Komatsu 210M - User Manual

The Komatsu 210M is a heavy-duty dump truck designed for mining operations, as detailed in its Operation & Maintenance Manual. This manual provides comprehensive information for operators and maintenance personnel to ensure safe and efficient operation and upkeep of the machine.

Function Description:

The Komatsu 210M is a DUMP TRUCK, specifically a 210M HAULPAK® TRUCK, manufactured by Komatsu Mining Systems, Inc. Its primary function is to transport large quantities of material in mining environments. The truck is equipped with a powerful engine, robust transmission, and advanced braking systems to handle demanding operational conditions. It features a hydraulic hoist system for dumping materials and a sophisticated control system for precise operation.

Important Technical Specifications:

The Komatsu 210M is powered by a Cummins QSK-19C diesel engine, capable of speeds up to 35 MPH (56.7 km/h).

• Engine: Cummins QSK-19C diesel engine.
• Transmission: Allison CLT-6063 w/ATEC, a torque converter with 6 speeds forward and 2 reverse.
• Suspension: HYDRAIR® II, with 10.88 in. (276 mm) stroke (Front & Rear).
• Final Drive: Bevel set (differential) with a ratio of 3.85:1, Planetary with a ratio of 3.70:1, and a total reduction of 14.21:1. Maximum speed is 35 MPH (56.7 km/h).
• Tires: Standard 24.00-35, 36 PR(E-3).
• Rated Tonnage: 210M.
• Dump Body Capacities: Payload (Rated) is 55 Tons. Struck capacity is 31.1 cu. yds. (23.8 m³), heaped at 2:1 (SAE) is 44.0 cu. yds. (33.7 m³).
• Service Capacities (U.S. Gallons / Liters):
  • Engine Lube Oil: 14.2 / 53.7
  • Crankcase (incl. lube oil filters): 15.4 / 58.3
  • Cooling System: 48 / 181.7
  • Fuel Tank: 144 / 545.0
  • Hydraulic System (incl. tank): 95 / 359.0
  • Hydraulic Tank: 20 / 75.6
  • Transmission: 20 / 75.6
  • Final Drive: 1 / 3.8
  • Front Spindle: 1 / 3.8
• Weight Distribution (Empty / Loaded):
  • Front Axle: 44,390 lbs / 20,135 kg (Empty), 66,700 lbs / 30,255 kg (Loaded)
  • Rear Axle: 20,240 lbs / 9,180 kg (Empty), 133,600 lbs / 60,600 kg (Loaded)
  • Total: 64,630 lbs / 29,315 kg (Empty), 200,300 lbs / 90,855 kg (Loaded)
• Maximum Allowable GVW: 210,000 lbs / 95,340 kg.
• Overall Truck Dimensions:
  • Height with body raised: 21' 5" (6.56m)
  • Overall length: 29' 10" (9.09m)
  • Overall width: 14' 7" (4.44m)
  • Wheelbase: 13' 4" (4.06m)
  • Ground clearance: 2' 8" (0.812m)

Usage Features:

The 210M is designed for ease of operation and safety in challenging mining environments.

• Operator Controls: The manual details various controls including steering wheel, turn signals, dimmer switch, tilt lever, horn, hoist control lever, throttle pedal, service brake pedal, retarding pedal, cigarette lighter, and ash tray.
• Instrument Panel: A comprehensive instrument panel provides critical information such as engine oil pressure, water temperature, transmission oil pressure, voltmeter, speedometer, turn indicators, high beam indicator, tachometer, hourmeter, shift indicator, and various warning lights (e.g., engine overspeed, stop engine, fault scroll, check engine, emergency steering, brake lock, low brake pressure, parking brake, coolant temperature, hydraulic oil filter, main filter, brake oil temperature, transmission cooler filter, low accumulator precharge, automatic fire control, low fuel, air cleaner, lamp test, alarm horn).
• Safety Features: The truck incorporates numerous safety features, including a warning decal for unsafe use, a warning to read the operation & maintenance manual, and specific warnings for engine operation, braking, and maintenance. It also includes a ROPS/FOPS protective structure for the operator's cab.
• HAULPAK® System: The truck utilizes the HAULPAK® system, which is a key component of its design and operation, particularly in relation to its suspension and overall performance.
• Dynamic Retarding: The dynamic retarding system, actuated by depressing the operator's retarding pedal, applies oil-cooled, rear-mounted, wet disc brakes. This system ensures that the front brakes are not applied during retarding, which is crucial for stability and control.
• Power Steering: The HAULPAK® Truck is equipped with an orbital power steering system mounted under the cab floor, designed to minimize noise and vibration. An accumulator automatically provides emergency power to safely steer the truck while stopping.

Maintenance Features:

The manual emphasizes the importance of periodic lubrication and service to maintain the truck's design potential.

• Lubrication and Service Schedule: Detailed schedules are provided for 10-hour (daily), 100-hour, 250-hour, 1000-hour, and 5000-hour lubrication and maintenance checks. These schedules cover various components such as the engine, fuel tank, transmission, hydraulic system, final drive, and suspensions.
• Fluid Checks: Regular checks for engine oil, engine fuel filters, radiator coolant, hydraulic tank, transmission fluid, and final drive fluid are outlined.
• Component Inspections: The manual specifies inspections for drive belts, engine and turbochargers, tires, panhard rod, final drive pivot pin, body hinge pins, hoist cylinder pivots, steering ball studs/pivot and tie rod, suspension bearings, cab, instrument panel, front wheel, throttle cable linkage, brakes, U-joints/drive shafts, fuel tank, hydraulic tank breather, and air cleaner.
• Brake Maintenance: Specific instructions are given for checking torque on front spindle retaining nut, and for inspecting and maintaining the wet disc brakes.
• Cooling System: Procedures for cleaning the cooling system and checking antifreeze recommendations are provided.
• Hydraulic System: Checks for hydraulic pressure (steering, hoist up/down, brake pilot, brake) and accumulator precharge are detailed.
• Engine Checks: Includes checking engine mounts, adjusting/replacing fuel injectors, and adjusting intake and exhaust valves.
• Filter Replacements: Schedules for replacing various filters, including engine fuel filters, transmission filters, and hydraulic filters.
• California Proposition 65 Warning: The manual includes a warning about diesel engine exhaust and some of its constituents being known to cause cancer, birth defects, and other reproductive harm.
• Documentation: The manual stresses the importance of referring to the appropriate sections in the Truck Service Manual for major repairs and the engine manufacturer's service manual for engine servicing. It also notes that Komatsu Mining Systems, Inc. reserves the right to make changes or add improvements without incurring any obligation to install such changes on products sold previously.