Komatsu Dump Truck Manual (EN)

FOREWORD

OM1018.1 11/00 Introduction - Section 1 Page 1-1 FOREWORD This Manual is written for use by the operator and/or the service technician and is designed to help these persons to become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel should read and understand the materials in this manual before operating the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings and cautions should be understood and followed when operating or accomplishing repairs on the truck.

The first section is an Introduction to the manual and contains a Table of Contents to locate specific areas of interest. Other sections include Safety, Operation, Maintenance, Specifications, and Optional Equipment. The illustrations used in this manual are TYPICAL of the component shown and may not be an exact reproduction of what is found on the truck. This manual shows dimensioning of metric and (U.S. standard) units throughout. All references to “Right”, “Left”, “Front”, or “Rear” 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 Introduction section and individual torques are provided in the text in bold face type, such as 723 kg.m (100 ft.lbs.) torque. All torque specifications have ± 10% tolerance unless otherwise specified. A Product Identification plate is normally located on the truck frame upright in front of the left side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating. The KOMATSU Haulpak Truck Model designation consists of three numbers and one letter (i.e. 330M). The three numbers represent the basic truck model.

The letter “M” designates a Mechanical drive and the letter “E” designates an Electrical wheelmotor drive system. The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration. The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight (GVW) and this means the TOTAL WEIGHT:

the Empty Vehicle Weight + the fuel & lubricants + the payload . To determine allowable payload: Service all lubricants for proper level and fill fuel tank of empty truck (which includes all accessories, body liners, tailgates, etc.) and then weigh truck. Record this value and subtract from the GVW rating. The result is the allowable payload. NOTE: Accumulations of mud, frozen material, etc. become a part of the GVW and reduces allowable payload. To maximize payload and to keep from exceeding the GVW rating, these accumulations should be removed as often as practical. Exceeding the allowable payload will reduce expected life of truck components .

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ALERTS Page - DANGER, WARNING, CAUTION

Introduction - Section 1 OM1018.1 11/00 Page 1-2 This “ALERT” symbol is used with the signal words, “CAUTION”, “DANGER”, and “WARNING” 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 if proper precautions are not taken. “WARNING” identifies a specific potential hazard WHICH MAY RESULT in either INJURY OR DEATH if proper precautions are not taken. “CAUTION” is used for general reminders of proper safety practices OR to direct the reader’s attention to avoid unsafe or improper practices which may result in damage to the equipment.

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TABLE OF CONTENTS

OM1018.1 11/00 Introduction - Section 1 Page 1-3 TABLE OF CONTENTS SUBJECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION / PAGE INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 ALERTS Page - a description of the DANGER, WARNING, and CAUTION symbols used in this manual. 1-2 TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Truck Model Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. 1-6 About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 STANDARD CHARTS and TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 2 Safety records of most organizations will show that the greatest percentage of accidents are caused by unsafe acts of persons. The remainder are caused by unsafe mechanical or physical conditions. Report all unsafe conditions to the proper authority. These safety rules are provided as a guide for the Haulpak Truck operator.

However, local conditions and regulations may add many more to this list. GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 PRECAUTIONS DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Operating Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 PRECAUTIONS FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . 2-12 Before Carrying Out Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 During Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 WARNING, CAUTION, and Instruction Plates / Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 This portion of the manual covers Identification, location,and operation of the controls, switches, and indicators in the Operator’s Cab and use / function of these controls, switches, and indicators. OPERATING INSTRUCTIONS Preparing For Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Safety Is Thinking Ahead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 At The Truck - Ground Level Walk-Around Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ENGINE START-UP SAFETY PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 AFTER ENGINE HAS STARTED . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 MACHINE OPERATION SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 HAULING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 PASSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 DUMPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 SAFE PARKING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . 3-11 SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 BRAKE RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 RELEASE OF PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 RELEASE OF EMERGENCY BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

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TABLE OF CONTENTS

Introduction - Section 1 OM1018.1 11/00 Page 1-4 TABLE OF CONTENTS (Continued) SUBJECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION / PAGE OPERATION (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3 OPERATOR CAB and CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 STEERING WHEEL AND CONTROLS (Figure 3-1) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 RETARDER CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 SERVICE BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 THROTTLE PEDAL .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 CENTER CONSOLE AND CONTROLS (Figure 3-2) . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 ENGINE ELECTRICAL CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Determining “FAULT” Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Exiting The Diagnostics Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 DIFFERENTIAL LOCK PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 HOIST CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-22 Safety Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 OPERATOR SEAT (Figure 3-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 INSTRUMENT PANEL AND INDICATOR LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 GAUGE AND MONITOR PANEL (Figure 3-4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 INDICATORS AND CONTROLS PANEL (Figures 3-5) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 INDICATORS AND CONTROLS PANEL (Figures 3-6, -7) . . . . . . . . . . . . . . . . . . . . . . . . 3-30 INSTRUMENT PANEL, RIGHT SIDE (Figure 3-8) . . . . . . . . . . . . . . . . . . . .

. . . . . . . . 3-35 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 4 This portion of the manual pertains mainly to the periodic Lubrication and Service required to keep the truck operating at its design potential. Routine lubrication and maintenance procedures are provided in this section. For major repairs, refer to the appropriate section in the Truck Shop Manual. Refer to the engine shop manual when servicing the engine. LUBRICATION AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 4-2 10 HOUR (SHIFT) Lubrication And Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . 4-3 250 HOUR Lubrication And Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 500 HOUR Lubrication And Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 1000 HOUR Lubrication And Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 2000 HOUR Lubrication And Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 5000 HOUR Lubrication And Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 HYDRAULIC TANK SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . 4-15 HIGH PRESSURE HYDRAULIC FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 TRANSMISSION FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 PERODIC REPLACEMENT OF COMPONENT PARTS FOR SAFETY DEVICES . . . . . . . . . . . . 4-20 BRAKE CIRCUIT CHECKOUT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 CHECKING FRONT BRAKE PAD WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 CHECKING REAR BRAKE DISC WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 BRAKE SYSTEM BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . 4-23 PARKING BRAKE INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 4-24

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