Komatsu 210M Operation & Maintenance Manual
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Komatsu 210M Operation & Maintenance Manual

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: Foreword

    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. 210M). The three numbers represent the basic truck model. The letter "M" designates a Mechanical drive and the letter "E" designates an Electrical wheelmotor drive system.
  • Page 6 Introduction - Section 1 OM1012.1 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 if proper precautions are not taken.

  • Page 7: Table Of Contents

    OM1012.1 Introduction - Section 1 Page 1-3 TABLE OF CONTENTS SUBJECT ........SECTION / PAGE INTRODUCTION .

  • Page 8: Table Of Contents

    Introduction - Section 1 OM1012.1 Page 1-4 TABLE OF CONTENTS (Continued) SUBJECT ....... . . SECTION / PAGE OPERATOR CONTROLS and EQUIPMENT (FIGURE 3-2) (Continued) .
  • Page 9 OPTIONAL EQUIPMENT ........SECTION 6 This portion of the manual covers operation/maintenance of OPTIONAL EQUIPMENT. NONE INCLUDED FOR 210M...
  • Page 10 Introduction - Section 1 OM1012.1 Page 1-6 ® 210M HAULPAK TRUCK...

  • Page 11: 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 America International Company Haulpak Division, Service Publications P.O. Box 240...
  • Page 12 Introduction - Section 1 OM1012.1 Page 1-8 NOTES...
  • Page 13 OM1012.2 Introduction - Section 1 Standard Charts and Tables Page 1-9 STANDARD CHARTS AND TABLES This manual provides dual dimensioning for most Effect Of Special Lubricants On Fasteners And specifications. U.S. standard units are specified first, Standard Torque Values with metric (SI) units in parentheses. References Haulpak Division does NOT recommend the use of throughout the manual to standard torques or other special "friction-reducing"...
  • Page 14 Introduction - Section 1 OM1012.2 Page 1-10 Standard Charts and Tables TABLE II TORQUE CONVERSIONS Foot Pounds -- ft. lbs. To Newton.meters (N.m) FT. LBS. (N.m) 1.36 2.71 4.07 5.42 6.78 8.14 9.49 10.85 12.20 13.56 14.91 16.27 17.63 18.98 20.34 21.69 23.05...
  • Page 15 OM1012.2 Introduction - Section 1 Standard Charts and Tables Page 1-11 TABLE IV TABLE VI 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 16 Introduction - Section 1 OM1012.2 Page 1-12 Standard Charts and Tables NOTE: Tables such as Table II, IIA, VIII, and IX may be used as in the following example: Example: Convert 975 psi to kilopascals (kPa). 1. Select Table VIII. 4.
  • Page 17 OM1012.2 Introduction - Section 1 Standard Charts and Tables Page 1-13 SUGGESTED* SOURCES FOR TABLE X -- COMMON CONVERSION MULTIPLIERS RUST PREVENTIVE GREASE: TO CONVERT MULTIPLY FROM • AMERICAN ANTI-RUST GREASE # 3-X from inch -- in. millimeter (mm) 25.40 Standard Oil Company, inch -- in.
  • Page 18 Introduction - Section 1 OM1012.2 Page 1-14 Standard Charts and Tables NOTES...

  • Page 19: Safety

    OM2012.1 Safety - Section 2 General Safety Rules Page 2-1 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 If engine has been running, allow coolant to cool conditions to the proper authority.

  • Page 20: Truck Operation

    Safety - Section 2 OM2012.1 Page 2-2 General Safety Rules 8. Read and understand the contents of this hand- 23. Check for flat tires periodically during shift. If truck book. Read the sections pertaining to safety and has been run on a ‘‘flat’’, it must not be parked operating instructions with special attention.

  • Page 21: Additional Job Site Rules

    OM2012.1 Safety - Section 2 General Safety Rules Page 2-3 ADDITIONAL JOB SITE RULES Use this space to add any ADDITIONAL Job Site Rules not covered in any of the previous discussions. ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ ____________________________________________________________________________________________________ ____________________________________________________________________________________________________...

  • Page 22: When Repairs Are Necessary

    Safety - Section 2 OM2012.1 Page 2-4 General Safety Rules WHEN REPAIRS ARE NECESSARY 9. If truck is to be towed for any reason, use a rigid 1. Only qualified maintenance personnel who under- tow bar. Check truck cab for decal recommending stand the systems being repaired should accom- special towing precautions.
  • Page 23 OM2012.2 Safety - Section 2 Warnings and Cautions Page 2-5 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.
  • Page 24 Safety - Section 2 OM2012.2 Page 2-6 Warnings and Cautions 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 25: Operation

    OM2012.2 Safety - Section 2 Warnings and Cautions Page 2-7 The Warning on the right specifies that if any of the red Attached to the exterior of the battery compartment is lights on the instrument panel are "ON" (during truck danger plate WA9704.
  • Page 26 Safety - Section 2 OM2012.2 Page 2-8 Warnings and Cautions 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"...
  • Page 27 OM2012.2 Safety - Section 2 Warnings and Cautions Page 2-9 WA9712 Warning plate is attached to both the hydrau- WA9719 Hydraulic Oil Level Check decal is located on lic and fuel tank. For the safety of technicians who may the hydraulic tank for models that include the combi- be working on the truck with the body in the raised nation oil level/thermometer sight glass.
  • Page 28 Safety - Section 2 OM2012.2 Page 2-10 Warnings and Cautions WA9723 decal is located above the transmission fill A Product Identification plate is located on the left 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 the complete serial number on this plate whenever proper filling instructions to avoid serious damage to...

  • Page 29: Operating Instructions

    OM3012.1 Operation - Section 3 Operating Instructions Page 3-1 OPERATING INSTRUCTIONS PREPARING FOR OPERATION At The Truck - Ground Level Walk Around Inspection The safest trucks are those which have been properly prepared for operation. At the beginning of each shift, At the beginning of each shift, a careful walk around a careful check of the truck should be made before the inspection of the truck should be made before the...
  • Page 30 Operation - Section 3 OM3012.1 Page 3-2 Operating Instructions START HERE FIGURE 3-1. 210M WALK-AROUND INSPECTION...
  • Page 31 OM3012.1 Operation - Section 3 Operating Instructions Page 3-3 5. Look overhead at bottom of cab and check for 15. While standing behind final drive housing, look up leakage of the steering control valve, brake valves, to see that rear lights are in good condition, along and/or hoses.

  • Page 32: Engine Start-Up Safety Practices

    Operation - Section 3 OM3012.1 Page 3-4 Operating Instructions 25. Move in front of the radiator, inspect for any debris ENGINE START-UP SAFETY PRACTICES that might be stuck in front of the radiator and remove it. Check for any coolant leaks. Inspect all headlamps and fog lights.

  • Page 33: After Engine Has Started

    OM3012.1 Operation - Section 3 Operating Instructions Page 3-5 6. When getting a battery assist from one truck to 4. Give special attention to braking and steering another, all switches must be "Off" prior to making circuit warning lights. If warning lights come on, any connections.

  • Page 34: Loading

    Operation - Section 3 OM3012.1 Page 3-6 Operating Instructions 4. Observe all regulations pertaining to the job site’s HAULING traffic pattern. Be alert to any unusual traffic pat- 1. Always stay alert! If unfamiliar with the road, drive tern. Obey the spotter’s signals. with extreme caution.

  • Page 35: Passing

    OM3012.1 Operation - Section 3 Operating Instructions Page 3-7 If brake oil temperature exceeds 250 F (121 DUMPING the Brake Oil Temperature Warning light will turn 1. Pull into dump area with extreme caution. Make on. As quickly as safety will permit, bring the sure area is clear of persons and obstructions, truck to a complete stop away from traffic, move including overhead utility lines.

  • Page 36: Towing

    Operation - Section 3 OM3012.1 Page 3-8 Operating Instructions TOWING 6. Reduce engine RPM as last stage of hoist cylinder Prior to towing a truck, many factors must be carefully begins to extend and let engine go to low idle as considered.

  • Page 37: Safe Parking Procedures

    OM3012.1 Operation - Section 3 Operating Instructions Page 3-9 SAFE PARKING PROCEDURES SHUTDOWN PROCEDURE The operator must continue the use of safety precau- The following sequence of shutdown procedure is im- tions when preparing for parking and engine shut- portant and should be followed at each shutdown. down.
  • Page 38 Operation - Section 3 OM3012.1 Page 3-10 Operating Instructions NOTES...

  • Page 39: Operator Controls And Equipment (Figure 3-2)

    OM3012.2 Operation - Section 3 Operator Cab and Controls Page 3-11 OPERATOR CONTROLS AND EQUIPMENT FIGURE 3-2. OPERATOR CONTROLS 1. Steering Wheel 4. Horn/Telescope Adj. 7. Service Brake Pedal 10. Ash Tray 2. Turn Signals 5. Hoist Control 8. Throttle Pedal 11.

  • Page 40: Hoist Control Lever

    Operation - Section 3 OM3012.2 Page 3-12 Operator Cab and Controls Retarder Operation Hazard Flasher Switch (Not Shown) The operator should use the retarder pedal instead of Not shown in the illustration is the "HAZ- the service brake pedal for slowing the truck and for ARD"...

  • Page 41: Service Brake Pedal

    OM3012.2 Operation - Section 3 Operator Cab and Controls Page 3-13 (7) Service Brake Pedal "R2" position may be used for job operations that The Service Brake Pedal is the middle pedal of the would benefit from a three pedals. It controls a dual hydraulic valve, which higher speed reverse operation.

  • Page 42: Do Not Shift Light

    Operation - Section 3 OM3012.2 Page 3-14 Operator Cab and Controls (12) Do Not Shift Light Operator Seat This light comes on anytime the on-board computer The operator’s seat provides a fully adjustable cush- finds a potentially serious problem in the system. The ioned ride for the driver’s comfort and ease of opera- computer will cause the transmission to lock- in-gear tion.

  • Page 43: Instruments And Controls

    OM3012.3 Operation - Section 3 Instrument Panel and Controls Page 3-15 INSTRUMENTS AND CONTROLS INSTRUMENT PANEL (FIGURE 3-5) (4) Windshield Washer The operator must understand the function and opera- The windshield washer switch, tion of each instrument and control. This knowledge is when held in the "On"...
  • Page 44 Operation - Section 3 OM3012.3 Page 3-16 Instrument Panel and Controls FIGURE 3-5. INSTRUMENT PANEL...

  • Page 45: Transmission Temperature Gauge

    OM3012.3 Operation - Section 3 Instrument Panel and Controls Page 3-17 (8) Transmission Temperature (11) Engine Oil Pressure The transmission temperature The engine oil pressure gauge indi- gauge indicates the temperature of cates engine lube oil pressure. the transmission oil during opera- Normal operating pressure after en- tion.

  • Page 46: Left Turn Indicator (Red Light)

    Operation - Section 3 OM3012.3 Page 3-18 Instrument Panel and Controls Retarder Operation (15) Left Turn Indicator (Red Light) When approaching a descending grade, the operator This light flashes to indicate that the should slow the truck and select the proper transmis- left turn signal lights on the truck sion gear range to maintain an engine speed of 1650 -- have been activated.

  • Page 47: Shift Indicator Gauge

    OM3012.3 Operation - Section 3 Instrument Panel and Controls Page 3-19 FIGURE 3-6. INSTRUMENT PANEL (RIGHT SIDE) (19) Shift Indicator Gauge (20) Engine Overspeed Warning Light If the warning light (20) illuminates and the warning The shift indicator buzzer (47) sounds, the operator MUST take some gauge (19, Figure 3-6), action to reduce the engine speed BELOW 2350 RPM.

  • Page 48: Cummins "Quantum" Engine Electronic Control System

    Operation - Section 3 OM3012.3 Page 3-20 Instrument Panel and Controls • "Warning" faults (light ON) are ones that require (21) WARNING DECAL attention in the near future, but in most conditions This decal warns the opera- will not greatly affect performance. tor that the transmission will •...

  • Page 49: Check Engine Light

    OM3012.3 Operation - Section 3 Instrument Panel and Controls Page 3-21 3. If there is an active fault: (25) CHECK ENGINE Light a. The amber/yellow Check Engine light (25) will This amber/yellow light, when illuminated, indicates an flash once. engine "fault" exists. Current engine operation may b.

  • Page 50: Alt. Fault Light

    Operation - Section 3 OM3012.3 Page 3-22 Instrument Panel and Controls (27) ALT. FAULT Light (30) Emergency Steering This light will illuminate if the alternator output exceeds The Emergency Steering Light, 30 VDC, or battery voltage is less than 24 VDC, or if when actuated, indicates that the voltage for each battery differs more than 0.75 V.

  • Page 51: Coolant Temperature Indicator Light

    OM3012.3 Operation - Section 3 Instrument Panel and Controls Page 3-23 (34) Coolant Temperature Light (37) Engine Oil Pressure The Engine Oil Pressure Warning This warning light indicates the light will come "On" indicating en- engine coolant temperature has gine oil pressure is below normal exceeded 200 F (93 operating range.

  • Page 52: Low Accumulator Precharge Warning Light

    Operation - Section 3 OM3012.3 Page 3-24 Instrument Panel and Controls (40) Transmission Cooler Filter (45) Air Cleaner Indicator (Optional) The transmission Cooler Filter light If truck is equipped with OPTIONAL alerts the operator that oil passing Air Cleaner Indicator System, this through the elements in the filter indicator light (when illuminated) in- assembly is being restricted.

  • Page 53: And (52) Brake Off Decals

    OM3012.3 Operation - Section 3 Instrument Panel and Controls Page 3-25 (49) and (52) Brake ON (55) Circuit Breaker This 30 amp circuit breaker protects the heater blower motor and the air conditioning system from overloads. When the Parking Brake switch (50) The circuit breaker can be reset manually by pushing or Brake Lock switch (53) is in this the red reset button.

  • Page 54: Heater/Air Conditioner (Figure 3-7)

    Operation - Section 3 OM3012.3 Page 3-26 Instrument Panel and Controls HEATER/AIR CONDITIONER (FIGURE 3-7) (60) Fan The fan switch controls the heater/air condition three-speed blower motor. The speeds are High, Medium, and Low. (61) 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 throughout the cab.

  • Page 55: Lubrication And Service

    "H" for Suspensions, etc.). recommended intervals in lieu of an oil analysis 210M SERVICE CAPACITIES program which may determine different intervals. However, if truck is being operated under extreme Gallons...

  • Page 56: Lubrication Chart

    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 57 OM4005 10/96 Maintenance - Section 4 Lubrication and Service Page 4-3 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.
  • Page 58 Maintenance - Section 4 OM4005 10/96 Page 4-4 Lubrication and Service 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.

  • Page 59: 100 Hour Lubrication And Maintenance Checks

    OM4005 10/96 Maintenance - Section 4 Lubrication and Service Page 4-5 100 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 ’...
  • Page 60 Maintenance - Section 4 OM4005 10/96 Page 4-6 Lubrication and Service 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.

  • Page 61: 250 Hour Lubrication And Maintenance Checks

    OM4005 10/96 Maintenance - Section 4 Lubrication and Service Page 4-7 250 HOUR LUBRICATION AND MAINTENANCE CHECKS NOTE: 10 Hour and 100 Hour service should be in- Truck Serial Number ____________________________ cluded with the following: Site Unit Number ______________________________ Date:______________Hour Meter_________________ Serviceperson Name___________________________ √...
  • Page 62 Maintenance - Section 4 OM4005 10/96 Page 4-8 Lubrication and Service NOTES...

  • Page 63: 1000 Hour Lubrication And Maintenance Checks

    OM4005 10/96 Maintenance - Section 4 Lubrication and Service Page 4-9 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___________________________ √...
  • Page 64 Maintenance - Section 4 OM4005 10/96 Page 4-10 Lubrication and Service 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).

  • Page 65: 5000 Hour Lubrication And Maintenance Checks

    OM4005 10/96 Maintenance - Section 4 Lubrication and Service Page 4-11 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___________________________ FRONT WHEELS -...
  • Page 66 Maintenance - Section 4 OM4005 10/96 Page 4-12 Lubrication and Service NOTES...

  • Page 67: Specifications

    MAJOR COMPONENTS AND SPECIFICATIONS ENGINE SERVICE BRAKE SYSTEM ® The 210M HAULPAK Truck is powered by a Cummins The service brakes are controlled by an all hydraulic QSK--19C diesel engine. It is capable of speeds up to actuation system. Depressing the service brake pedal 35 MPH (56.7 km/h).

  • Page 68: Specifications

    Specifications - Section 5 OM5004 Page 5-2 Major Components and Specifications ® MODEL 210M HAULPAK MAJOR COMPONENTS...
  • Page 69 OM5004 Specifications - Section 5 Major Components and Specifications Page 5-3 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 ....QSK--19C Tandem Pump Capacity: Number of Cylinders .
  • Page 70 Specifications - Section 5 OM5004 Page 5-4 Major Components and Specifications OVERALL TRUCK DIMENSIONS...
  • Page 71 Komatsu Mining Systems, Inc. Peoria Operations, P.O. Box 240 Peoria, IL 61650-0240 Printed in U.S.A. 040398...

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