating Instructions NOTES...
  • Page 65 OM3018 08/07 Operation - Section 3 Operating Instructions Page 3-25 INSTRUMENT PANEL AND INDICATORS The instrument panel consists of the gauge and The monitors and gauges inside the monitor module monitor module, speedometer module, monitor and speedometer module are actuated by the signal module, service (Hour) meter, odometer, plate, and from the gauge and monitor module, and the odom- the parts connected to them.
  • Page 66 Operation - Section 3 08/07 OM3018 Page 3-26 Operating Instructions FIGURE 3-4. WARNING AND CAUTION LAMPS 1. Central Warning Lamp W = Warning Monitor Lamp 2. Action Display Code E = Electronic Controller Monitor C = Caution Monitor Lamp WARNING & CAUTION LAMPS "C", Caution Monitor Lamp - These lamps monitor other important truck functions.

  • Page 67: Gauge And Monitor Panel (Figure 3-4)

    OM3018 08/07 Operation - Section 3 Operating Instructions Page 3-27 FIGURE 3-5. GAUGE AND MONITOR PANEL 1. Air Pressure Monitor 3. Coolant Temperature Monitor The Air Pressure Monitor (1, Fig- The Coolant Temperature Moni- ure 3-5) is a lamp which monitors tor (3) is a lamp which indicates a the air pressure in the air tank.
  • Page 68 Operation - Section 3 08/07 OM3018 Page 3-28 Operating Instructions 5. Torque Converter Oil Temperature Monitor 9. High Beam Pilot Lamp The Torque Converter Oil Tem- The High Beam Pilot Lamp (9) perature Monitor (5, Figure 3-5) lights up when the head lamps is a lamp which indicates a rise in are on high beam.
  • Page 69 OM3018 08/07 Operation - Section 3 Operating Instructions Page 3-29 15. Lock-up Pilot Lamp 20. Other Mechatronics Monitor (OPTIONAL) The Lock-Up Pilot Lamp (15, Fig- This red indicator (20) flashes when- ure 3-5) lights up whenever the ever any abnormality occurs in the torque converter is locked up and mechatronics related parts of the PMC the transmission enters direct...
  • Page 70 Operation - Section 3 08/07 OM3018 Page 3-30 Operating Instructions 26. Service Meter 28. Odometer The Service Meter (26, Figure 3-5) The Odometer (28) indicates displays the total hours of opera- the total distance that the truck tion for the truck. has traveled in miles.
  • Page 71 OM3018 08/07 Operation - Section 3 Operating Instructions Page 3-31 30. Coolant Level Monitor 35. Front Brake ON/OFF Switch The Coolant Level Monitor (30, Figure 3-6) indicates a low radia- tor coolant level. If this monitor lamp flashes and alarm buzzer sounds, stop truck, shutdown engine, and add coolant as required.
  • Page 72 Operation - Section 3 08/07 OM3018 Page 3-32 Operating Instructions 37. AISS/Auto Switch 39. Starting Switch The AISS (Automatic Idle The Starting Switch (39, Figure Selector Switch, 37, Figure 3-6) is a three-position key- 3-6) may be positioned to switch: LOW or AUTO as desired.
  • Page 73 OM3018 08/07 Operation - Section 3 Operating Instructions Page 3-33 43. Parking Brake Monitor 48. Steering Oil Temperature The Parking Brake Monitor (43) This lamp (48) indicates a rise in lights up when the parking brake the steering oil temperature. If is applied.
  • Page 74 Operation - Section 3 08/07 OM3018 Page 3-34 Operating Instructions 52. Exhaust Brake Switch (Optional) 54. Central Warning Lamp (Red Convex Lens) For operation of the Exhaust Brake Switch (52, Fig- ure 3-6), refer to the following switch positions: This Central Warning lamp (54, Figure 3-6) flashes The exhaust brake is actuated whenever an abnormality has occurred in any one of when the foot brake is depressed...

  • Page 75: Instrument Panel, Right Side (Figure 3-8)

    OM3018 08/07 Operation - Section 3 Operating Instructions Page 3-35 FIGURE 3-8. INSTRUMENT PANEL - RIGHT SIDE 55. Temperature Adjustment Lever 57. Air Selector Lever The Temperature Adjustment Lever (55, Figure 3-8) The Air Selector Lever (57) selects the source of air. is used to adjust the cab air temperature for heating Outside air enters through a filter and is sent to the or cooling.
  • Page 76 Operation - Section 3 08/07 OM3018 Page 3-36 Operating Instructions 59. Air Vent 62. Correction Code Display Air Vents (59, Figure 3-8) are provided for circulation When an action code appears in this area (62, Figure of cooled or heated air through the cab. 3-6), refer to the decal (Figure 3-9) in the upper left- hand corner of the windshield.

  • Page 77: Lubrication And Service

    Preventive Maintenance will contribute to the long life The service intervals presented here are in hours of and dependability of the Komatsu truck and its com- operation. These intervals are recommended in ponents. The use of proper lubricants and the perfor-...
  • Page 78 Maintenance - Section 4 08/07 OM4016 Page 4-2 Lubrication and Service...
  • Page 79 OM4016 08/07 Maintenance - Section 4 Lubrication and Service Page 4-3 10 HOUR (DAILY) INSPECTION Prior to each operating shift, a “walk around” inspec- Truck Serial Number ________________________ tion should be performed. Check the truck’s general Site Unit Number ____________________________ condition.
  • Page 80 Maintenance - Section 4 08/07 OM4016 Page 4-4 Lubrication and Service 10 HOUR (DAILY) INSPECTION (continued) e. Check air cleaner COMMENTS CHECKED INITIALS service indicator (1). If the RED area is show- ing in the indicator, the filters must cleaned or replaced before operating truck.

  • Page 81: Wheels And Tires

    OM4016 08/07 Maintenance - Section 4 Lubrication and Service Page 4-5 10 HOUR (DAILY) INSPECTION (continued) ENGINE COMMENTS CHECKED INITIALS 1. Check alternator and fan belts for proper tension, alignment, and general condition. 2. Engine Oil Level- (lower right side) (Engine stopped for at least 15 minutes) a.
  • Page 82 Maintenance - Section 4 08/07 OM4016 Page 4-6 Lubrication and Service 10 HOUR (DAILY) INSPECTION (continued) WHEELS COMMENTS CHECKED INITIALS a. Check to see that all wheel lugs/wedges are in place and tight. b. Inspect rear wheels for any leakage that may be coming from inside the wheel housing that would indicate planetary leakage.

  • Page 83: Operational Checks

    OM4016 08/07 Maintenance - Section 4 Lubrication and Service Page 4-7 10 HOUR (DAILY) INSPECTION (continued) OPERATIONAL CHECKS - With Engine Running COMMENTS CHECKED INITIALS For these checks, park the truck on a level surface, lower the dump body, and operate engine at approxi- mately 1000 RPM, until air pressure, coolant temper- ature, engine oil temperature, and transmission oil temperature gauges all indicate "Normal (green)
  • Page 84 Maintenance - Section 4 08/07 OM4016 Page 4-8 Lubrication and Service NOTES...

  • Page 85: Hours Service

    OM4016 08/07 Maintenance - Section 4 Lubrication and Service Page 4-9 250 HOURS SERVICE INITIAL 250 HOURS SERVICE ONLY Truck Serial Number ________________________ Site Unit Number ____________________________ Perform the following maintenance after running the machine for the first 250 hours. Thereafter, these Date: __________ Hour Meter _________________ services are to be accomplished at the 500/1000/ 2000 hour interval as scheduled.
  • Page 86 Maintenance - Section 4 08/07 OM4016 Page 4-10 Lubrication and Service 250 HOURS SERVICE (continued) 6. HYDRAULIC TANK BREATHERS - Remove COMMENTS CHECKED INITIALS breathers, disassemble breathers remove filter ele- ment, clean in solvent. Dry with air pressure and reassemble then reinstall. 7.

  • Page 87: Hour Service

    OM4016 08/07 Maintenance - Section 4 Lubrication and Service Page 4-11 500 HOUR SERVICE Truck Serial Number ________________________ Site Unit Number ____________________________ In addition to the 250 hour lubrication and inspection Date: __________ Hour Meter _________________ schedule, perform the following: Name of Service Person ______________________ COMMENTS CHECKED...
  • Page 88 Maintenance - Section 4 08/07 OM4016 Page 4-12 Lubrication and Service 1000 HOUR SERVICE Truck Serial Number ________________________ Site Unit Number ____________________________ In addition to the 250 and 500 hour lubrication and inspection schedules, perform the following: Date: __________ Hour Meter _________________ Name of Service Person ______________________ 1.
  • Page 89 OM4016 08/07 Maintenance - Section 4 Lubrication and Service Page 4-13 EVERY 2000 HOUR SERVICE Maintenance for every 250, 500 and 1000 hours Truck Serial Number ________________________ should also be carried out at this time. Site Unit Number ____________________________ 1. STEERING, HOIST OIL TANK Date: __________ Hour Meter _________________ Drain oil from tank and refill tank to specified level, Name of Service Person ______________________...
  • Page 90 Maintenance - Section 4 08/07 OM4016 Page 4-14 Lubrication and Service EVERY 5000 HOUR SERVICE Truck Serial Number ________________________ Site Unit Number ____________________________ Maintenance for every 250, 500 and 1000 hours should also be carried out at this time. Date: __________ Hour Meter _________________ Name of Service Person ______________________ 1.

  • Page 91: Hydraulic Tank Service

    OM4016 08/07 Maintenance - Section 4 Lubrication and Service Page 4-15 HYDRAULIC TANK SERVICE 5. If hydraulic components have been removed and lines drained, start the engine and raise the Filling Instructions (Hoist Oil Supply) dump body 2-3 times to circulate oil and fill all voids.

  • Page 92: Hydraulic Filters

    Maintenance - Section 4 08/07 OM4016 Page 4-16 Lubrication and Service HYDRAULIC FILTERS Filter Replacement 1. Lower the dump body and shut down the engine. Release hydraulic tank filler cap slowly to remove any internal pressure. 2. Turn the oil filler caps (3 & 8, Figure 4-3) slowly counterclockwise to release internal tank pres- sure.
  • Page 93 OM4016 08/07 Maintenance - Section 4 Lubrication and Service Page 4-17 HIGH PRESSURE HYDRAULIC FILTERS Filter Assembly Removal 1. Lower the dump body and shut down the engine. Clean dirt accumulation from the high pressure hydraulic filters and tube connections in front of the hydraulic tank.
  • Page 94 Maintenance - Section 4 08/07 OM4016 Page 4-18 Lubrication and Service Filter Element Replacement 3. Install new element (2) into filter housing (1) 1. Place filter assembly (Figure 4-7) on work using new O-Ring (3) and Backup Ring (4). bench. Using a spanner tool at both ends, hold housing (1) and loosen (counter-clockwise) 4.

  • Page 95: Transmission Filter Service

    OM4016 08/07 Maintenance - Section 4 Lubrication and Service Page 4-19 TRANSMISSION FILTER The transmission filter element (Beta 25 = 200) should be replaced every 500 hours of operation or sooner if the warning light indicates high restriction. This maintenance interval may be increased or reduced, depending on operating conditions, by observing the warning light indicator.

  • Page 96: Perodic Replacement Of Component Parts For Safety Devices

    Maintenance - Section 4 08/07 OM4016 Page 4-20 Lubrication and Service PERIODIC REPLACEMENT OF COMPONENT PARTS FOR SAFETY DEVICES To ensure safety in operation, the user is requested The following parts should be considered for repair or to perform the periodic maintenance recommended replacement every 4000 hours, or every two years, in the previous schedules.

  • Page 97: Brake Circuit Checkout And Adjustment

    OM4016 08/07 Maintenance - Section 4 Lubrication and Service Page 4-21 BRAKE CIRCUIT CHECKOUT AND ADJUSTMENT CHECKING FRONT BRAKE PAD WEAR NOTE: This check is nominally specified for every 500 hours of truck operation. If truck is operated in a very abrasive environment (i.e.

  • Page 98: Checking Rear Brake Disc Wear

    Maintenance - Section 4 08/07 OM4016 Page 4-22 Lubrication and Service CHECKING REAR BRAKE DISC WEAR 5. After measuring the disc wear, remove wear gauge and install the air bleed plug, and bleed Operational complaints can be expected when wear the air.

  • Page 99: Brake Bleeding

    OM4016 08/07 Maintenance - Section 4 Lubrication and Service Page 4-23 BRAKE BLEEDING Start the engine and wait for the air gauge to enter the green range, then bleed the air from the circuit as follows. Rear brakes 1. Bleed the air at the slack adjuster end first. Depress the brake pedal, then loosen air bleed plugs (1 or 2, Figure 4-13) 3/4 turns.

  • Page 100: Parking Brake Adjustment

    Maintenance - Section 4 08/07 OM4016 Page 4-24 Lubrication and Service PARKING BRAKE PARKING BRAKE PAD Inspection PARKING BRAKE INSPECTION ITEM LIMIT REMEDY Disc Face 0.4 mm 0.8 mm Runout (0.016 in) (0.032 in) Replace Disc 25 mm 20 mm Thickness (0.99 in) (0.79 in)
  • Page 101 OM4016 08/07 Maintenance - Section 4 Lubrication and Service Page 4-25 Standard clearance: 5. After adjusting, return capscrew (2) to a position where capscrew retainer (3) stops it from turn- Total for both clearances = 1.6 ± 0.08 mm. ing. (0.063 ±...
  • Page 102 Maintenance - Section 4 08/07 OM4016 Page 4-26 Lubrication and Service NOTES...

  • Page 103: Brake System Bleeding

    Page 5-1 MAJOR COMPONENTS AND SPECIFICATIONS ENGINE POWER STEERING The KOMATSU 330M Truck is powered by a The 330M is equipped with full hydraulic power steer- Komatsu SA12V140Z-1 diesel engine. ing. The system includes an electric motor driven pump which automatically provides emergency power if the steering pump hydraulic flow is reduced below an established minimum.

  • Page 104: Major Components

    Specifications - Section 5 10/97 OM5010 Page 5-2 330M MAJOR COMPONENTS...

  • Page 105: Specifications

    SERVICE CAPACITIES Komatsu ..... . SA12V140Z-1 ....Liters ..U.S. Gallons Number of Cylinders .

  • Page 106: Weight Distribution

    Based on SAE 2:1 Heaped ..60 m (78 yds (w/Komatsu SA12V140Z-1 Engine; and 27.00R49 Min Turning Radius ....9.9 m (32' 6") Tires) Automatic Emergency Steering .
  • Page 107 OM6005 11/01 Optional Equipment - Section 6 Payload Meter II Page 6-1 PAYLOAD METER II™ ON BOARD WEIGHING SYSTEM (OBWS) INDEX PAYLOAD METER II ON BOARD WEIGHING SYSTEM (OBWS) ......6-4 GENERAL INFORMATION .
  • Page 108 Optional Equipment - Section 6 11/01 OM6005 Page 6-2 Payload Meter II DISPLAYS AT START-UP ............6-18 NORMAL OPERATION .
  • Page 109 OM6005 11/01 Optional Equipment - Section 6 Payload Meter II Page 6-3 NOTES...

  • Page 110: Payload Meter Ii On Board Weighing System (Obws)

    Optional Equipment - Section 6 11/01 OM6005 Page 6-4 Payload Meter II PAYLOAD METER II ON BOARD WEIGHING SYSTEM (OBWS) GENERAL INFORMATION ple of suspension and inclinometer data. After trav- eling 160 m (0.10 mi.) from the loading site, the PLM ™...

  • Page 111: Lights, Switches, And Components

    OM6005 11/01 Optional Equipment - Section 6 Payload Meter II Page 6-5 LIGHTS, SWITCHES, and COMPONENTS 6. Calibration/Clear Switch On The Face Of The Payload Meter Used to calibrate the machine when the condi- tions regulate this action. Also used with the (Refer to Figure 6-1) TOTAL/SFT switch to clear total payload and 1.

  • Page 112: Tips For Operation

    • For most Komatsu Trucks: Use only the brake lock switch to hold the truck stationary at the loading and dumping area. For Komatsu 330M/HD785 Trucks ONLY: Use the park brake switch to hold the truck stationary at the loading and dumping area.

  • Page 113: Theory Of Operation

    OM6005 11/01 Optional Equipment - Section 6 Payload Meter II Page 6-7 THEORY OF OPERATION Basic Description The payload meter uses the four suspension pres- sures and the inclinometer to determine the load in the truck. These inputs are critical to the calculation of the load.

  • Page 114: Gain Factor

    Optional Equipment - Section 6 11/01 OM6005 Page 6-8 Payload Meter II Gain Factor Sources of Error Gain factor is part of the formula the payload meter Poorly charged suspensions can lead to systematic uses to calculate the payload. The gain factor is a error in the calculation of payload.

  • Page 115: Example Calculation Of Payload

    OM6005 11/01 Optional Equipment - Section 6 Payload Meter II Page 6-9 NOTE: This screen is the only place that the Viewing Payload Calculation Inputs value of the G gain potentiometer can be ™ The PLM II estimates payload by monitoring sus- checked.

  • Page 116: Checking The Gain

    Optional Equipment - Section 6 11/01 OM6005 Page 6-10 Payload Meter II Checking the Gain Adjusting the Gain 1. Press and hold the LIGHT/INC and Before adjusting the gain perform the following steps: MODE switches until "CHEC" is 1. Confirm the suspension oil and nitrogen flashing on the meter.

  • Page 117: Types Of Data Stored

    OM6005 11/01 Optional Equipment - Section 6 Payload Meter II Page 6-11 TYPES OF DATA STORED Cycle Data One cycle is considered to be from the point where a load is dumped to the point where the next load is dumped. Data between these two points is recorded in memory.

  • Page 118: Engine On/Off Data

    Optional Equipment - Section 6 11/01 OM6005 Page 6-12 Payload Meter II Engine ON/OFF Data When the engine is started or stopped, the following data is recorded. ITEM UNIT RANGE REMARKS Engine Operation Number Number 1 - 65535 Advances by one each time the engine is started.

  • Page 119: Engine Operation

    OM6005 11/01 Optional Equipment - Section 6 Payload Meter II Page 6-13 Engine Operation ITEM UNIT RANGE REMARKS Every time the engine is started the Number when Canceled Number 1 - 65535 number advances by one. Last Two Digits Of Year Year 0 - 99 Month...

  • Page 120: Operator Functions

    Optional Equipment - Section 6 11/01 OM6005 Page 6-14 Payload Meter II OPERATOR FUNCTIONS Clearing the Operator Load Counter 1. Press the TOTAL/SFT switch once. The num- Using the Operator Load Counter ber displayed is the total tons hauled since the last time the counter was cleared.

  • Page 121: Initial Setup Of Payload Meter

    OM6005 11/01 Optional Equipment - Section 6 Payload Meter II Page 6-15 INITIAL SETUP OF PAYLOAD METER There are several things that must be checked and Switch Position programmed when a payload meter is first installed. Initial Setup should be set to 1.00 - Gain 1.

  • Page 122: Checking The Operator Check Mode

    Optional Equipment - Section 6 11/01 OM6005 Page 6-16 Payload Meter II Checking the Operator Check Mode Checking the Service Check Mode The Operator Check Mode is used to check and change several settings. These should be checked before the payload meter is put into service. 1.

  • Page 123: Checking The Gt Setting

    3. Whenever the suspensions have been serviced or the Nitrogen levels have changed. An alternative method is to use a personal computer running the Komatsu Payload Download Program for 4. Whenever any major change to the truck has Microsoft Windows. The "Monitor Pressures" section been performed that would change the empty of the program displays live inclinometer data.

  • Page 124: Displays At Start-Up

    Optional Equipment - Section 6 11/01 OM6005 Page 6-18 Payload Meter II DISPLAYS AT START-UP 7. The display will show: This display indicates POWER ON: Machine ID code where "xxx" indicates a value All external display lamps (Figure 6-2) will come on between 0 and 200.

  • Page 125: Setup And Maintenance

    OM6005 11/01 Optional Equipment - Section 6 Payload Meter II Page 6-19 SETUP AND MAINTENANCE Setting the Option Code 1. Press and hold the MODE switch Speed Limit until "Cd:dP" is displayed. A warning can be displayed if the machine exceeds a 2.

  • Page 126: Setting The Machine I.d. Code

    Optional Equipment - Section 6 11/01 OM6005 Page 6-20 Payload Meter II Setting The Machine I.D. Code Setting The Time and Date 1. Press and hold the MODE switch 1. Press and hold the MODE switch until "Cd:dP" is displayed. until "Cd:dP"...

  • Page 127: Download Of Information

    OM6005 11/01 Optional Equipment - Section 6 Payload Meter II Page 6-21 DOWNLOAD OF INFORMATION DISPLAY OF FAULT CODES 1. Press and hold the MODE switch Payload information and fault codes recorded should until "Cd:dP" is displayed. be downloaded to a personal computer on a regular basis.
  • Page 128 Optional Equipment - Section 6 11/01 OM6005 Page 6-22 Payload Meter II • Condition of the Engine Oil Pressure signal. The panel will display ":C3:XX" for 3 seconds, then indicate: "C3:oo" Engine is running. "C3:- -" Engine is not running. •...
  • Page 129 OM6005 11/01 Optional Equipment - Section 6 Payload Meter II Page 6-23...
  • Page 130 Optional Equipment - Section 6 11/01 OM6005 Page 6-24 Payload Meter II...

  • Page 131: Monitoring Input Signals

    OM6005 11/01 Optional Equipment - Section 6 Payload Meter II Page 6-25 Monitoring Input Signals Service Check Mode 1. Press and hold the LIGHT/INC and MODE This procedure can be used to monitor the current switches until "CHEC" is flashing. input signals to the payload meter.

  • Page 132: Up Factor - Payload Calculation Gain

    Optional Equipment - Section 6 11/01 OM6005 Page 6-26 Payload Meter II UP Factor - Payload Calculation Gain Careful consideration must be given to the use of PL:01 and PL:10. These modes divide the data Description of UP Factor transmitted by Modular Mining and the data stored in the payload meter's memory.

  • Page 133: Final Gear Ratio Selection

    OM6005 11/01 Optional Equipment - Section 6 Payload Meter II Page 6-27 FINAL GEAR RATIO SELECTION For an 830E truck, the proper gear ratio has to be selected. 1. Press and hold the MODE and LIGHT/INC switches until "CHEC" is displayed. 2.

  • Page 134: Battery Replacement Procedure

    Optional Equipment - Section 6 11/01 OM6005 Page 6-28 Payload Meter II BATTERY REPLACEMENT PROCEDURE Remove the cover (Figure 6-8). This will expose the battery, its wires, and the connector. ERROR CODE, F-09, DISPLAYED Replacing the Battery The payload meter has an internal battery used to protect the memory from being erased when the key switch is turned to the OFF position.

  • Page 135: After Replacing The Battery

    OM6005 11/01 Optional Equipment - Section 6 Payload Meter II Page 6-29 SUSPENSION PRESSURE SENSOR The pressure sensors are mounted on top of each suspension cylinder. The sensors produce a voltage signal from 1 - 5 volts output. The pressure sensor is mounted to the suspension cylinder using a Schrader Valve assembly, adapter and sensor.

  • Page 136: Installation

    Optional Equipment - Section 6 11/01 OM6005 Page 6-30 Payload Meter II Installation Installation 1. Install a new O-ring onto sensor (4, Figure 6-11) 1. Install inclinometer (3, Figure 6-13) with cap- and install sensor onto adapter (3). Tighten the screws, nuts and lockwashers (4).

  • Page 137: Payload Meter Back Panel

    OM6005 11/01 Optional Equipment - Section 6 Payload Meter II Page 6-31 PAYLOAD METER BACK PANEL...

  • Page 138: Connections

    Optional Equipment - Section 6 11/01 OM6005 Page 6-32 Payload Meter II CONNECTIONS CN1 - AMP MIC-MKII 13 Pins White Connector CN3 - AMP MIC-MKII 9 Pins White (RS-232C Port) Description Comments Description Power +24V (Battery) Lamp Relay 1 Lamp Relay 2 Lamp Relay 3 Lamp Relay 4 Lamp Relay 5...

  • Page 139: Payload Meter 2 Re-Initialization Procedure

    OM6005 11/01 Optional Equipment - Section 6 Payload Meter II Page 6-33 PAYLOAD METER 2 RE-INITIALIZATION PROCEDURE This procedure is designed to reset the Payload Meter 2 to clear repeated F.CAL errors. 6. Start the engine. 7. Set the time, date, OP, PL, and UP settings. All other user settings should updated at this time.

  • Page 140: Payload Circuit Numbers

    Optional Equipment - Section 6 11/01 OM6005 Page 6-34 Payload Meter II PAYLOAD CIRCUIT NUMBERS Circuit Designation Circuit Description 39F, 39F1...39F5 +18 volt sensor power supply 39FA Pressure signal Right Rear 39FB Pressure signal Left Rear 39FC Pressure signal Right Front 39FD Pressure signal Left Front 39FE...
  • Page 142 ® www.komatsuamerica.com Copyright 2007 Komatsu Komatsu America Corp. Printed in U.S.A. 2300 N.E. Adams Street Peoria, IL 61639 Phone: 309-672-7577 Fax: 309-672-7072...

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