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Komatsu 530M Operation & Maintenance Manual

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  • Page 2 This material is proprietary to Komatsu Mining Systems, Inc. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu Mining Systems, Inc.

  • Page 4: Foreword

    (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.
  • Page 5 Introduction - Section 1 OM1006.1 10/98 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 6: Table Of Contents

    OM1006.1 10/98 Introduction - Section 1 Page 1-3 TABLE OF CONTENTS SUBJECT ........SECTION / PAGE INTRODUCTION .

  • Page 7: Table Of Contents

    Introduction - Section 1 OM1006.1 10/98 Page 1-4 TABLE OF CONTENTS (Continued) SUBJECT ....... . . SECTION / PAGE OPERATION (Continued) .
  • Page 8 OM1006.1 10/98 Introduction - Section 1 Page 1-5 TABLE OF CONTENTS (Continued) SUBJECT ........SECTION / PAGE OPERATION (Continued) .
  • Page 9 Introduction - Section 1 OM1006.1 10/98 Page 1-6 KOMATSU 530M Haulpak Truck...

  • Page 10: 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...
  • Page 11 Introduction - Section 1 OM1006.1 10/98 Page 1-8 NOTES...
  • Page 12 OM1006.2 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 13 Introduction - Section 1 OM1006.2 Page 1-10 Standard Charts and Tables TABLE I STANDARD TIGHTENING TORQUE FOR METRIC HEX HEAD CAPSCREW AND NUT ASSEMBLY Capscrew Thread Width Kilogram.meters Newton.meters Foot Pounds Diameter Across Flat (kg.m) (N.m) (ft.lbs.) ± ± ± (mm) (mm) Tolerances...
  • Page 14 OM1006.2 Introduction - Section 1 Standard Charts and Tables Page 1-11 TABLE V TEMPERATURE CONVERSIONS ÷ FORMULA: F° -- 32 1.8 = C° C° x 1.8 + 32 = F° CELSIUS FAHRENHEIT CELSIUS FAHRENHEIT CELSIUS FAHRENHEIT C° F° C° F° C°...
  • Page 15 Introduction - Section 1 OM1006.2 Page 1-12 Standard Charts and Tables TABLE VIII 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 99.6 113.8 128.0 142.2 156.5 170.7 185.0...
  • Page 16 NOTE: These sealants and adhesives are manufactured and sold by Three Bond U.S.A., Inc. For information, call or write to: PART NUMBERS Three Bond U.S.A., Inc. Three Bond Komatsu 6184 Schumacher Park Drive TB1374 09940-00030 West Chester, OH 45069 TB1521...
  • Page 17 Introduction - Section 1 OM1006.2 Page 1-14 Standard Charts and Tables TABLE XI STANDARD TORQUE CHART SAE HEX HEAD CAPSCREW AND NUT ASSEMBLY (LUBRICATED THREADS) ± TOLERANCES GRADE 5 GRADE 8 CAP- TORQUE -- GRADE 5 TORQUE -- GRADE 8 TORQUE -- GRADE 5 TORQUE -- GRADE 8 CAPSCREW...
  • Page 18 OM1006.2 Introduction - Section 1 Standard Charts and Tables Page 1-15 TABLE XIII TABLE XV TORQUE CHART FOR JIC 37° SWIVEL NUTS TORQUE CHART FOR WITH OR WITHOUT O-RING SEAL O-RING BOSS FITTINGS SIZE TUBE SIZE THREADS TORQUE SIZE TUBE SIZE THREADS TORQUE CODE...
  • Page 19 Introduction - Section 1 OM1006.2 Page 1-16 Standard Charts and Tables TABLE XVII -- COMMON CONVERSIONS ENGLISH -to- METRIC TO CONVERT MULTIPLY FROM inch -- in. millimeter (mm) 25.40 inch -- in. centimeter (cm) 2.54 foot -- ft. meter (m) 0.3048 yard -- yd.

  • Page 20: Safety

    UNAUTHORIZED MODIFICATION • Any modification made without authorization from Komatsu can create hazards. • Before making a modification, consult your Komatsu distributor. Komatsu will not be responsible for any injury or damage caused by any unauthorized modification.
  • Page 21 Safety - Section 2 OM2006.1 06/98 Page 2-2 General Safety STANDING UP FROM THE SEAT • To prevent any accident occurring if you should touch any control lever that is not locked, always carry out the following before standing up from the operator’s seat. •...
  • Page 22 OM2006.1 06/98 Safety - Section 2 General Safety Page 2-3 PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURES • Immediately after operations, the engine cooling water, engine oil, differential and final drive case 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 23 • The Komatsu ROPS fulfills all of the regulations and standards for all countries, but if it is rebuilt without authorization or is damaged when the machine rolls over, the strength will drop and it will not be able to fulfill its function properly.

  • Page 24: Precautions During Operation

    OM2006.1 06/98 Safety - Section 2 General Safety Page 2-5 PRECAUTIONS DURING OPERATION BEFORE STARTING ENGINE SAFETY AT WORKSITE • Before starting the engine, thoroughly check the area for any unusual conditions that could be dangerous. • Examine the road surface in the jobsite and determine the best and safest method of operation. •...
  • Page 25 Safety - Section 2 OM2006.1 06/98 Page 2-6 General Safety KEEP MIRRORS, WINDOWS, AND LIGHTS CLEAN • Remove any dirt from the surface of the windows or lights to ensure good visibility. • Adjust the rear view mirror to a position where the operator can see best from the operator’s seat, and keep the surface of the mirror clean.

  • Page 26: Operating Machine

    OM2006.1 06/98 Safety - Section 2 General Safety Page 2-7 OPERATING MACHINE WHEN STARTING ENGINE • Walk around your machine again just before mounting it, checking for people and objects that might be in the way. • NEVER start the engine if a warning tag has been attached to the control. •...
  • Page 27 Safety - Section 2 OM2006.1 06/98 Page 2-8 General Safety ENSURE GOOD VISIBILITY • When working in dark places, install working lamps and head lamps, and set up lighting in the work area if necessary. • Stop operations if the visibility is poor, such as in mist, snow, or rain, and wait for the weather to improve to a condition that allows the operation to be carried out safely.
  • Page 28 OM2006.1 06/98 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 29: Battery

    Safety - Section 2 OM2006.1 06/98 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 30: Towing

    OM2006.1 06/98 Safety - Section 2 General Safety Page 2-11 TOWING WHEN TOWING, FIX WIRE TO HOOK • Towing in the wrong way may lead to serious personal injury or damage. • When using another machine to tow this machine, use a wire rope with ample strength for the weight of this machine.

  • Page 31: 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 32: During Maintenance

    OM2006.1 06/98 Safety - Section 2 General Safety Page 2-13 DURING MAINTENANCE PERSONNEL • Only authorized personnel can service and repair the machine. Extra precaution should be used when grinding, welding, and using a sledge-hammer. ATTACHMENTS • Place attachments that have been removed from the machine in a safe place so that they do not fall.
  • Page 33 Safety - Section 2 OM2006.1 06/98 Page 2-14 General Safety RADIATOR WATER LEVEL • If it is necessary to add water to the radiator, stop the engine and allow the engine and radiator to cool down before adding the water. •...
  • Page 34 OM2006.1 06/98 Safety - Section 2 General Safety Page 2-15 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE AT HIGH TEMPERATURE OR HIGH PRESSURE • Immediately after stopping operations, the engine cooling water and oil at all parts are at high temperature and under high pressure. In this condition, if the cap is removed, or the oil or water are drained, or the filters are replaced, it may result in burns or other injury.

  • Page 35: Tires

    If you do not understand the proper procedure for carrying out maintenance or replacement of the wheel or tire, and you use the wrong method, the wheel or tire may burst and cause serious injury or damage. When carrying out such maintenance, please consult your Komatsu distributor or tire maker. STORING TIRES AFTER REMOVAL •...

  • Page 36: When Repairs Are Necessary

    1. Only qualified maintenance personnel who understand the systems being repaired should accomplish repairs. 2. Many components on the 530M Truck are large and heavy. Insure that lifting equipment - hoists, slings, chains, lifting eyes - are of adequate capacity to handle the lift.

  • Page 37: Additional Job Site Rules

    Safety - Section 2 OM2006.1 06/98 Page 2-18 General Safety ADDITIONAL JOB SITE RULES Use this space to add any ADDITIONAL Job Site Rules not covered in any of the previous discussions. __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________...
  • Page 38 The following pages give an explanation of the Warning, Caution, and Service Instruction plates and decals attached to the 530M Truck. The plates and decals listed here are typical of this truck model, but because of customer options, individual trucks may have plates and decals that are different from those shown here.
  • Page 39 Safety - Section 2 OM2006.2 6/98 Page 2-20 Warnings and Cautions A plate attached to the right rear corner of the cab states the Rollover Protective Structure and Falling Object Protective Structure meets various SAE performance requirements. ! WARNING ! Do not make modifications to this structure, or attempt to repair damage without written approval from the Manufacturer.
  • Page 40 OM2006.2 6/98 Safety - Section 2 Warnings and Cautions Page 2-21 A plate is mounted on the left hand side of the trans- mission oil pan to provide instructions for proper trans- mission oil level check. 1. Engine Stopped: • Oil level must be visible in upper part of sight gauge (STOP) between "H"...
  • Page 41 Safety - Section 2 OM2006.2 6/98 Page 2-22 Warnings and Cautions A plate on the side of the hydraulic tank furnishes instructions for filling the hydraulic tank. Keep the system open to the atmosphere only as long as absolutely necessary to lessen chances of system contamination.

  • Page 42: Operation

    OM2006.2 6/98 Safety - Section 2 Warnings and Cautions Page 2-23 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 in tank when removing filler cap.
  • Page 43 Safety - Section 2 OM2006.2 6/98 Page 2-24 Warnings and Cautions A product identification plate is located on the right hand frame rail near the front bumper. 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 manufacturing bill of material for this unit.

  • Page 44: Operating Instructions

    2. Move behind the front of the left front tire, inspect Only qualified operators or technicians should attempt the hub and the oil disc brake assemblies for leaks to operate or maintain the 530M Truck. and any abnormal conditions. Safe practices start before the operator gets to...
  • Page 45 Operation - Section 3 OM3006.1 04/98 Page 3-2 Operating Instructions START HERE KOMATSU 530M Haulpak Truck...
  • Page 46 OM3006.1 04/98 Operation - Section 3 Operating Instructions Page 3-3 10. Before leaving this position, look to see that there 20. Move in behind the right front wheel, and inspect is no leakage or any other unusual condition with the tie-rod pivots and steering cylinder for proper transmission or drive shaft.

  • Page 47: Engine Start-Up Safety Practices

    Operation - Section 3 OM3006.1 04/98 Page 3-4 Operating Instructions 29. Check air cleaner indicator. If the RED area is With Transmission Selector Lever showing in the indicator, the air filter must be in the ‘‘Neutral’’ position, rotate cleaned/replaced before operating truck. key switch fully clockwise to ‘‘start’’...

  • Page 48: After Engine Has Started

    OM3006.1 04/98 Operation - Section 3 Operating Instructions Page 3-5 NOTE: 530M Haulpak Trucks are equipped with four MACHINE OPERATION SAFETY 12 volt batteries connected in series and parallel to PRECAUTIONS provide 24 volt output. Be certain to maintain correct After the truck engine is started and all systems are voltage and polarity when connecting booster cables.

  • Page 49: Loading

    Operation - Section 3 OM3006.1 04/98 Page 3-6 Operating Instructions 8. Before starting down a grade, maintain a speed LOADING that will insure safe operation and provide effec- 1. Pull into the loading area with caution. Remain at tive retarding under all conditions. a safe distance while truck ahead is being loaded.

  • Page 50: Passing

    OM3006.1 04/98 Operation - Section 3 Operating Instructions Page 3-7 The short-length rating (sometimes called the Continue to run engine at high idle until Brake Oil ‘‘three-minute’’ limit) will successfully accommo- Temperature Warning light turns off and brake oil date most downhill loaded hauls. It is necessary temperature cools to below 248 F (120 C).

  • Page 51: Dumping

    Operation - Section 3 OM3006.1 04/98 Page 3-8 Operating Instructions To Raise dump body: DUMPING 1. Pull into dump area with extreme caution. Make sure area is clear of persons and obstructions, including overhead utility lines. Obey signals di- The dumping of very large rocks (10% of payload, rected by the spotter, if present.

  • Page 52: Safe Parking Procedures

    OM3006.1 04/98 Operation - Section 3 Operating Instructions Page 3-9 To Lower Body: SAFE PARKING PROCEDURES 7. After material being dumped clears body, lower The operator must continue the use of safety precau- body to frame by moving the Hoist Control Lever tions when preparing for parking and engine shut- forward to the ‘‘DOWN’’...

  • Page 53: Towing

    Operation - Section 3 OM3006.1 04/98 Page 3-10 Operating Instructions TOWING 5. Release disabled truck brakes and remove all Prior to towing a truck, many factors must be carefully blocking. considered. Serious personal injury and/or significant property damage may result if important safety prac- tices, procedures, and preparation for moving heavy equipment are not observed.

  • Page 54: Operator Cab And Controls

    OM3006.2 04/98 Operation - Section 3 Operator Cab and Controls Page 3-11 OPERATOR CAB AND CONTROLS FIGURE 3-1. CAB INTERIOR - OPERATOR VIEW 1. Steering Wheel 6. Heater/Air Conditioner Controls 13. ‘‘PMC’’ Interface Connector 2. Retarder Control Lever 7. Heater/Air Conditioner Vents 14.

  • Page 55: Steering Wheel And Controls

    Operation - Section 3 OM3006.2 04/98 Page 3-12 Operator Cab and Controls STEERING WHEEL AND CONTROLS The steering wheel (1, Figure 3-2) will telescope ‘‘in’’ and ‘‘out’’ and adjust through a tilt angle to provide a comfortable wheel position for most operators. HORN BUTTON The horn (2, Figure 3-2) is actuated by pushing the button in the center of the steering wheel.

  • Page 56: Retarder Control Lever

    OM3006.2 04/98 Operation - Section 3 Operator Cab and Controls Page 3-13 RETARDER CONTROL LEVER The Retarder Control Lever (6, Figure 3-2) is mounted on the right side of the steering column. It can be used to modulate the full range of retarding/braking effort being applied to both the front and rear oil disc brakes.

  • Page 57: Heater/Air Conditioner Compartment And Controls

    Operation - Section 3 OM3006.2 04/98 Page 3-14 Operator Cab and Controls HEATER / AIR CONDITIONER Moving the switch ‘‘Up’’ directs out- COMPARTMENT AND CONTROLS side air to be circulated through the The heater/air conditioner compartment contains the heater assembly and through the heater/air conditioner controls (6, Figure 3-1) and cab.

  • Page 58: Retarding Capacity Chart

    OM3006.2 04/98 Operation - Section 3 Operator Cab and Controls Page 3-15 HEATER/AIR CONDITIONER VENTS RETARDING CAPACITY CHART The heater/air conditioner vents (7, Figure 3-3) The Retarding Capacity chart (8, Figure 3-1 & shown may be rotated 360°. There are three in the below) provides the recommended MAXIMUM truck Heater/Air Conditioner Compartment (shown be- speeds for descending various grades with a fully...

  • Page 59: Radio Speakers

    Operation - Section 3 OM3006.2 04/98 Page 3-16 Operator Cab and Controls RADIO SPEAKERS AIR CLEANER VACUUM GAUGES Radio Speakers (9, Figure 3-1) for the AM/FM Stereo The air cleaner vacuum gauges (14, radio are located at the far left and right of the overhead Figure 3-1) provide a continuous panel.

  • Page 60: Center Console Structure

    OM3006.2 04/98 Operation - Section 3 Operator Cab and Controls Page 3-17 CENTER CONSOLE STRUCTURE The Center Console (1, Figure 3-4) located to the right The housing below the passenger seat provides an of the operator seat, is a housing structure which easy access to various control components (relays, provides a mounting surface for certain operator con- solenoids, valves, etc.) for the service technican.
  • Page 61 Operation - Section 3 OM3006.2 04/98 Page 3-18 Operator Cab and Controls Transmission Range Selector (2, Figure 3-4) Control Switches (3, 4, 6, & 7, Figure 3-4) The Transmission Range Selector is mounted to the These switches are simple ‘‘Rocker-type’’ switches right of the operator’s seat.

  • Page 62: Parking Brake Switch

    OM3006.2 04/98 Operation - Section 3 Operator Cab and Controls Page 3-19 Parking Brake Switch (6, Figure 3-4) L.H. Window Control Switch (8, Figure 3-4) When this switch is in the ‘‘On’’ position, the parking brake is applied. This control switch is spring-loaded to the center, ‘‘OFF’’, position.

  • Page 63: Operator Seat

    Operation - Section 3 OM3006.2 04/98 Page 3-20 Operator Cab and Controls OPERATOR SEAT The operator’s seat provides a fully adjustable cush- Installation ioned ride for the driver’s comfort and ease of opera- 1. Mount seat assembly to seat riser. Install cap- tion.

  • Page 64: Instrument Panel And Indicators

    OM3006.3 04/98 Operation - Section 3 Instrument Panel and Indicators Page 3-21 INSTRUMENT PANEL AND INDICATORS FIGURE 3-6. INSTRUMENT PANEL 1. Keyswitch 4. Center Display Panel 8. BackUp/Deck Lights 9. Mode Change Switch 2. Auxiliary Brake Switch 5. L.H. Panel (Pod) Switch 10.

  • Page 65: Keyswitch

    Operation - Section 3 OM3006.3 04/98 Page 3-22 Instrument Panel and Indicators Keyswitch The keyswitch (1, Figure 3-6) is a three position (Off, Run, Start) switch. Starting fluid is extremely volatile and flammable! Use with extreme care. If truck is equipped with optional Engine Starting Aid and ambient temperature is below 50 F (10 C), turn...

  • Page 66: Control/Indicator Panel (Pod)

    OM3006.3 04/98 Operation - Section 3 Instrument Panel and Indicators Page 3-23 R.H. Control/Indicator Panel (Pod) Ladder Light Switch The Control/Indicator Panel (3, Figure 3-6), located to The switch (6, Figure 3-6) turns the the right of the steering wheel, provides an array of ladder lights ‘‘On’’...
  • Page 67 Operation - Section 3 OM3006.3 04/98 Page 3-24 Instrument Panel and Indicators R.H. Control/Indicator Panel (Pod) The Control/Indicator Panel (3, Figure 3-6), located to the right of the steering wheel, contains the following: Front Brake Cut-Off Switch (Option) The Optional Front Brake Cut-Off Switch (1, Figure 3-7) is used to change the ap- plication of the truck service brakes ac- cording to the road conditions.
  • Page 68 OM3006.3 04/98 Operation - Section 3 Instrument Panel and Indicators Page 3-25 Automatic Idle Selector Switch (AISS) Air Conditioner & Heater Vent The AISS Switch (4, Figure 3-7) controls The air conditioner/heater vent (5, Figure 3-7) swivels the ‘‘idle’’ speed of the engine (released on a vertical axis to direct air toward or away from the throttle pedal).

  • Page 69: Center Display Panel (Figure 3-8)

    Operation - Section 3 OM3006.3 04/98 Page 3-26 Instrument Panel and Indicators Center Display Panel The monitors and gauges inside the monitor module The Center Display Panel (4, Figure 3-6) consists of a and speedometer module are actuated by the signal gauge and monitor module (1 -- 27, Figure 3-8), with an from the gauge and monitor module, and the odometer odometer module (29) and a service/hour meter mod-...
  • Page 70 OM3006.3 04/98 Operation - Section 3 Instrument Panel and Indicators Page 3-27 Air Pressure Monitor (NOT USED) Retarder Oil Temperature Monitor The Air Pressure Monitor (1, Figure 3-8) is The Retarder Oil Temperature Monitor NOT USED on this truck. lamp (7, Figure 3-8) warns that the retarder oil temperature has risen.
  • Page 71 Operation - Section 3 OM3006.3 04/98 Page 3-28 Instrument Panel and Indicators Tachometer Automatic Transmission Mechatronics Monitor The Tachometer (13, Figure This red indicator (19, Figure 3-8) flashes 3-8) indicates 0-2500 RPM whenever any abnormality occurs in the engine speed. mechatronics related parts of the trans- Each bar represents 100 mission control system.

  • Page 72: Control/Indicator Panel (Pod) (Figure 3-9)

    OM3006.3 04/98 Operation - Section 3 Instrument Panel and Indicators Page 3-29 Auto Cruise Control (OPTIONAL) L.H. Control/Indicator Panel (Pod) This indicator (25, Figure 3-8) illuminates The Control/Indicator Panel (5, Figure 3-6), located to whenever the OPTIONAL Auto Cruise the left of the steering wheel, contains the following: Control system (if installed) is activated.
  • Page 73 Operation - Section 3 OM3006.3 04/98 Page 3-30 Instrument Panel and Indicators Engine Coolant Level Parking Brake The Engine Coolant Level Monitor light (3, The Parking Brake Monitor light (8, Figure Figure 3-9) will illuminate, if the engine 3-9) will illuminate if the transmission con- coolant level is below the sensor for a troller detects that the parking brake is continuous period of 5 seconds.
  • Page 74 OM3006.3 04/98 Operation - Section 3 Instrument Panel and Indicators Page 3-31 Transmission Oil Filters Crankcase Pressure The Transmission Oil Filters Monitor lamp The Crankcase Pressure Monitor lamp (13, Figure 3-9) will illuminate if the trans- (17, Figure 3-9) will illuminate if the engine mission controller detects that a trans- crankcase pressure is greater than mission filter is restricted, or that the wire...

  • Page 75: Rear Of Operator Cab

    Refer to the Service/Shop Manual for specific information regarding this device. 7. ATC - Automatic Transmission Controller This panel controls and monitors the Komatsu fully automatic transmission. It controls the Shift schedules and Lock-up Clutch modulation and monitors numerous other sensor inputs.
  • Page 76 OM3006.3 04/98 Operation - Section 3 Instrument Panel and Indicators Page 3-33 FIGURE 3-10. REAR WALL OF OPERATOR CAB 1. Circuit Breaker Panel 6. ASC - Automatic Suspension Controller (OPTIONAL) 2. Relay Board 7. ATC - Automatic Transmission Controller 3. Relay Board 8.

  • Page 77: Determining ''Fault'' Codes

    Operation - Section 3 OM3006.3 04/98 Page 3-34 Instrument Panel and Indicators CENTRY™ ™ FUEL SYSTEM DIAGNOSTICS Determining ‘‘FAULT’’ Codes - CUMMINS Engine Only - Centry™ ™ fault codes consist of three numerical digits. Each digit is indicated with up to five light flashes The CHECK ENGINE Monitor Light (7, Figure 3-9) (CHECK ENGINE Monitor Light) per each digit.

  • Page 78: Exiting The Diagnostics Mode

    OM3006.3 04/98 Operation - Section 3 Instrument Panel and Indicators Page 3-35 Exiting The Diagnostics Mode 4. Pressing the Lamp Test switch to the bottom (‘‘√’’) Starting the engine or turning the keyswitch to the OFF again will advance to the next fault code (if more position will EXIT the diagnostics fault flash mode.
  • Page 79 Operation - Section 3 OM3006.3 04/98 Page 3-36 Instrument Panel and Indicators NOTES...

  • Page 80: Messages For Operation And Maintenance (''Mom'')

    OM3006.4 04/98 Operation - Section 3 Electronic Displays and Messages Page 3-37 MESSAGE FOR OPERATION AND MAINTENANCE ("MOM") "MOM" (Message for Operation and Maintenance) is 1. Screen i1, Initial Message the message display screen located in the upper panel just above the operator’s head. It is used to display messages to the operator and service personnel.
  • Page 81 Operation - Section 3 OM3006.4 04/98 Page 3-38 Electronic Displays and Messages The reason why the engine start is not acceptable If any controller detects a fault, i3 is changed to is also indicated at the same time. If the screen the warning message screen i6 automatically.
  • Page 82 OM3006.4 04/98 Operation - Section 3 Electronic Displays and Messages Page 3-39 c. The data for current payload is not indicated After the operator has been informed of the fault until the payload meter recognizes that the code the action that should be taken is as truck is being loaded.
  • Page 83 Operation - Section 3 OM3006.4 04/98 Page 3-40 Electronic Displays and Messages 6. Screen i7, Back Light Off With one of the previously listed failure codes the transmission will fail to "Neutral", in order to move the truck the following procedure should be followed. 1.

  • Page 84: Center Electronic Display Panel

    OM3006.4 04/98 Operation - Section 3 Electronic Displays and Messages Page 3-41 If any of the severe fault codes that are listed below CENTER ELECTRONIC DISPLAY PANEL appear on the warning screen, Action Code Display Fault As previously discussed, if a fault occurs in any of the Description Remarks Code...
  • Page 85 Operation - Section 3 OM3006.4 04/98 Page 3-42 Electronic Displays and Messages After the operator has been informed of the fault code, Cancellation of Action Code the action that should be taken is as follows: If either of the following requirements is satisfied then 1.

  • Page 86: 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 530M Haulpak operation. These intervals are recommended in lieu Truck and its components. The use of proper lubricants...

  • Page 87: Lubrication Chart

    LUBRICATION LUBRICATION SPECIFICATIONS -65 o F TO -25 o F -25 o F TO + 32 o F + 32 o F T0 + 90 o F ABOVE 90 o F LUBE TYPE LUBRICANT CHART ENGINE OIL SEE ENG. MANUAL* SEE ENG.
  • Page 88 OM4006.1 06/98 Maintenance - Section 4 Lubrication and Service Page 4-3 10 HOUR (DAILY) INSPECTION Truck Serial Number ____________________________ Prior to each operating shift, a ‘‘walk around’’ inspec- tion should be performed. Check the truck for general Site Unit Number ______________________________ condition.
  • Page 89 Maintenance - Section 4 OM4006.1 06/98 Page 4-4 Lubrication and Service 10 HOUR (DAILY) INSPECTION (continued) √’d AIR CLEANERS COMMENTS INITIALS Check service indicator. If indicator shows red, clean filter. Push the indicator reset button to return the red piston to original position. DRIVE BELTS a.
  • Page 90 OM4006.1 06/98 Maintenance - Section 4 Lubrication and Service Page 4-5 250 HOURS SERVICE Truck Serial Number ____________________________ INITIAL 250 HOURS SERVICE Site Unit Number _____________________________ Date:______________Hour Meter_________________ Perform the following maintenance after running the Serviceperson Name___________________________ machine for the first 250 hours. Thereafter, these services are to be accomplished at the 1000/2000 hour interval as scheduled.
  • Page 91 Maintenance - Section 4 OM4006.1 06/98 Page 4-6 Lubrication and Service 250 HOURS SERVICE (continued) √’d COMMENTS INITIALS 4. ALTERNATOR BELT - Check condition of the 24V alternator belt for evidence of belt slippage, loose- ness or physical defects. 5. AIR CONDITIONER COMPRESSOR BELT - Check for condition of belt and proper tension.
  • Page 92 OM4006.1 06/98 Maintenance - Section 4 Lubrication and Service Page 4-7 500 HOUR SERVICE Truck Serial Number ____________________________ In addition to the 250 hour lubrication and inspection Site Unit Number ______________________________ schedule, perform the following: Date:______________Hour Meter_________________ Serviceperson Name___________________________ √’d COMMENTS INITIALS 1.
  • Page 93 Maintenance - Section 4 OM4006.1 06/98 Page 4-8 Lubrication and Service 1000 HOUR SERVICE Truck Serial Number ____________________________ Site Unit Number ______________________________ Date:______________Hour Meter_________________ In addition to the 250 and 500 hour lubrication and Serviceperson Name___________________________ inspection schedules, perform the following: √’d COMMENTS INITIALS...
  • Page 94 OM4006.1 06/98 Maintenance - Section 4 Lubrication and Service Page 4-9 EVERY 2000 HOUR SERVICE Truck Serial Number ____________________________ Site Unit Number ______________________________ Maintenance for every 250, 500 and 1000 hours should Date:______________Hour Meter_________________ also be carried out at this time. Serviceperson Name___________________________ √’d COMMENTS...

  • Page 95: Hydraulic Tank Service

    Maintenance - Section 4 OM4006.1 06/98 Page 4-10 Lubrication and Service HYDRAULIC TANK SERVICE Filling Instructions 1. Lower the dump body, shut down the engine, and turn the keyswitch ‘‘Off’’. Hydraulic tank may be pressurized! Depress relief valve (2) and release hydraulic tank filler cap slowly to remove any internal pressure.

  • Page 96: Steering Circuit Filters

    OM4006.1 06/98 Maintenance - Section 4 Lubrication and Service Page 4-11 STEERING CIRCUIT FILTER Removal The brake and steering circuit filter is located on the left frame rail, forward of the hydraulic tank. Relieve pressure before disconnecting hydraulic and other lines. Tighten all connections before applying pressure.

  • Page 97: Hydraulic Tank Breather Service

    Maintenance - Section 4 OM4006.1 06/98 Page 4-12 Lubrication and Service HYDRAULIC TANK BREATHER Cleaning 1. Shut down the engine and open hydraulic tank filler caps slowly to relieve any internal pressure. 2. Clean dirt accumulation from area of breather (3, Figure 4-2).

  • Page 98: Lincoln Automatic Lubrication System

    The system is controlled by an electric timer which signals solenoid valves to cause operation of a hydraulically operated grease pump. For the 530M, these components (valves, pump, and reservoir/cannister) are mounted on the right deck structure to the right of the hydraulic cabinet just above the right front suspension.
  • Page 99 Maintenance - Section 4 OM4006.2 10/98 Page 4-14 Automatic Lube System FIGURE 4-6. 530M AUTO LUBE ARRANGEMENT Group Lube Location ‘‘A’’ Contains 3 Injectors 1. Grease Pump/Cylinder Group Lube Location ‘‘B’’ Contains 3 Injectors 2. Cylinder Pressure Gauge Group Lube Location ‘‘C’’ Contains 3 Injectors 3.
  • Page 100 L.H. Front Suspension, RR ‘‘A’’-Arm grease pump piston to reciprocate, or ‘‘pump’’. L.H. Front Suspension, FRT ‘‘A’’-Arm R.H. Steering Cylinder, Spindle 4. Grease Reservoir: For the 530M, the Cannister or ‘‘C’’ R.H. Steering Rod, Spindle Reservoir (6, Figure 4-5) is mounted on the right R.H.

  • Page 101: System Operation

    Maintenance - Section 4 OM4006.2 10/98 Page 4-16 Automatic Lube System System Operation: 1. During truck operation, with the pump and timer systems in a rest state, a preset time interval (2.5 to 80 minutes) occurs. 2. The solid state system timer sends out a 24 VDC Over pressurizing of the system, modifying parts, signal to energize SV1, and also the flasher timer using incompatible chemicals and fluids, or using...

  • Page 102: System Priming

    OM4006.2 10/98 Maintenance - Section 4 Automatic Lube System Page 4-17 System Priming If pressure is not correct, adjust the Pressure The system must be full of grease and free of air Reducing Valve as necessary (refer to ‘‘Pressure pockets to function properly. After maintenance, if the Reducer Adjustment’’).

  • Page 103: 24Vdc Solid State Timer Check

    Maintenance - Section 4 OM4006.2 10/98 Page 4-18 Automatic Lube System 6. Observe the 5000 PSI (35 MPa) pressure test 3. The timer should cycle in five minutes if the truck gauge in the grease supply line. Pressure should engine is operating. be 2500 - 3000 PSI (17.2 - 20.7 MPa).

  • Page 104: Injectors & Adjustment

    OM4006.2 10/98 Maintenance - Section 4 Automatic Lube System Page 4-19 Injectors (SL-1) a. Each lube injector services only one grease point. b. Injectors are available in banks of two, three, four and five as well as single replacement units. c.

  • Page 105: Pump Cycle Timer

    Maintenance - Section 4 OM4006.2 10/98 Page 4-20 Automatic Lube System Pump Cycle Timer (Flasher Timer) Adjustment: Pump Cycle Timer (Flasher Timer): The Pump Cycle timer is factory set at 1 second ‘‘On’’ The Pump Cycle Timer mounts on SV2 solenoid and and 1 second ‘‘Off’’...
  • Page 106 OM4006.2 10/98 Maintenance - Section 4 Automatic Lube System Page 4-21 FIGURE 4-10. HYDRAULIC SCHEMATIC FOR AUTOMATIC LUBE 1. Grease Pump Cylinder 5. Combination Valve 8. Solenoid (SV1) 12. Hydraulic Supply 2. Grease Pump (Pressure Reducing & 9. Gauge (Cyl. Press.) 13.

  • Page 107: Troubleshooting Chart

    Maintenance - Section 4 OM4006.2 10/98 Page 4-22 Automatic Lube System TROUBLESHOOTING CHART If the following procedures do not correct the problem, contact a factory authorized service center. When submitting equipment to be repaired, be sure to state the nature of the problem and indicate if a repair cost estimate is required. POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION TROUBLE: Pump Does Not Operate.
  • Page 108 OM4006.2 10/98 Maintenance - Section 4 Automatic Lube System Page 4-23 POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION TROUBLE: Cylinder Pressure Gauge Does Not Register Pressure. No system pressure to the pump. Determine problem in hydraulic system. No 24 VDC signal at solenoids SV1 and SV2. Determine problem in 24 VDC electric system.
  • Page 109 Maintenance - Section 4 OM4006.2 10/98 Page 4-24 Automatic Lube System POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION TROUBLE: Timer Turns On At Intervals Two (2) To Ten (10) Times More Often Than Set Time Interval: Electrical noise is being introduced into the power IMPORTANT: In some instances, electrical noise supply to the timer overcoming suppressor capacitor may be generated into vehicle electrical system...

  • Page 110: Preventive Maintenance Procedures

    OM4006.2 10/98 Maintenance - Section 4 Automatic Lube System Page 4-25 Preventive Maintenance Procedures The following maintenance procedures should be used to insure proper system operation. Daily Lubrication System Inspection 1. Check grease reservoir level. 4. Inspect all bearing points for a bead of lubricant around the bearing seal.
  • Page 111 Maintenance - Section 4 OM4006.2 10/98 Page 4-26 Automatic Lube System NOTES...

  • Page 112: Specifications

    ENGINE POWER STEERING The KOMATSU 530M Haulpak Truck is powered by a The 530M Haulpak Truck is equipped with a full time Cummins diesel engine. power steering system which provides positive steer- ing control with a minimum of effort by the operator.
  • Page 113 Specifications - Section 5 OM5005 04/98 Page 5-2 530M MAJOR COMPONENTS...
  • Page 114 OM5005 04/98 Specifications - Section 5 Page 5-3 SPECIFICATIONS ENGINE SERVICE CAPACITIES ....Liters . U.S. Gallons Cummins ....KTA-50 Cummins .
  • Page 115 Specifications - Section 5 OM5005 04/98 Page 5-4 STEERING OVERALL TRUCK DIMENSIONS Turning Circle Diameter (SAE) ..24.4 m (80 ft) Loading Height ... 4.965 m (16’ 3") Automatic Emergency Steering .
  • Page 116 OM6007 2/99 Optional Equipment - Section 6 Payload Meter II Page 6-1 INDEX PAYLOAD METER II - ON BOARD WEIGHING SYSTEM (OBWS) ........6-3 GENERAL INFORMATION .
  • Page 117 Optional Equipment - Section 6 OM6007 2/99 Page 6-2 Payload Meter II DISPLAY OF FAULT CODES ............. . . 6-19 CHARTS OF ERROR CODES AND OTHER INFORMATION .

  • Page 118: Payload Meter Ii

    OM6007 2/99 Optional Equipment - Section 6 Payload Meter II Page 6-3 PAYLOAD METER II ON BOARD WEIGHING SYSTEM (OBWS) GENERAL INFORMATION The payload meter stores in memory various operating data. This data includes: The Payload Meter II On Board Weighing System 1) The payload, time, distance, and travel speed for displays and records the payload weight along with each cycle.
  • Page 119 Optional Equipment - Section 6 OM6007 2/99 Page 6-4 Payload Meter II LIGHTS, SWITCHES, and COMPONENTS On The Face Of The Payload Meter (Refer to Figure 6-1) 1. Display Panel 7. Total/Shift Switch Digital display area for the data being recorded in Used to display payload and overall number of memory.
  • Page 120 OM6007 2/99 Optional Equipment - Section 6 Payload Meter II Page 6-5 TIPS FOR OPERATION EXTERNAL DISPLAY LIGHTS To assure that the On Board Weighing System records The Payload Meter II controls three light relays. The the most accurate and consistent data, these impor- relays operate three deck mounted lights on each side tant steps should be followed: of the truck.
  • Page 121 Optional Equipment - Section 6 OM6007 2/99 Page 6-6 Payload Meter II THEORY OF OPERATION Linkage Factor The linkage factor is part of the complex calculations Basic Description performed by the payload meter to determine the load in the truck. The linkage factor is dependent on the load The payload meter uses the four suspension pres- on the rear suspensions.
  • Page 122 OM6007 2/99 Optional Equipment - Section 6 Payload Meter II Page 6-7 Brake Lock Typical Data From Service Check Mode The Brake Lock only applies the rear brakes. This Number Data Description allows the front wheels to rotate slightly as the truck is 13:09 Current Time being loaded.
  • Page 123 Optional Equipment - Section 6 OM6007 2/99 Page 6-8 Payload Meter II In order to adjust this gain: Calculation of the Calibration Load 1. Start with the payload meter in normal operation This procedure is similar to the manual calculation of mode.
  • Page 124 OM6007 2/99 Optional Equipment - Section 6 Payload Meter II Page 6-9 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 125 Optional Equipment - Section 6 OM6007 2/99 Page 6-10 Payload Meter II Engine ON/OFF Data When the engine is started or stopped, the following data is recorded. ITEM UNIT RANGE REMARKS Advances by one each time the Engine Operation Number Number 1 - 65535 engine is started.
  • Page 126 OM6007 2/99 Optional Equipment - Section 6 Payload Meter II Page 6-11 Engine Operation ITEM UNIT RANGE REMARKS Every time the engine is started Number when Canceled Number 1 - 65535 the number advances by one. Last Two Digits Of Year Year 0 - 99 Month...
  • Page 127 Optional Equipment - Section 6 OM6007 2/99 Page 6-12 Payload Meter II OPERATOR FUNCTIONS Clearing the Operator Load Counter 1. Press the TOTAL/SFT switch once. The number Using the Operator Load Counter displayed is the total tons hauled since the last time the counter was cleared.
  • Page 128 Only after all of these steps have been 5 - 630E performed can the payload meter be released for B - 730E service. C - 930E D - 530M E - 330M Switch Settings F - 830E DOWN DOWN...
  • Page 129 TOTAL/SFT switches. The display An alternative method is to use a Personal Computer will show. running the Komatsu Payload Download Program for windows. The "Monitor Pressures" section of the pro- 3. Press the CAL/CLR switch once. gram displays live inclinometer data. The inclinometer The display will show.
  • Page 130 OM6007 2/99 Optional Equipment - Section 6 Payload Meter II Page 6-15 Calibrating a Truck The payload meter should be calibrated whenever one of the following occurs: 1. When a new payload meter is installed. 2. When a suspension sensor has been changed. 3.
  • Page 131 Optional Equipment - Section 6 OM6007 2/99 Page 6-16 Payload Meter II DISPLAYS AT START-UP 7. The display will show: POWER ON: This display indicates the Machine ID code where ‘‘xxx’’ indicates a value between 0 and 200. ALL external display lamps (Figure 6-2) will come on and stay on for approximately 27 seconds during the 8.
  • Page 132 The display will show: equipped with Modular Mining System (MMS) (Except 530M). 4. Press the MODE switch repeatedly 2. The 530M with Powertrain Management Control until "SP.XX" is displayed. (PMC) system uses ‘‘10" as the setting for the Option Code.
  • Page 133 Optional Equipment - Section 6 OM6007 2/99 Page 6-18 Payload Meter II 9. Press the LIGHT/INC switch to change the first 7. Press the LIGHT/INC switch to change the hours. digit to the desired number. The clock is a 24 hour clock. 10.
  • Page 134 OM6007 2/99 Optional Equipment - Section 6 Payload Meter II Page 6-19 • Condition of the Engine Oil Pressure signal. DISPLAY OF FAULT CODES :C3:XX The panel will display ‘‘ ’’ for 3 seconds, 1. Press and hold the MODE switch then indicate: until "Cd:dP"...
  • Page 135 Optional Equipment - Section 6 OM6007 2/99 Page 6-20 Payload Meter II...
  • Page 136 OM6007 2/99 Optional Equipment - Section 6 Payload Meter II Page 6-21...
  • Page 137 Optional Equipment - Section 6 OM6007 2/99 Page 6-22 Payload Meter II Monitoring Input Signals Service Check Mode This procedure can be used to monitor the current 1. Press and hold the LIGHT/INC and MODE input signals to the payload meter. switches until "CHEC"...
  • Page 138 OM6007 2/99 Optional Equipment - Section 6 Payload Meter II Page 6-23 UP Factor - Payload Calculation Gain Careful consideration must be given to the use of PL:01 and PL:10. These modes divide the data trans- mitted by Modular Mining and the data stored in the Description of UP Factor payload meter’s memory.
  • Page 139 Optional Equipment - Section 6 OM6007 2/99 Page 6-24 Payload Meter II 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 140 OM6007 2/99 Optional Equipment - Section 6 Payload Meter II Page 6-25 BATTERY REPLACEMENT PROCEDURE 4. Remove the electrical connector. Remove the screws on the top surface and the rear face. ERROR CODE, F-09, DISPLAYED Remove the cover (Figure 6-8). This will expose the battery, its wires, and the connector.
  • Page 141 Optional Equipment - Section 6 OM6007 2/99 Page 6-26 Payload Meter II 9. Forcibly clear the data for the total payload and overall number of cycles. With this operation performed, all the unwanted data inside the payload meter is cleared. Except for the calibration data, all the data recorded in the previous steps is also erased.
  • Page 142 OM6007 2/99 Optional Equipment - Section 6 Payload Meter II Page 6-27 Installation Installation 1. Install new O-ring on sensor (4, Figure 6-11) and 1. Install inclinometer (3, Figure 6-13) with cap- install sensor into adapter (3). Tighten sensor to screws, nuts and lockwashers (4).
  • Page 143 Page 6-28 Payload Meter II SCOREBOARD Description The Scoreboard from Komatsu Mining Systems uses information from the Payload Meter to display the current load. It uses ultra-high-brightness LED tech- nology to form 3 digits. The sign is fully sunlight read- able and housed in a rugged steel enclosure.
  • Page 144 OM6007 2/99 Optional Equipment - Section 6 Payload Meter II Page 6-29...
  • Page 145 Optional Equipment - Section 6 OM6007 2/99 Page 6-30 Payload Meter II Normal Operation of the Scoreboard On power up, the Scoreboard will display "888" and then display the current software version, "10". The sign will then go blank until the Payload Meter begins sending load information.
  • Page 146 OM6007 2/99 Optional Equipment - Section 6 Payload Meter II Page 6-31 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 147 Optional Equipment - Section 6 OM6007 2/99 Page 6-32 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 148 OM6007 2/99 Optional Equipment - Section 6 Payload Meter II Page 6-33 PAYLOAD METER II RE-INITIALIZATION PROCEDURE This procedure is designed to reset the Payload Meter II to clear repeated F.CAL errors. This procedure is necessary to fix a rare condition in 7.
  • Page 149 Optional Equipment - Section 6 OM6007 2/99 Page 6-34 Payload Meter II NOTES PORTIONS OF THIS PRODUCT RELATING TO PAYLOAD MEASURING SYSTEMS ARE MANUFACTURED UNDER LICENSE FROM L. G. HAGENBUCH holder of U.S. Patent Numbers 4,831,539 and 4,839,835...
  • Page 150 OM6007.1 2/99 Optional Equipment - Section 6 Cab Radio Page 6-35 CAB RADIO To operate the Radio 7. Clock - If time-of-day is not on the display, press RCL (7). 1. Rotate the ON-OFF control (1) clockwise to turn Press and hold SET button and at the same the radio ON;...
  • Page 151 Optional Equipment - Section 6 OM6007.1 2/99 Page 6-36 Cab Radio To Operate The Tape Player 12. Insert tape into door marked AUTO REVERSE. NOAA - Weather Radio is a service of the ‘‘Voice of the Raised portion of cassette cartridge should be to National Weather Service.’’...
  • Page 152 Komatsu Mining Systems, Inc. Peoria Operations, P.O. Box 240 Peoria, IL 61650-0240 Printed in U.S.A. 040398...

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