PDF Operation & Maintenance Manual Komatsu 210M Dump Truck - 300 KB
This is the complete operation and maintenance manual for the Komatsu 210M Dump Truck.
It provides operators with essential information on safety, controls, and daily inspection procedures.
The manual also outlines the recommended maintenance schedule to ensure the truck's reliability and long service life.
This is a critical document for all personnel involved with this machine.
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--- Page 3 ---
OM1005.1 Introduction - Section 1
Page 1-7
About This Manual
This Manual is written for use by the operator and/or the service technician and is designed to help these persons to
become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently. All
operators and maintenance personnel should read and understand the materials in this manual before operating the
truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings, and cautions
should be understood and followed when operating or accomplishing repairs on the truck.
The 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
Peoria, IL 61650-0240
(309)-672-7072 -- FAX
This first section is an Introduction to the manual and contains a Table of Contents to locate specific areas of interest.
Other sections include Safety, Operation, Maintenance, Specifications, and Optional Equipment.
When searching for a specific area of interest, go first to the Table of Contents to locate the Section in which the
subject might generally be included. Then, go to that Section of the Table of Contents to find a Subject description
that most closely describes the specific area of interest to find a page number and go to that page.
Section Numbers and Page Numbers are located at the top, outside corner of the page.
At the top, inside corner of the page is a document (module) number. If there is ever a question regarding the
information in a particular Section, refer to the document (module) number, the manual Form No., and use the address
shown above to correspond. If there is a date (month/year) behind the document (module) number, that indicates the
latest revision date of that page.
The illustrations used in this manual are TYPICAL of the component shown and may not be an exact reproduction of
what is found on the truck.
This manual shows dimensioning of U.S. standard and metric (SI) units throughout. All references to "Right", "Left",
"Front", or "Rear" are made with respect to the operator’s normal seated position, unless specifically stated otherwise.
When assembly instructions are provided without references to torque values, standard torque values should be
assumed. Standard torque requirements are shown in torque charts on the following pages of this section, and in the
General Information section of the truck service manual. Individual torques when provided in the text are in bold face
type, such as 100 ft.lbs. (135 N.m) torque. All torque specifications have ± 10% tolerance unless otherwise specified.
--- Page 4 ---
OM2005.1 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.
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--- Page 5 ---
OM3005.1 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. with back up horn. Inspect anti-sway bar to see
that it is getting proper greasing. Also look at both
6. Move outboard of the front wheel, and inspect body hinge pins for greasing and any abnormal
attaching lugs/wedges to be sure all are tight and condition.
complete. Check tires for cuts, damage or "bub-
bles" and that inflation appears to be correct. 16. Perform the same inspection on the right rear
suspension as done on the left.
7. Move behind the rear of the front wheel, inspect for
leaks at hub or brakes or any unusual conditions. 17. Move on around the right dual tires, inspect be-
Inspect suspension hardware to be sure it is all in tween the tires for rocks, and for condition of the
place. Inspect the tie-rod and steering cylinder for rock ejector, inspect the tires for cuts or damage,
proper greasing, and for security of all parts. and for correct inflation.
Inspect for any hydraulic leaks.
18. Perform the same inspection for wheel
8. Inspect sight glass for transmission oil level. With lugs/wedges, wheel cover latches, and for leaks
engine stopped, hydraulic fluid should be visible that was done on the left hand dual wheels.
about half way up in the glass. Also check the
transmission filter for leaks. 19. Move in front of right dual tires, and inspect the
hoist cylinder the same as was done on the left
9. Move to the side of the hydraulic tank and check side.
the hydraulic fluid level in the hydraulic tank. Oil
Inspect the final drive anchor pivot area for evi-
should be visible in sight glass with engine
dence of proper greasing of the bearing and any
stopped and body down.
evidence of wear or looseness in the pin or bear-
10. Move on around the hydraulic tank and in front of ing.
the rear dual tires, inspect the hoist cylinder for
20. Move on around the fuel tank, inspect the fuel
any damage and leaks. Inspect both upper and
breather. Inspect the attaching hardware for the
lower hoist cylinder pins for security, and for
fuel tank at the upper saddles, and then at the
proper greasing.
lower back of the tank for the security and condi-
11. Before leaving this position, look to see that there tion of the mounts.
is no leakage or any other unusual condition with On the inside of the frame rail, check the hoist
transmission, drive shaft, or parking brake. control valve and auxiliary manifold for leakage
12. Move on around the dual tires, check to see that and security.
all lugs/wedges are in place and tight. Inspect Check pumps on the right front of transmission
wheel for any leakage that may be coming from for leakage, and that all parts are secure.
inside the wheel housing that would indicate
planetary leakage. 21. Move in behind the right front wheel, and inspect
the tie-rod and steering cylinder for proper greas-
Check dual tires for cuts, damage or "bubbles" ing, and for security of all parts. Be sure the
and that inflation appears to be correct. If truck suspension protective cover is in good condition.
has been run on a "flat", the tire must be cooled Check suspension attaching hardware and sus-
before parking truck inside. Inspect for any pension extension, as well as greasing and attach-
rocks that might be lodged between dual tires, ing hardware for the steering cylinder.
and that rock ejector is in good condition and
straight so that it can not damage a tire. 22. Move out and around the right front wheel, inspect
that all lugs/wedges are in place and tight.
13. Inspect left rear suspension for damage and for
proper inflation, and that there are no leaks. 23. Move in behind the front of the right front wheel,
Inspect also for proper greasing, and that the check hub and brakes for leaks and any unusual
covers over the chromed piston rod are in good condition. Inspect the engine compartment for
condition. any leaks and unusual condition. Inspect the fan
guard, and belts also for any rags or debris behind
14. Check final drive housing breather. Clean or re- radiator.
place breather, if obstructed. Check for leakage
around final drive housing and wet disc brake 24. Move on around to the right front of the truck.
housings and the hoses connected to the hous-
ings.
--- Page 6 ---
OM3005.2 Operation - Section 3
Operator Cab and Controls Page 3-13
(7) Service Brake Pedal
The Service Brake Pedal is the middle pedal of the "R2" position may be used for job operations that
three pedals. It controls a dual hydraulic valve, which would benefit from a
applies both the front dry disc brakes and the rear wet higher speed reverse operation.
disc brakes. The service brakes should be used to slow This range selection utilizes a 3.43 : 1 gear
or stop the truck whenever safety and/or truck reduction ratio.
speed/load conditions exceeds the capability of the COMPLETELY STOP the truck and bring engine
retarder. RPM to low idle before shifting from "N" to "R1";
"R1" to "R2"; "R2" to "R1"; or from either position
to "N".
(8) Throttle Pedal
"D" DRIVE - position. The transmission will shift to first
The Throttle Pedal is the right pedal of the three pedals.
gear and as truck speed increases, the transmission
The operator increases engine RPM by depressing the
will automatically upshift through each gear to sixth
throttle pedal. Engine RPM is decreased by releasing
gear operation. As the truck slows down, the transmis-
the pedal.
sion will automatically downshift to the correct gear.
5, 4, 3, 2 - positions. Road and load conditions some-
(9) Lighter times make it desirable to limit the automatic shifting
to a lower range. These positions provide greater en-
Used for lighting cigars/cigarettes. Always use CAU- gine braking on grades. The transmission will not shift
TION with smoking materials. above the highest gear selected. When conditions
improve, select position D for full range operation.
1 - Use this range selection when pulling through mud
(10) Ash Tray and deep snow, or when maneuvering in tight spaces,
and when driving up or down steep grades where
Used for extinguishing and depositing smoking mate-
maximum driving power and maximum engine braking
rials. DO NOT use for flammable materials such as
is needed.
paper wrappers. Be certain that all fire ash is extin-
guished. NOTE: As engine and ground speed increases, the
transmission will automatically UPSHIFT to the gear
range required up to the highest range selected. How-
(11) Range Selector ever, DOWNSHIFTS will not occur, regardless of gear
range selected, until engine and ground speed are
The lever-type range selector has nine positions (R2, reduced to match the next lower gear range require-
R1, N, D, 5, 4, 3, 2 and 1). To change positions, release ments.
the range holding mechanism (below knob) on the
lever, and move lever to the desired range.
"N" NEUTRAL - used when truck is stopped/parked
with engine operating, and when starting engine.
The truck cannot be started unless the Range Selector
is in NEUTRAL position.
"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 FOR-
WARD range to a REVERSE range or vice-versa.
"R1" position should be used for normal reverse
operation.
This range selection utilizes the standard 5.12 :
1 gear reduction ratio. RANGE SELECTOR
11. Range Selector Knob 12. DO NOT SHIFT Light
--- Page 7 ---
OM3005.3 7/96 Operation - Section 3
Instrument Panel and Controls Page 3-23
(52) EQUAL FAULT Light Cummins "Quantum" Engine
The charge condition of the two 12 Volt batteries is Electronic Control System
monitored to make sure that both batteries are being The following information (items 55 through 59, Figure
charged equally. The Equal Fault Light will illuminate if 3-6) relates to the Cummins "Quantum" Engine Elec-
more than a 0.85 volt variance between the two batter- tronic Control System.
ies is detected.
If an abnormal engine condition develops, the control
(53) CHECK TRANS Light system will record a "fault" code associated with that
condition. By use of a series of indicator lamps and
The ATEC system has a built in computer that monitors switches, the system will display the numerical "fault"
various functions and performances. When the com- code.
puter senses that the system is not performing prop-
erly, the CHECK TRANS light comes "On" to warn and When the keyswitch is turned "On", the lamps (56, 57,
alert the operator that a problem has occurred and that 58) should illuminate for about 2 seconds and then turn
the vehicle should be serviced as soon as possible. The "Off", if no "faults" are detected in the system. This is a
CHECK TRANS light will come "On" when the ignition system lamp test.
is turned "On". After about two seconds, the light will
go "Off". This provides a light bulb check and a system
check.
In cold weather, when the transmission oil is below
-10oF (-23oC), the DO NOT SHIFT lights on the range
selector and the CHECK TRANS light will stay on after
the engine is started. The transmission will stay in
NEUTRAL, regardless of which range is selected until
the oil is warmer than -10oF (-23oC). When the trans-
mission oil warms up, the CHECK TRANS and DO NOT
SHIFT lights will turn off and the transmission will
operate in first gear or reverse only. At 20oF (-7oC), the
transmission may be operated safely in all ranges. If a light stays ON, or FLASHES, then active "faults"
have been detected by the system and the engine
Do Not Check should not be started until the condition has been
Sump Oil Truck
Shift Trans corrected. Refer to DETERMINING "FAULT" CODES.
Temperature Operation
Light Light
-10°F (-24°C) NEUTRAL During engine operation, if a "fault" is detected in the
ON ON system, a light associated with that condition will turn
And BELOW ONLY
"ON" and stay on for "Warning faults", or it will turn "ON
-9°F (-23°C) NEUTRAL, and FLASH" for more severe faults that can affect
to OFF OFF 1st (FIRST), & engine operation and require immediate attention.
+ 19°F (-7°C) REVERSE Only
+ 20°F (-6°C) Full Operation • "Warning" faults (light ON) are ones that require
OFF OFF attention in the near future, but in most conditions
And ABOVE In All Ranges
will not greatly affect performance.
If the transmission oil temperature reaches 250oF • "Severe" faults (light FLASHING) are ones that
(121oC), the CHECK TRANS indicator light will come require immediate attention, because the engine
"On". The ECU (Electronic Control Unit) will inhibit could be significanly affected.
operation of the truck in higher gears.
NOTE: The Transmission Temperature Gauge (23)
indicates the converter temperature. The ECU senses
oil temperature in the sump.
The two temperatures may be different.
(54) ALT. FAULT Light
Active fault conditions MUST be corrected as soon
This light will illuminate if the alternator output exceeds
as possible.
30 VDC, or battery voltage is less than 24 VDC, or if
voltage for each battery differs more than 0.75 V.
--- Page 8 ---
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___________________________
ENGINE COMMENTS √ ’d INITIALS
a. Crankcase Oil -- Change engine oil (use Lube Key
‘‘A’’ on Lubrication and Specification chart) and
corrosion filters.
b. Lube Oil Filters -- Change.
c. By- Pass Filter -- Change.
d. Other EngineChecks --
• Remove primary air filters if indicator shows
RED. Clean or replace as required.
• Change safety filter when green dot disappears
from wing nut on safety element. If safety ele-
ment is disturbed, replace O-ring seal.
• Check air filter cover gasket, replace as re-
quired.
• Check radiator, water pump, hoses and pipes
for leaks, replace or repair as required.
• Check cooling system for correct coolant mix-
ture. Add mixture as required.
• Check exhaust manifolds, gaskets, pipes &
exhaust box for leaks, repair as required.
• Check lubrication hoses and pipes for leaks,
replace or repair as required.
FUEL FILTER AND STRAINER -
Change filter and strainer element.
HYDRAULIC FILTERS -
Change two (2) filter elements.
OTHER CHECKS AND ADJUSTMENTS -
Check hydraulic tank, lines, valves and cylinders
for leaks and/or wear, repair as required.
Check orbitrol steering control unit for binding,
steering column for excess play, hoses and tubes
for wear or leaks, steering cylinders for excessive
play or leaks, repair as required.
Check parking brake actuator, hoses and tubes
for leaks or wear, repair as required.
Check parking brake adjustments (lining and link-
age), adjust/repair as required.