Komatsu 530M Dump Truck Operation & Maintenance Manual – PDF Download

Description

Komatsu 530M Dump Truck Operation & Maintenance Manual

Description:

Komatsu 530M Dump Truck Operation & Maintenance Manual

• 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 Haulpak Model designation consists of three numbers and one letter (i.e. 530M).  The three numbers represent the basic truck model.  The letter ‘‘M’’ designates a Mechanical drive system, 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.

Table Of Contents:

Komatsu 530M Dump Truck Operation & Maintenance Manual

MAIN MENU..........................................................................................  0
COVER..............................................................................................  1
INTRODUCTION.......................................................................................  4
	FOREWORD.......................................................................................  4
	ALERTS PAGE - A DESCRIPTION OF THE DANGER, WARNING, AND CAUTION SYMBOLS USED IN THIS MANUAL....  5
	TABLE OF CONTENTS..............................................................................  6
	TRUCK MODEL ILLUSTRATION.......................................................................  9
	ABOUT THIS MANUAL.............................................................................. 10
	STANDARD CHARTS AND TABLES..................................................................... 12
SAFETY............................................................................................. 20
	GENERAL SAFETY................................................................................. 20
	PRECAUTIONS DURING OPERATION................................................................... 24
		OPERATING MACHINE.......................................................................... 26
		BATTERY.................................................................................... 29
		TOWING..................................................................................... 30
	PRECAUTIONS FOR MAINENANCE..................................................................... 31
		BEFORE CARRYING OUT MAINTENANCE............................................................ 31
		DURING MAINTENANCE......................................................................... 32
		TIRES...................................................................................... 35
		WHEN REPAIRS ARE NECESSARY................................................................. 36
		ADDITIONAL JOB SITE RULES.................................................................. 37
	WARNING, CAUTION , AND INSTRUCTION PLATES/DECALS............................................... 38
OPERATION.......................................................................................... 44
	OPERATING INSTRUCTIONS......................................................................... 44
		PREPARING FOR OPERATION.................................................................... 44
		SAFETY IS THINKING AHEAD................................................................... 44
		AT THE TRUCK - GROUND LEVEL WALK AROUND INSPECTION......................................... 44
	ENGINE START-UP SAFETY PRACTICES............................................................... 47
	AFTER ENGINE HAS STARTED....................................................................... 48
	MACHINE OPERATION SAFETY PRECAUTIONS........................................................... 48
	LOADING........................................................................................ 49
	HAULING........................................................................................ 49
		RETARDER OPERATION......................................................................... 49
	PASSING........................................................................................ 50
	DUMPING........................................................................................ 51
	SAFE PARKING PROCEDURES........................................................................ 52
	SHUTDOWN PROCEDURE............................................................................. 52
	TOWING......................................................................................... 53
	OPERATOR CAB AND CONTROLS...................................................................... 54
		STEERING WHEEL AND CONTROLS................................................................ 55
		RETARDER CONTROL LEVER..................................................................... 56
		SERVICE BRAKE PEDAL........................................................................ 56
		ACCELERATOR (THROTTLE) PEDAL............................................................... 56
		INSTRUMENT PANEL........................................................................... 56
		HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS............................................ 57
		RETARDING CAPACITY CHART................................................................... 58
		RADIO SPEAKERS............................................................................. 59
		"MOM" DISPLAY SCREEN....................................................................... 59
		WARNING ALARM BUZZER....................................................................... 59
		CAB RADIO.................................................................................. 59
		AIR CLEANER VACUUM GAUGES.................................................................. 59
		PAYLOAD METER.............................................................................. 59
		WINDSHIELD WIPERS.......................................................................... 59
		CENTER CONSOLE STRUCTURE................................................................... 60
			TRANSMISSION RANGE SELECTOR............................................................ 61
			CONTROL SWITCHES....................................................................... 61
			SHIFT LIMITER SWITCH................................................................... 61
			F1 START SWITCH........................................................................ 61
			HOIST CONTROL LEVER.................................................................... 61
			PARKING BRAKE SWITCH................................................................... 62
			BRAKE LOCK SWITCH...................................................................... 62
			L.H. WINDOW CONTROL SWITCH............................................................. 62
			R.H. WINDOW CONTROL SWITCH............................................................. 62
			ASH TRAY............................................................................... 62
			LIGHTER................................................................................ 62
			PASSENGER SEAT W/SAFETY BELT........................................................... 62
		OPERATOR SEAT.............................................................................. 63
	INSTRUMENT PANEL AND INDICATORS................................................................ 64
		KEYSWITCH.................................................................................. 65
		AUXILIARY BRAKE SWITCH..................................................................... 65
		R.H. CONTROL/INDICATOR PANEL (POD)......................................................... 66
		CENTER DISPLAY PANEL....................................................................... 66
		L.H. CONTROL/INDICATOR PANEL (POD)......................................................... 66
		LADDER LIGHT SWITCH........................................................................ 66
		HEADLIGHT SWITCH........................................................................... 66
		BACKUP/DECK LIGHTS SWITCH.................................................................. 66
		MODE CHANGE SWITCHES....................................................................... 66
	R.H. CONTROL/INDICATOR PANEL (FIGURE 3-7)...................................................... 67
		DISCUSSION OF ITEMS 1-10, FIGURE 3-7....................................................... 67
	CENTER DISPLAY PANEL (FIGURE 3-8).............................................................. 69
		DISCUSSION OF ITEMS 1-29, FIGURE 3-8....................................................... 69
	L.H. CONTROL/INDICATOR PANEL (POD) (FIGURE 3-9)................................................ 72
		DISCUSSION OF ITEMS 1-21, FIGURE 3-9....................................................... 72
	REAR OF OPERATOR CAB........................................................................... 75
	CUMMINS ENGINE CENTRY FUEL SYSTEM DIAGNOSTICS.................................................. 77
		DETERMINING "FAULT" CODES.................................................................. 77
		EXITING THE DIAGNOSTICS MODE............................................................... 78
	MESSAGE FOR OPERATION AND MAINTENANCE ("MOM").................................................. 80
		DISCUSSION OF SCREEN DISPLAYS.............................................................. 80
	CENTER ELECTRONIC DISPLAY PANEL................................................................ 84
		DISCUSSION OF SCREEN DISPLAYS.............................................................. 84
MAINTENANCE........................................................................................ 59
	LUBRICATION AND SERVICE........................................................................ 86
		LUBRICATION CHART.......................................................................... 87
		10 HOUR (SHIFT) INSPECTION................................................................. 88
		250 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................ 90
		500 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................ 92
		1000 HOUR LUBRICATION AND MAINTENANCE CHECKS............................................... 93
		2000 HOUR LUBRICATION AND MAINTENANCE CHECKS............................................... 94
	HYDRAULIC TANK SERVICE......................................................................... 95
		STEERING CIRCUIT FILTERS................................................................... 96
		HYDRAULIC TANK BREATHER SERVICE............................................................ 97
	LINCOLN AUTOMATIC LUBRICATION SYSTEM........................................................... 98
		SYSTEM COMPONENTS.......................................................................... 98
		SYSTEM OPERATION...........................................................................101
		SYSTEM PRIMING.............................................................................102
		SYSTEM CHECKOUT............................................................................102
		PRESSURE REDUCER ADJUSTMENT................................................................102
		24 VDC SOLID STATE TIMER CHECK.............................................................103
			24 VDC SOLID STATE TIMER ADJUSTMENT....................................................103
		INJECTORS & ADJUSTMENT.....................................................................104
		PUMP CYCLE TIMER...........................................................................105
		TROUBLESHOOTING CHART......................................................................107
		PREVENTIVE MAINTENANCE PROCEDURES..........................................................110
SPECIFICATIONS.....................................................................................112
	MAJOR COMPONENTS AND SPECIFICATIONS............................................................112
	SPECIFICATIONS.................................................................................114
OPTIONAL EQUIPMENT.................................................................................116
	PAYLOAD METER II (REFER TO SEPARATE PAYLOAD METER II INDEX.....................................116
		PAYLOAD METER II - ON BOARD WEIGHING SYSTEM (OBWS).........................................118
		GENERAL INFORMATION........................................................................118
		LIGHTS, SWITCHES, AND COMPONENTS...........................................................119
		TIPS FOR OPERATION.........................................................................120
		EXTERNAL DISPLAY LIGHTS....................................................................120
		THEORY OF OPERATION........................................................................121
			LINKAGE FACTOR.........................................................................121
			BRAKE LOCK.............................................................................122
			CALCULATION METHOD.....................................................................122
			SOURCES FOR ERROR......................................................................122
			TYPICAL DATA FROM SERVICE CHECK MODE...................................................122
			EXAMPLE CALCULATION OF PAYLOAD.........................................................123
			CALCULATION OF CALIBRATION LOAD........................................................123
		TYPES OF DATA STORED.......................................................................124
			CYCLE DATA.............................................................................124
			ENGINE ON/OFF DATA.....................................................................125
			FAULT CODES AND WARNING DATA...........................................................125
			ENGINE OPERATION.......................................................................126
			TOTAL PAYLOAD AND TOTAL NUMBER OF CYCLES...............................................126
			OTHER DATA.............................................................................126
		OPERATOR FUNCTIONS.........................................................................127
			USING THE OPERATOR LOAD COUNTER........................................................127
				DESCRIPTION........................................................................127
				VIEWING THE OPERATOR LOAD COUNTER..................................................127
				CLEARING THE OPERATOR LOAD COUNTER.................................................127
			DIMMING THE LIGHTS ON THE DISPLAY......................................................127
		INITIAL SET UP OF PAYLOAD METER............................................................128
			SWITCH SETTINGS........................................................................128
			CHECKING THE OPERATOR CHECK MODE.......................................................128
			CHECKING THE SERVICE CHECK MODE........................................................129
				SETTING "UP:00"....................................................................129
				SETTING "PL:00"....................................................................129
			CHECKING THE GT SETTING................................................................129
			CHECKING THE INCLINOMETOR SETTINGS.....................................................129
			CALIBRATING A TRUCK....................................................................130
		DISPLAY AT START-UP........................................................................131
		SETUP AND MAINTENANCE......................................................................132
			SETTING THE SPEED LIMIT................................................................132
			SETTING THE OPTION CODE................................................................132
			SETTING THE MACHINE I.D. CODE..........................................................132
			SETTING THE OPERATOR I.D. CODE.........................................................133
			SETTING THE TIME AND DATE..............................................................133
		DOWNLOAD OF PAYLOAD AND FAULT CODES........................................................133
		DISPLAY OF FAULT CODES.....................................................................134
		CHARTS OF ERROR CODES AND OTHER INFORMATION................................................135
		SERVICE CHECK MODE.........................................................................137
			MONITORING INPUT SIGNALS...............................................................137
			UP FACTOR- PAYLOAD CALCULATION GAIN....................................................138
			PL MODE - LOAD CALCULATION TIMING......................................................138
		FINAL GEAR RATIO SELECTION.................................................................139
		BATTERY REPLACEMENT PROCEDURE..............................................................140
			REPLACING THE BATTERY..................................................................140
			AFTER REPLACING THE BATTERY............................................................141
		SUSPENSION PRESSURE SENSOR.................................................................141
			REMOVAL................................................................................141
			INSTALLATION...........................................................................142
		INCLINOMETER...............................................................................142
			REMOVAL................................................................................142
			INSTALLATION...........................................................................142
		SCOREBOARD.................................................................................143
			DESCRIPTION............................................................................143
			MAKING CONNECTIONS.....................................................................143
			WIRING DIAGRAM.........................................................................144
			NORMAL OPERATION OF SCOREBOARD.........................................................145
		PAYLOAD METER BACK PANEL...................................................................145
			AMP PIN IDENTIFICATION.................................................................146
		PAYLOAD CIRCUIT NUMBERS....................................................................147
		PAYLOAD METER II RE-INITIALIZATION PROCEDURE...............................................148
	RADIO, AM/FM STEREO CASSETTE...................................................................150

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KOMATSU 530M DUMP TRUCK OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:

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