Komatsu 210M Manual

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.
ItisthepolicyoftheCompanytoimproveproductswheneveritispossible
andpracticaltodoso.TheCompanyreservestherighttomakechanges
oraddimprovementsatanytimewithoutincurringanyobligationtoinstall
such changes on products sold previously.
Because of continuous research and development, periodic revisions
may be made to this publication. Customers should contact their local
distributor for information on the latest revision.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to
the State of California to cause cancer, birth defects and other
reproductive harm.
Unsafe use of this machine may cause serious injury or death.
Operators and maintenance personnel must read and understand
this manual before operating or maintaining this machine.
This manual should be kept in or near the machine for reference,
and periodically reviewed by all personnel who will come into
contact with it.

FOREWORD
This handbook is intended to provide the HAULPAK®operator with the necessary
information to allow for safe and efficient truck operation.
The HAULPAK®operator should be a qualified individual who has had proper training to
achieve full production with the truck. An efficient, qualified operator can help insure long
production life of the truck and avoid costly down time due to misuse of the unit and its
systems. Training for both operators and maintenance personnel is recommended and is
available upon request. Operator training is accomplished at the job site by qualified
operator instructors. Maintenance training is provided both in the factory setting and in
field schools. All requests for operator and/or maintenance training should be forwarded
to the local HAULPAK®Distributor for action.
This handbook shows dimensioning of U.S. standard and metric (SI) units, and all
references to "Right", "Left", "Front", or "Rear" are made with respect to the operator’s
normal seated position, unless specifically stated otherwise. Illustrations used in this
handbook are typically representative and may not necessarily depict a specific model.
A Product Identification plate is normally located on the frame in front of the right side front
wheel and designates the Truck Model 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).
Thethreenumbersrepresentthebasictruckmodel.Theletter"M"designatesaMechanical
drive and the letter "E" designates an Electrical propulsion system.
The Product Identification Number (vehicle serial number) contains information which will
identify the original manufacturing bill of material for this unit. This complete number will
be necessary for proper ordering of many service parts and/or warranty consideration.
The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame,
tires, and other components. The vehicle design and application guidelines are sensitive
to the total maximum Gross Vehicle Weight (GVW) and this means the total weight:
the Empty Vehicle Weight + the fuel/lubricants + the payload.
To determine allowable payload:
Service all lubricants for proper level and fill fuel tank of empty truck (which includes all
accessories, body liners, tailgates, etc.) and then weigh truck.
Record this value and subtract from the GVW rating. The result is the allowable payload.
NOTE:Accumulationsofmud,frozenmaterial,etc.becomeapartoftheGVWandreduces
allowable payload. To maximize payload and to keep from exceeding the GVW rating,
these accumulations should be removed as often as practical.
Exceeding the allowable payload will reduce expected life of truck components.
HB0010 7/95 Introduction HB-1

"DANGER" identifies a specific potential hazard
WHICH WILL RESULT
in either INJURY OR DEATH
if proper precautions are not taken.
"WARNING" identifies a specific potential hazard
WHICH MAYRESULT
in either INJURY OR DEATH
if proper precautions are not taken.
"CAUTION"is used for general reminders
of proper safety practices
OR
to direct the reader’s attention to avoid unsafe
or improper practices which may result
in damage to the equipment.
This "ALERT"symbol is used with the signal words,
"CAUTION", "DANGER", and "WARNING"in this manual to
alert the reader to hazards arising from
improper operating and maintenance practices.
HB-2 Introduction HB0010 7/95

TABLE OF CONTENTS
SUBJECT PAGE
MAJOR COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . HB1-1
GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HB2-1
WARNINGS AND CAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . HB3-1
OPERATOR CONTROLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . HB4-1
INSTRUMENTS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . HB5-1
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . HB6-1
LUBRICATION AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . HB7-1
HB0010 7/95 Introduction HB-3

MODEL 210M HAULPAK® TRUCK
HB-4 Introduction HB0010 7/95

COMPONENT DESCRIPTION AND SPECIFICATIONS
ENGINE
The 210M HAULPAK®Truck is powered by
a Cummins KTTA--19C diesel engine. It is
capableofspeedsup to 35MPH(56.7km/h).
TRANSMISSION
The diesel engine drives a remote-mounted
Allison CLT-6063 transmission incorporating
a TC683 torque converter. The transmission
has six "Forward" speeds and two "Reverse"
speeds and uses Allison Transmission Elec-
tronicControl(ATEC)forcompleteautomatic
shift sequencing.
The operator may select "R1" or "R2" for
Reverse, "N" for Neutral, or any one of the six
Forward driving ranges by using the Trans-
mission Range Selector. Each position (R2,
R1, N, D, 5, 4, 3, 2, 1) is selected by releasing
a range locking mechanism on the lever and
choosing the desired range. "D" will permit
completely automatic up and down shifts
through all six ranges. "5" will limit upshifts to
5th range only. "4" will limit upshifts to 4th
range only. "3" will limit upshifts to 3rd range
only. "2" will limit upshifts to 2nd range only.
"1" is a first range hold position and no up-
shifts are permitted.
"R1"or "R2"REVERSE position is used to
back the truck. "R1"position should be used
for normal reverse operation. This range se-
lection utilizes the standard 5.12:1 gear re-
duction ratio. "R2"position may be used for
job operations that would benefit from a
higher speed reverse operation. This range
selection utilizes a 3.43:1 gear reduction ra-
tio.
FINAL DRIVE
The Planetary Final Drive has full floating axle
shaftsandaplug-indifferentialcarrierassem-
bly.
SERVICE BRAKE SYSTEM
The service brakes are controlled by an all
hydraulic actuation system. Depressing the
service brake pedal actuates front dry disc
brakes and rear wet disc brakes.
Automatic Emergency Braking is provided if
system pressure falls below a preset value.
All functioning wheel brakes will be automat-
ically applied by accumulators.
DYNAMIC RETARDING
Dynamic retarding is actuated by depressing
the operator’s retarder pedal which applies
oil-cooled, rear mounted, wet disc brakes
only; the front brakes are not applied.
Application of the retarder pedal may be fully
modulated and should be used to slow the
truck during normal truck operation, to con-
trol speed coming down a grade or to make
non-emergency stops. Use of the retarder
pedal saves wear on the front brakes and
provides better steering control.
POWER STEERING
The HAULPAK®Truck is equipped with an
orbital power steering system mounted un-
der the cab floor with noise and vibration
isolators. An accumulator automatically pro-
vides emergency power to safely steer the
truck while stopping.
INSTRUMENTS
The cab instrument panel displays for the
operator all switches and gauges which are
necessary to safely control the truck and
monitor the truck’s operating systems.
SUSPENSION
HYDRAIR®IIsuspensioncylinderslocatedat
each wheel provide a smooth and comfort-
able ride for the operator and dampens
shock loads to the chassis during loading.
HB1042 Component Description and Specifications HB1-1

MODEL 210M HAULPAK® MAJOR COMPONENTS
HB1-2 Component Description and Specifications HB1042