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Komatsu 210M 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 5 Maximum G.V.W. (Gross Vehicle Weight) rating. ® The HAULPAK Model designation consists of three numbers and one letter (i.e. 210M). The three numbers represent the basic truck model. The letter "M" designates a Mechanical drive and the letter "E" designates an Electrical propulsion system.
  • Page 6 "ALERT" This symbol is used with the signal words, "CAUTION" "DANGER" "WARNING" , and in this manual 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.

  • Page 7: Table Of Contents

    TABLE OF CONTENTS SUBJECT PAGE MAJOR COMPONENT DESCRIPTION ..... . HB1-1 GENERAL SAFETY ....... . HB2-1 WARNINGS AND CAUTIONS .
  • Page 8 ® MODEL 210M HAULPAK TRUCK HB-4 Introduction HB0010 7/95...
  • Page 9 COMPONENT DESCRIPTION AND SPECIFICATIONS ENGINE SERVICE BRAKE SYSTEM ® The 210M HAULPAK Truck is powered by The service brakes are controlled by an all a Cummins KTTA--19C diesel engine. It is hydraulic actuation system. Depressing the capable of speeds up to 35 MPH (56.7 km/h).
  • Page 10 ® MODEL 210M HAULPAK MAJOR COMPONENTS HB1-2 Component Description and Specifications HB1042...
  • Page 11 The SPECIFICATIONS listed on these pages cover standard production. When optional equipment is selected, some of these specifications and/or capacities may change. ENGINE HOIST SYSTEM Cummins ....KTTA--19C Tandem Pump Capacity: Number of Cylinders .
  • Page 12 OVERALL TRUCK DIMENSIONS HB1-4 Component Description and Specifications HB1042...

  • Page 13: General Safety

    GENERAL SAFETY 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. ®...
  • Page 14 c. When checking coolant in radiator, relieve pressure before removing radiator cap. Do not stand in front of rim and locking ring when inflating tire. d. Check tires for cuts, damage or ‘‘bubbles’’. Check tires for proper inflation. If tire is warm from operation, allow tire to cool before adjusting tire pres- sure.
  • Page 15 11. Insure steering wheel, horn, controls and pedals are free of any oil, grease or mud. 12. Insure headlights, worklights and taillights are in proper working order. 13. Insure windshield and all cab windows are clean and unbroken. Good visibility may prevent an accident.
  • Page 16 26. Keep serviceable fire fighting equipment at hand. Report used extinguishers for replacement or refilling. Tire and rim assembly may expode if subjected to excessive heat. Personnel should move to a remote or protected location if sensing excessively hot brakes, smell of burning rubber or evidence of fire near tire and wheel area.
  • Page 17 8. Always disconnect the positive and negative battery cables of the vehicle before doing any welding on the unit. Failure to do so may seriously damage the battery and electrical equipment. Disconnect battery charging alternator lead wire and isolate electronic control components before making welding repairs. It is not necessary to disconnect or remove any control circuit cards on electric drive ®...
  • Page 18 NOTES HB2-6 General Safety Rules HB2002 4/94...

  • Page 19: Warnings And Cautions

    WARNINGS AND CAUTIONS The following paragraphs give an explanation of the The plates and decals must be kept clean and legible. Warning, Caution, Danger and Service Instruction If any decal or plate becomes worn or unable to be plates and decals attached to the truck. The plates and read, it should be replaced with a new one.
  • Page 20 The welding "Caution" plate WA9713 is located in the WA9779 Caution decal is located in the cab on the back cab above the windshield. These instructions MUST be of the sunvisor and specifies that during first four hours followed when welding is done on the truck to avoid of operation, the Truck Speed SHOULD NOT Exceed damage to the ATEC components.
  • Page 21 The center Warning specifies that if any of the red lights Attached to the exterior of the battery compartment is on the instrument panel are "ON" (during truck opera- danger plate WA9704. This plate stresses the need to tion), the truck should not be operated. The switch in keep from making any sparks near the battery.
  • Page 22 Decal WA9722 is located on the engine air cleaner Warning plates WA9705 are mounted on the frame in which is on the deck above the right front wheel. front of and to the rear of both front tires. Technicians Refer to the service manual, Section "C" for air cleaner making adjustments are warned that the clearances service.
  • Page 23 WA9712 Warning plate is attached to both the hydrau- TY5888 Warning decal is applied to the Steering accu- lic and fuel tank. For the safety of technicians who may mulator and both Brake accumulators to warn servic- be working on the truck with the body in the raised ing personnel of both high gas pressure and hydraulic position, they are warned to make sure safety pin pressure.
  • Page 24 WA9723 decal is located above the transmission fill VH8394 Identification plate is located on the right side tube on front side of the hydraulic tank. It cautions the of the main frame, just in front of the front wheel. Refer servicing technician to refer to the service manual for to serial number on this plate whenever reporting truck proper filling instructions to avoid serious damage to...

  • Page 25: Operator Controls And Equipment

    OPERATOR CONTROLS AND EQUIPMENT OPERATOR CONTROLS 1. Steering Wheel 4. Horn/Telescope Adj. 9. Cigarette Lighter 2. Turn Signals 5. Hoist Control 10. Ash Tray and Dimmer Switch 6. Retarder Pedal 11. Range Selector 3. Steering Wheel 7. Service Brake Pedal 12.
  • Page 26 (3) TILT LEVER Adjust the tilt of the steering wheel by pulling the Tilt Lever toward the steering wheel and moving the wheel to the desired angle. Releasing the lever will lock the wheel in the desired location. (4) HORN AND TELESCOPING ADJUSTMENT The horn is activated by depressing the center "button".
  • Page 27 (6) RETARDER PEDAL The Retarder Pedal is the left pedal of the three pedals and should be used by the operator to slow the truck during normal operation and to maintain a safe productive speed while decending grades. When the retarder pedal is activated, only the rear oil-cooled brakes are applied;...
  • Page 28 (7) SERVICE BRAKE PEDAL The Service Brake Pedal is the middle pedal of the three pedals. It controls a dual hydraulic valve, which applies both the front dry disc brakes and the rear wet disc brakes. The service brakes should be used to slow or stop the truck whenever safety and/or truck speed/load conditions exceeds the capability of the retarder.
  • Page 29 "R1" or "R2" REVERSE position - is used to back the truck. The Reverse Warning Horn is activated when either gear is selected. When selecting either reverse position, COMPLETELY STOP the truck and bring engine RPM to low idle before shifting from a FORWARD range to a REVERSE range or vice-versa.
  • Page 30 RESET PROCEDURE - When the DO NOT SHIFT LIGHT and/or CHECK TRANS light (on instrument panel) comes "On", the system can be reset. To reset, bring the vehicle to a stop at a safe location and shutdown engine. Wait about 10 seconds and restart engine.
  • Page 31 3. To adjust weight: a. Turn knob "Weight Adjust" (3). b. Moving knob clockwise decreases cushioning effect of seat and turning counterclockwise increases cushioning effect. c. Proper adjustment results in Weight Indicator (4) being flush with seat base while operator is seated. 4.
  • Page 32 NOTES HB4-8 Operator Controls HB4021 6/95...
  • Page 33 INSTRUMENTS AND CONTROLS INSTRUMENT PANEL The operator must understand the function and operation of each instrument and control. This knowledge is essential for proper and safe operation of the machine. Items that are marked (OPTIONAL) may not apply to this truck. (1) FOG LIGHTS (OPTIONAL) The fog lights are an optional piece of equipment, useful in heavy rain and foggy conditions.
  • Page 34 INSTRUMENT PANEL HB5-2 Instruments and Controls HB5014 4/94...
  • Page 35 (5) WINDSHIELD WIPER The windshield wiper control switch is a three position rocker switch. Moving the switch from "Off" to the second position places the wiper in the low or slow cycle. Pushing the switch to the third position places the wiper motor in high or fast cycle. (6) ENGINE STARTING AID The ether starting aid is used for cold weather starting and is controlled by a switch, spring-loaded to the "Off"...
  • Page 36 (10) TURN SIGNAL FUSE HOLDER This is a 15 amp.- dual element, time delay (slow blow) type fuse. Replacement with any other type is not recommended. (11) CIRCUIT BREAKER 5 amp circuit breaker protects the warning cluster and the sound alarm from overloads.
  • Page 37 The parking brake is automatically applied when the engine is shut-down and hydraulic pressure is bled down. (20) SLIPPERY ROAD (21) SWITCH OPEN (22) SWITCH CLOSED SWITCH ® (Not used on 140M/210M HAULPAK with Rear Wet Disc Brakes) HB5014 4/94 Instruments and Controls HB5-5...
  • Page 38 (23) TRANSMISSION TEMPERATURE The transmission temperature gauge indicates the temperature of the transmission oil during operation. Maximum operating oil tem- perature is 250 F (121 C). If oil temperature exceeds this maxi- mum, CHECK TRANS light (35) will turn on. As quickly as safety will permit, bring the truck to a complete stop away from traffic, move transmission range selector to "Neutral", apply the parking brake, and run engine at high idle.
  • Page 39 (27) BRAKE OIL TEMPERATURE The brake oil temperature gauge indicates the temperature of the rear brake cooling oil during operation. Maximum operating oil temperature is 250 F (121 C). If oil temperature exceeds this maximum, Brake Oil Temperature Warning light (48) will turn on. As quickly as safety will permit, bring the truck to a complete stop away from traffic, move transmission range selector to "Neu- tral", apply the parking brake, and run engine at high idle.
  • Page 40 (33) TACHOMETER and HOURMETER This gauge includes an Hourmeter to reg- ister engine hours of operation and a Tachometer which registers engine speed in hundreds of Revolutions Per Minute (RPM). Adjusted Engine Speeds are: ± Low Idle -- 700 25 RPM. High Idle, No load -- 2450 RPM Governed Speed -- 2100 RPM Retarder Operation...
  • Page 41 INSTRUMENT PANEL WARNING INDICATORS The charge condition of the two 12 Volt batteries is monitored to make sure that both batteries are being charged equally. The Equal Fault Light will illuminate if more than a 0.85 volt variance between the two batteries is detected. (35) CHECK TRANS LIGHT The ATEC system has a built in computer that monitors various functions and performances.
  • Page 42 If the transmission oil temperature reaches 250 F (121 C), the CHECK TRANS indicator light will come "On". The ECU (Electronic Control Unit) will inhibit operation of the truck in higher gears. NOTE: The Transmission Temperature Gauge (23) indicates the converter tempera- ture.
  • Page 43 (40) BRAKE LOCK The Brake Lock light is on only when the brake lock switch has been activated by the operator. The light indicates that only the rear brakes have been applied. The brake lock switch is to be used only at the shovel or dump area.
  • Page 44 (44) COOLANT LEVEL This light indicates the coolant level in the radiator is low. If light comes On, bring truck to a safe stop as soon as possible out of way of traffic and call maintenance personnel to correct problem. Have coolant level checked.
  • Page 45 (48) BRAKE OIL TEMPERATURE Brake Oil Temperature Warning light will turn on if the brake oil temperature exceeds 250 F (121 As quickly as safety will permit, bring the truck to a complete stop away from traffic, move transmission range selector to "Neutral", apply the parking brake, and run engine at high idle.
  • Page 46 (55) FAN The fan switch controls the heater/air condition three-speed blower mo- tor. The speeds are High, Medium, and Low. (56) TEMPERATURE CONTROL KNOB The push/pull knob controls the amount of hot water that will flow through the heater core to heat the air as it passes through the core and circulates through- out the cab.

  • Page 47: Operating Instructions

    OPERATING INSTRUCTIONS PREPARING FOR OPERATION The safest trucks are those which have been properly prepared for operation. At the beginning of each shift, a careful check of the truck should be made before the operator attempts engine start-up. 1. When walking to and from the truck, BE ALERT, remain a safe distance from all other machines even if the operator is visible.
  • Page 48 ENGINE START-UP SAFETY PRACTICES Safety rules must be observed upon engine start-up. 1. Insure all personnel are clear of truck before starting engine. Always sound the horn as a warning before actuating any operational controls. 2. Check and insure Transmission Range Selector is in "Neutral" before starting. 3.
  • Page 49 AFTER ENGINE HAS STARTED 1. Become thoroughly familiar with steering and emergency controls. Test the truck steering in extreme right and left directions. If the steering system is not operating properly, shut engine down immediately. Determine the steering system problem and have repairs made before resuming operation. 2.
  • Page 50 MACHINE OPERATION SAFETY PRECAUTIONS After the truck engine is started and all systems are functioning properly, the operator must follow all local safety rules to insure safe machine operation. If any of the red warning lights come "On" or if any gauge reads in the red area during truck operation, a malfunction is indicated.
  • Page 51 LOADING 1. Pull into the loading area with caution. Remain at a safe distance while truck ahead is being loaded. 2. Do not drive over unprotected power cables. 3. When approaching or leaving a loading area, watch out for other vehicles and for personnel working in the area.
  • Page 52 9. When operating truck in darkness or when visibility is poor, do not move truck unless headlights are on. Do not back truck if back-up horn or lights are inoperative. 10. When backing the truck, give back-up signal (three blasts on air horn); when starting forward, two blasts on air horn.
  • Page 53 DUMPING 1. Pull into dump area with extreme caution. 2. Carefully maneuver truck into dump position. Obey signals directed by the spotter, if present. 3. When in dump position, apply Brake Lock and move Transmission Range Selector to the "Neutral" position To Raise dump body: 4.
  • Page 54 TOWING Prior to towing a truck, many factors must be carefully considered. Serious personal injury and/or significant property damage may result if important safety practices, procedures and preparation for moving heavy equipment are not observed. Both right and left planetary sun gears/drive axles should be removed before any towing.
  • Page 55 SAFE PARKING PROCEDURES The operator must continue the use of safety precautions when preparing for parking and engine shutdown. In the event that the equipment is being worked in consecutive shifts, any question- able truck performance the operator may have noticed must be checked by maintenance personnel before the truck is released to another operator.
  • Page 56 NOTES HB6-10 Operating Instructions HB6004 4/94...

  • Page 57: Lubrication And Service

    However, if truck is being operated under extreme "H" for Suspensions, etc.). conditions, some or all of the intervals may need to be shortened and the service performed more frequently. 140M SERVICE CAPACITIES 210M SERVICE CAPACITIES Gallons Liters Gallons Liters Cooling System 144.0...
  • Page 58 LUBRICATION CHART 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 ENGINE OIL SEE ENG. MANUAL* SEE ENG. MANUAL* SEE ENG. MANUAL SEE ENG.
  • Page 59 10 HOUR (DAILY) INSPECTION Prior to each operating shift, a "walk around" inspection Truck Serial Number ____________________________ should be performed. Check the truck for general Site Unit Number ______________________________ condition. Look for evidence of hydraulic leaks; check all lights and mirrors for clean and unbroken lenses; Date:______________Hour Meter_________________ check operator’s cab for clean and unbroken glass;...
  • Page 60 10 HOUR (DAILY) INSPECTION (continued) √ DRIVE BELTS COMMENTS ’ INITIALS a. Check alternator and fan belts for proper tension and condition. b. Inspect for alignment. ENGINE AND TURBOCHARGERS Inspect for leaks, vibrations or odd noises. TIRES IMPORTANT! After each wheel mounting opera- tion, recheck wheel mounting capscrew tightness after about five hours operation.
  • Page 61 100 HOUR LUBRICATION AND MAINTENANCE CHECKS NOTE: 10 Hour service should be included with the Truck Serial Number ____________________________ following: Site Unit Number _____________________________ Date:______________Hour Meter_________________ Serviceperson Name___________________________ √ COMMENTS ’ INITIALS a. Steering Column Linkage -- Use hand gun and lubricate with grease.
  • Page 62 100 HOUR LUBRICATION AND MAINTENANCE CHECKS continued) √ COMMENTS ’ INITIALS FINAL DRIVE -- Check oil level. Add oil as required. Lube Key ‘‘C’’. FINAL DRIVE BREATHER -- Remove and clean. REAR HYDRAIR SUSPENSION -- Grease bearings. Lube Key ‘‘E’’. (4 pts.). SUSPENSIONS -- Check suspension cylinders for leaks (more than 50% of dirt ring washed away).
  • Page 63 FUEL FILTER AND STRAINER - Change filter and strainer element. HYDRAULIC FILTERS - Change filter element(s). [1 - 140M; 2 - 210M] OTHER CHECKS AND ADJUSTMENTS - Check hydraulic tank, lines, valves and cylinders for leaks and/or wear, repair as required.
  • Page 64 NOTES HB7-8 Lubrication and Service HB7014 3/96...
  • Page 65 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS NOTE: All 10, 100, and 250 hour service points should Truck Serial Number ____________________________ be included with the following: Site Unit Number ______________________________ Date:______________Hour Meter_________________ Serviceperson Name___________________________ √ COMMENTS ’ INITIALS ENGINE - Remove and clean breather elements. Check engine mounts, repair as required.
  • Page 66 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS (continued) √ COMMENTS ’ INITIALS OTHER CHECKS AND ADJUSTMENTS - Check and record hydraulic pressures: - Steering pressure RH and LH -- 2750 psi (19.0 MPa). - Hoist up pressure -- 2750 psi (19.0 MPa). - Hoist down pressure -- 1000 psi (6.9 MPa).
  • Page 67 5000 HOUR LUBRICATION AND MAINTENANCE CHECKS NOTE: All 10, 100, 250, and 1000 hour service points Truck Serial Number ____________________________ should be included with the following: Site Unit Number ______________________________ Date:______________Hour Meter_________________ Serviceperson Name___________________________ √ COMMENTS ’ INITIALS FRONT WHEELS - Drain oil and check bearing preload as covered in Section ‘‘G’’...
  • Page 68 NOTES HB7-12 Lubrication and Service HB7014 3/96...
  • Page 69 Komatsu Mining Systems, Inc. Peoria Operations, P.O. Box 240 Peoria, IL 61650-0240 Printed in U.S.A. 040398...