Komatsu 530M Dump Truck Operation & Maintenance Manual - DG716

This manual PDF download describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment for the 530M Komatsu Dump Truck. It will help the operator or anyone realize peak performance through effective, economical and safe machine operation and maintenance.


APPLICABLE MODELS :

Komatsu 530M Dump Truck
SERIAL SUFFIX AFP49
A30003 and up


TABLE OF CONTENTS :

- INTRODUCTION
- SAFETY
- OPERATION
- MAINTENANCE
- SPECIFICATIONS
- OPTIONAL EQUIPMENT


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : DG716
Total Pages : 153


This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance.

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COVER
INTRODUCTION
FOREWORD
ALERTS PAGE - A DESCRIPTION OF THE DANGER, WARNING, AND CAUTION SYMBOLS USED IN THIS MANUAL
TABLE OF CONTENTS
TRUCK MODEL ILLUSTRATION
ABOUT THIS MANUAL
STANDARD CHARTS AND TABLES

SAFETY
GENERAL SAFETY
PRECAUTIONS DURING OPERATION
OPERATING MACHINE
BATTERY
TOWING
PRECAUTIONS FOR MAINENANCE
BEFORE CARRYING OUT MAINTENANCE
DURING MAINTENANCE
TIRES
WHEN REPAIRS ARE NECESSARY
ADDITIONAL JOB SITE RULES
WARNING, CAUTION , AND INSTRUCTION PLATES/DECALS

OPERATION
OPERATING INSTRUCTIONS
PREPARING FOR OPERATION
SAFETY IS THINKING AHEAD
AT THE TRUCK - GROUND LEVEL WALK AROUND INSPECTION
ENGINE START-UP SAFETY PRACTICES
AFTER ENGINE HAS STARTED
MACHINE OPERATION SAFETY PRECAUTIONS
LOADING
HAULING
RETARDER OPERATION
PASSING
DUMPING
SAFE PARKING PROCEDURES
SHUTDOWN PROCEDURE
TOWING
OPERATOR CAB AND CONTROLS
STEERING WHEEL AND CONTROLS
RETARDER CONTROL LEVER
SERVICE BRAKE PEDAL
ACCELERATOR (THROTTLE) PEDAL
INSTRUMENT PANEL
HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS
RETARDING CAPACITY CHART
RADIO SPEAKERS
"MOM" DISPLAY SCREEN
WARNING ALARM BUZZER
CAB RADIO
AIR CLEANER VACUUM GAUGES
PAYLOAD METER
WINDSHIELD WIPERS
CENTER CONSOLE STRUCTURE
TRANSMISSION RANGE SELECTOR
CONTROL SWITCHES
SHIFT LIMITER SWITCH
F1 START SWITCH
HOIST CONTROL LEVER
PARKING BRAKE SWITCH
BRAKE LOCK SWITCH
L.H. WINDOW CONTROL SWITCH
R.H. WINDOW CONTROL SWITCH
ASH TRAY
LIGHTER
PASSENGER SEAT W/SAFETY BELT
OPERATOR SEAT
INSTRUMENT PANEL AND INDICATORS
KEYSWITCH
AUXILIARY BRAKE SWITCH
R.H. CONTROL/INDICATOR PANEL (POD)
CENTER DISPLAY PANEL
L.H. CONTROL/INDICATOR PANEL (POD)
LADDER LIGHT SWITCH
HEADLIGHT SWITCH
BACKUP/DECK LIGHTS SWITCH
MODE CHANGE SWITCHES
R.H. CONTROL/INDICATOR PANEL (FIGURE 3-7)
DISCUSSION OF ITEMS 1-10, FIGURE 3-7
CENTER DISPLAY PANEL (FIGURE 3-8)
DISCUSSION OF ITEMS 1-29, FIGURE 3-8
L.H. CONTROL/INDICATOR PANEL (POD) (FIGURE 3-9)
DISCUSSION OF ITEMS 1-21, FIGURE 3-9
REAR OF OPERATOR CAB
CUMMINS ENGINE CENTRY FUEL SYSTEM DIAGNOSTICS
DETERMINING "FAULT" CODES
EXITING THE DIAGNOSTICS MODE
MESSAGE FOR OPERATION AND MAINTENANCE ("MOM")
DISCUSSION OF SCREEN DISPLAYS
CENTER ELECTRONIC DISPLAY PANEL
DISCUSSION OF SCREEN DISPLAYS

MAINTENANCE
LUBRICATION AND SERVICE
LUBRICATION CHART
10 HOUR (SHIFT) INSPECTION
250 HOUR LUBRICATION AND MAINTENANCE CHECKS
500 HOUR LUBRICATION AND MAINTENANCE CHECKS
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS
2000 HOUR LUBRICATION AND MAINTENANCE CHECKS
HYDRAULIC TANK SERVICE
STEERING CIRCUIT FILTERS
HYDRAULIC TANK BREATHER SERVICE
LINCOLN AUTOMATIC LUBRICATION SYSTEM
SYSTEM COMPONENTS
SYSTEM OPERATION
SYSTEM PRIMING
SYSTEM CHECKOUT
PRESSURE REDUCER ADJUSTMENT
24 VDC SOLID STATE TIMER CHECK
24 VDC SOLID STATE TIMER ADJUSTMENT
INJECTORS & ADJUSTMENT
PUMP CYCLE TIMER
TROUBLESHOOTING CHART
PREVENTIVE MAINTENANCE PROCEDURES

SPECIFICATIONS
MAJOR COMPONENTS AND SPECIFICATIONS
SPECIFICATIONS

OPTIONAL EQUIPMENT
PAYLOAD METER II (REFER TO SEPARATE PAYLOAD METER II INDEX
PAYLOAD METER II - ON BOARD WEIGHING SYSTEM (OBWS)
GENERAL INFORMATION
LIGHTS, SWITCHES, AND COMPONENTS
TIPS FOR OPERATION
EXTERNAL DISPLAY LIGHTS
THEORY OF OPERATION
LINKAGE FACTOR
BRAKE LOCK
CALCULATION METHOD
SOURCES FOR ERROR
TYPICAL DATA FROM SERVICE CHECK MODE
EXAMPLE CALCULATION OF PAYLOAD
CALCULATION OF CALIBRATION LOAD
TYPES OF DATA STORED
CYCLE DATA
ENGINE ON/OFF DATA
FAULT CODES AND WARNING DATA
ENGINE OPERATION
TOTAL PAYLOAD AND TOTAL NUMBER OF CYCLES
OTHER DATA
OPERATOR FUNCTIONS
USING THE OPERATOR LOAD COUNTER
DESCRIPTION
VIEWING THE OPERATOR LOAD COUNTER
CLEARING THE OPERATOR LOAD COUNTER
DIMMING THE LIGHTS ON THE DISPLAY
INITIAL SET UP OF PAYLOAD METER
SWITCH SETTINGS
CHECKING THE OPERATOR CHECK MODE
CHECKING THE SERVICE CHECK MODE
SETTING "UP:00"
SETTING "PL:00"
CHECKING THE GT SETTING
CHECKING THE INCLINOMETOR SETTINGS
CALIBRATING A TRUCK
DISPLAY AT START-UP
SETUP AND MAINTENANCE
SETTING THE SPEED LIMIT
SETTING THE OPTION CODE
SETTING THE MACHINE I.D. CODE
SETTING THE OPERATOR I.D. CODE
SETTING THE TIME AND DATE
DOWNLOAD OF PAYLOAD AND FAULT CODES
DISPLAY OF FAULT CODES
CHARTS OF ERROR CODES AND OTHER INFORMATION
SERVICE CHECK MODE
MONITORING INPUT SIGNALS
UP FACTOR- PAYLOAD CALCULATION GAIN
PL MODE - LOAD CALCULATION TIMING
FINAL GEAR RATIO SELECTION
BATTERY REPLACEMENT PROCEDURE
REPLACING THE BATTERY
AFTER REPLACING THE BATTERY
SUSPENSION PRESSURE SENSOR
REMOVAL
INSTALLATION
INCLINOMETER
REMOVAL
INSTALLATION
SCOREBOARD
DESCRIPTION
MAKING CONNECTIONS
WIRING DIAGRAM
NORMAL OPERATION OF SCOREBOARD
PAYLOAD METER BACK PANEL
AMP PIN IDENTIFICATION
PAYLOAD CIRCUIT NUMBERS
PAYLOAD METER II RE-INITIALIZATION PROCEDURE
RADIO, AM/FM STEREO CASSETTE

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