27000L WATER TANKER

KOMATSU HM300

OPERATORS MANUAL

ETT SERIAL #’s: WT-0334-27, WT-0335-27

FIRST ISSUE: Sept 2009

 1. OPERATING INSTRUCTIONS

NOTE: It is assumed that the operator is fully familiar with the operation of the standard
KOMATSU HM300 dump truck. These instructions only deal with the functions related to
the water tanker.

PRE-TRIP INSPECTION (DAILY):

1. Before using the tank, confirm that the tank is full or has sufficient water for the task. The
level can be seen on the level gauge fitted to the front of the tank. The red rollers on the
gauge represent water.
2. Open the rear compartment and check the water pump. The pump has a mechanical seal and
should not drip water or leak at all.

TANK OVERVIEW:

The tanker is designed for ease of operation. Other than the self filling and hydrant valves,
everything is controlled by the operator inside the cab. Additional personnel are not required.

VACUUM BREAKERS

REAR SPRAYBAR DUMP / BYPASS PENETRATION

VALVE VALVE SPRAYBAR VALVE

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The flow of water to the spraybars and cannon are controlled by diaphragm type valves (Photo
above). These valves are actuated by a hydraulic cylinder which pushes down onto the diaphragm
to close. The tank is fitted with 4 valves:

1. Rear spraybar on/off

2. Penetration spraybar on/off
3. Dump valve on/off
4. Water cannon on/off

The dump valve works in conjunction with the intermittent timer. This is to protect the water pump
from a ‘dead head’ situation. It opens when the other valves close so that there is always flow
through the pump. This is important when using the intermittent spray option which opens and
closes the spray bars regularly.

The dump valve is also used as a bypass back to tank when using the self filling option.

NB: The gate valve fitted after the dump valve is used to create back pressure. This is
required to avoid pump cavitation and should not be tampered with.

ADJUSTABLE NOZZLE

CONTROL VALVE

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 TANK CONTROLS

PUMP ON / OFF CANNON OR SPRAY SWITCH INTERMITTENT ON/OFF TANK FULL LIGHT

TANK EMPTY LIGHT

INTERMITTENT TIMER LOW (PENETRATION)

SPRAYBAR OR HIGH REAR
SPRAYBAR SWITCH
WATER CANNON JOYSTICK

Controls for the tank are all located on the control box mounted to the dash (See photo above). The
functions are all clearly labeled and there use will be detailed below. The hoist lever is no longer
used.

NOTE: The water pump speed (and flow rate) is dependant on the truck engine speed. The
maximum flow is achieved at maximum engine RPM.

WARNING: In order to maximize pump and motor life, do not

engage the pumps when the engine speed exceeds 1000RPM.
AUTOMATIC LOW LEVEL SHUT OFF FEATURE

The tank is fitted with an automatic pump shut off when the water level is too low. This level is
controlled by the bottom magnetic switch attached to the level gauge at the rear of the tank. This
feature protects the pumps from running dry. The “tank empty” light will activate to warn the
driver. The pumps cannot be activated again until water has been added to the tank. The rear
‘external suction’ switch can be used to bypass this function so that the truck can be filled using the
pump.

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AUTOMATIC TANK FULL FEATURE

The top magnetic switch on the level gauge is connected to the “tank full” light. This will tell the
driver when the tank is full. In addition, this will automatically turn the pump off when using the
‘external suction’ (self filling) switch at the rear of the tank.

EXTERNAL SUCTION – HYDRANT VALVES FOR

SELF FILLING CONNECTING HOSES

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 1. OPERATION OF WATER CANNON

The water cannon is activated and controlled from inside the cab. The water cannon is fitted with a
variable nozzle which can be manually turned to change from a wide (mist) to a narrow (Jet) spray.

Recommended operating procedure for the cannon is as follows:

o Start the truck. Make sure it is in neutral and the park brake is on.
o Ensure that the cannon/spray switch it on cannon.
o Manually check that the nozzle is set for mist or jet spray as required.
o Check that the cannon is pointing in the direction you want to spray.
o Engage the water pump switch at engine idle.
o Increase engine speed for better flow and distance.
o Use the joystick to move the cannon up / down or rotate left / right.
o When finished, take your foot off the accelerator and disengage the water pump switch.

NOTE: The cannon can be used while driving although not recommended as it may distract the
driver from watching the road! Also remember that the flow will vary with engine RPM. Do not
activate the pump switch while at high rpm.

Safety warnings:
1. Care must be taken not to aim at other people or windows due to the strength of the water
stream.
2. Always check where you plan to spray before activating the water cannon.
3. Always check that the cannon is pointing where you plan to spray before activating the
water cannon.

2. OPERATION OF SPRAYBARS
The water tanker has three spraybars at the rear: the top left and right spraybars (3 nozzles each)
work together. The bottom penetration spraybar has 7 nozzles.

SPRAYBAR ADJUSTMENT
The side spraybars have 140degree nozzles that spray outwards and cover an area to either side of
the truck. These nozzles have a union joint that can be loosened and rotated.
By rotating outwards a greater area can be covered. By rotating inwards and overlapping the spray
areas, a greater volume of water is achieved but in a smaller area. Experimentation is required to
find the ideal setting for your application. The penetration spraybar is not adjustable. It sprays
directly down and covers an area slightly wider than the truck.

INTERMITTENT OPTION
This tank is also fitted with a timer for intermittent spraying. The on/off time can be set using the
dial. Once again, experimentation is required to find the ideal setting for your application. To use
this option, make sure the “TIMER” switch is on and at least one spray bar.
NOTE: This option does not work with the cannon!

NOTE: It is not recommended to start the pump while at high engine RPM. The sudden
acceleration can shorten the life of the pump and/or motor. If you need to start/stop spraying while
driving rather turn the spraybars on/off while leaving the pump running.

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 3. TANK SELF FILLING

PUMP SWITCH

SUCTION CONTROL FOR

INTERNAL / EXTERNAL
SUCTION CHANGEOVER

EXTERNAL SUCTION HOSE HAND PRIMING PUMP EXTERNAL SUCTION INLET

o Move the suction control lever from the “internal suction” position to the “external suction
position”.
o Remove the external suction hose from its storage position at the rear of the tank
o Insert the suction strainer end of the hose into the external water source. (Dam or river)
o Fill the flexi hose as much as possible with water. Once full, couple it to the “external suction
inlet”.
o Use the hand priming pump to ensure the flexi hose is completely filled with water. Keep
pumping until water comes out of the hand pumps overflow pipe, then close the gate valve just
below the hand pump.
o Start the truck.
o Engage the pump using the ‘external suction’ switch at the rear of the tank. This will
automatically close the spray valves and open the dump/bypass valve to allow water to enter the
tank.
o Climb on top of tank to check if water is entering the tank. Do not keep running the pump if
water is not flowing in. Check the fittings and valves are correct and no air is entering the pump.
o When the tank level reaches the high level sensor on the gauge, the pump will automatically
switch off.
o Although the pump is already ‘off’, remember to turn the switch back to the off position!
o Return the suction hose to its storage position.

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 4. HYDRANT VALVES

o Two manually operated hydrant type valves are fitted to the rear of the tank.
o Two 65mm, 30m long lay flat hoses with firefighting nozzles are supplied with the tank.
o These hoses can be connected to the hydrant valves individually are connected together for extra
length.
o Once connected, open the valve (red handles)
o Turn on the truck
o Activate the pump by turning the switch at the rear to the ‘hydrant valves’ setting.
o This will automatically activate the pump and close the spray valves and dump valve.
o Flow can be controlled by engine RPM.
o When finished, ensure that the valves are closed.
o Turn the switch back to the ‘off’ position.

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 5. MAINTENANCE

• The tank is designed to require minimal maintenance

• The water pump is fitted with a mechanical seal and sealed bearings. Oil is NOT required
in the bearing housing.
• As long as the pump does not run dry, the mechanical seal should give a long life. It must
be replaced once it starts to leak.
• The water cannon has grease nipples fitted to the swivel joints. Grease should be added if
the cannon is used regularly or the movement becomes erratic.

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