Komatsu HM300-1L Articulated Dump Truck Workshop Repair Service Manual PDF - MKMTSHM300L.zip
The full service and repair guide for the Komatsu Articulated Dump Truck HM300-1L, complete with Electrical Wiring Diagrams, delivers every technical detail professionals need to maintain, troubleshoot, fix, and rebuild the machine like an expert mechanic.
Inside the Komatsu HM300-1L articulated dump truck workshop service repair manual you'll find:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 1,491 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
CEAM015401 - Articulated Dump Truck HM300-1L Operation & Maintenance Manual.pdf
CEBM015200 - Articulated Dump Truck HM300-1L Shop Manual.pdf
MAIN SECTIONS
COVER...1
FOREWORD...2
SAFETY...3
SAFETY NOTICE...3
IMPORTANT SAFETY NOTICE...3
GENERAL PRECAUTIONS...3
PREPARATIONS FOR WORK...3
PRECAUTIONS DURING WORK...3
CONTENTS...2
GENERAL...5
GENERAL...5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD...5
TESTING, ADJUSTING AND TROUBLESHOOTING...5
DISASSEMBLY AND ASSEMBLY...5
DRAWINGS AND SCHEMATICS...5
HOW TO READ THE SHOP MANUAL...6
Volumes...6
Distribution And Updating...6
Filing Method...6
Revised Edition Mark...6
Revisions...6
Symbols...6
HOISTING INSTRUCTIONS...7
HOISTING...7
Wire Ropes...7
PUSH PULL COUPLER...8
Type 1...8
Disconnection...8
Connection...8
Type 2...9
Disconnection...9
Connection...9
Type 3...10
Disconnection...10
Connection...10
COATING MATERIALS...11
STANDARD TIGHTENING TORQUE...13
Torque For Bolts And Nuts...13
Torque For Hose Nuts...14
Torque For Split Flange Bolts...14
Torque For Flared Nuts...14
Torques For O-ring Boss Piping Joints...15
Tightening Torques For O-ring Boss Plugs...15
Torque Table For Hoses (Taper Seal Type And Face Seal Type)...15
ELECTRIC WIRE CODE...16
Classification By Thickness...16
Classification By Color And Code...16
CONVERSION TABLES...17
Method Of Using The Conversion Table...17
01 GENERAL...23
SPECIFICATION DRAWING...24
SPECIFICATIONS...25
WEIGHT TABLE...28
FUEL, COOLANT AND LUBRICANTS...29
ENGINE OIL SPECIFICATIONS...30
NORMAL OPERATION...30
ARCTIC OPERATION...30
TRANSMISSION, TORQUE CONVERTER, TRANSFER CASE AND OIL COOLER, SERVICE BRAKES AND HYDRAULIC SYSTEM OIL SPECIFICATIONS...31
FINAL DRIVE OIL SPECIFICATIONS...31
DRIVE AXLE OIL SPECIFICATIONS...31
DIESEL FUEL SPECIFICATIONS...31
COOLANT SPECIFICATIONS...32
GENERAL...32
WATER...32
ANTIFREEZE...32
SUPPLEMENTAL COOLANT ADDITIVES...34
COOLING SYSTEM TEST KIT...38
10 STRUCTURE AND FUNCTION...39
COOLING SYSTEMS...42
POWER TRAIN...43
DRIVE SYSTEM...43
OUTPUT SHAFT...45
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING...47
TORQUE CONVERTER...48
TRANSMISSION POWER FLOW...52
WHEN LOCK-UP CLUTCH IS DISENGAGED...52
WHEN LOCK-UP CLUTCH IS ENGAGED...52
OIL FLOW...53
TRANSMISSION...54
FL - R CLUTCH...59
FH - 1ST CLUTCH...60
2ND - 3RD CLUTCH...61
DIFFERENTIAL LOCK...62
CLUTCH AND TRANSMISSION OPERATIONS...64
FORWARD 1ST...65
FORWARD 2ND...66
FORWARD 3RD...67
FORWARD 4TH...68
FORWARD 5TH...69
FORWARD 6TH...70
REVERSE 1ST...71
TRANSMISSION VALVE...72
ECMV (ELECTRONIC CONTROL MODULATION VALVE)...73
ECMV LOCK-UP CLUTCH...74
DURING DIRECT TRAVEL...75
FROM TORQUE CONVERTER TRAVEL TO DIRECT TRAVEL...75
ECMV SPEED CLUTCH...76
ECMV OUTLINE...76
ECMV AND PROPORTIONAL SOLENOID...76
ECMV AND FILL SWITCH...76
ECMV OPERATION...77
ECMV FOR DIFFERENTIAL LOCK...79
MAIN AND TORQUE CONVERTER RELIEF VALVE...80
TORQUE CONVERTER RELIEF VALVE...81
MAIN RELIEF VALVE...81
DRIVE SHAFT...82
DRIVE AXLE...83
FRONT...83
CENTER...84
REAR...85
LOCKING DIFFERENTIAL...86
FRONT...86
CENTER...88
REAR...90
LIMITED SLIP DIFFERENTIAL...92
FINAL DRIVE SYSTEM...96
FRONT...96
CENTER...98
REAR...100
STEERING COLUMN...102
WHEEL BRAKING SYSTEM...103
PIPING DIAGRAM...103
BRAKE VALVE...105
ACCUMULATOR CHARGE VALVE...108
ACCUMULATOR...112
SLACK ADJUSTER...113
FRONT BRAKE...115
CENTER, REAR BRAKE...117
PROPORTIONAL REDUCING VALVE...120
BRAKE SYSTEM TANK...121
PARKING BRAKE...122
PARKING BRAKE CALIPER...124
SPRING CYLINDER...125
PARKING BRAKE SOLENOID...126
SUSPENSION SYSTEM...128
FRONT...128
REAR...130
SUSPENSION CYLINDER...134
OSCILLATION HITCH JOINT...136
STEERING, HOIST OIL PIPING DIAGRAM...139
DUMP BODY CONTROL...140
HYDRAULIC TANK AND FILTER...141
FLOW AMPLIFIER VALVE...142
STEERING VALVE...145
HAND PUMP AND SLEEVE CONNECTION...147
FUNCTION OF CENTER SPRING...148
STEERING CYLINDER...149
HOIST VALVE...150
HOIST VALVE AT HOLD POSITION...152
HOIST VALVE AT RAISE POSITION...153
HOIST VALVE AT FLOAT POSITION...154
HOIST VALVE AT LOWER POSITION...155
EPC VALVE...156
PILOT CHECK VALVE...157
HOIST CYLINDER...158
HYDRAULIC PUMP...159
STEERING, HOIST + PILOT PUMP...159
TRANSMISSION + FRONT BRAKE COOLING PUMP...160
BRAKE COOLING + BRAKE PUMP...161
AUXILIARY STEERING PUMP...162
CAB TILT SYSTEM VIEW...163
AIR CONDITIONING SYSTEM VIEW...164
AIR CONDITIONER UNIT...165
RECEIVER DRYER...166
CONDENSER...167
REFRIGERANT COMPRESSOR...168
MACHINE MONITOR SYSTEM...169
NETWORK DATA...169
MACHINE MONITOR PANEL...172
OPTION SETTING CONNECTOR DIAGRAM...174
ADJUSTING MACHINE MONITOR...174
MACHINE MONITOR NORMAL DISPLAY FUNCTIONS...175
SELF-DIAGNOSTIC FUNCTION WHEN OPERATING IGNITION SWITCH...178
CHECK FUNCTION OF MONITOR LAMPS AND METERS...179
SERVICE METER DISPLAY...179
ODOMETER...179
SERVICE MODE...179
OPERATION METHOD...181
AUTOMATIC SHIFT CONTROL SYSTEM...182
TRANSMISSION CONTROLLER...184
SHIFT LEVER POSITION AND AUTOMATIC GEAR SHIFTING RANGE...187
GEAR SHIFTING CHARACTERISTICS...187
AUTOMATIC GEAR SHIFTING GRAPH...188
GEARSHIFT LEVER POSITIONS AND SHIFTING METHOD...189
SHIFT HOLD FUNCTION...190
GEAR SHIFTING TIME DELAY...190
SAFETY FUNCTIONS...190
SELF-DIAGNOSTIC FUNCTION...191
EMERGENCY STEERING SYSTEM...192
SENSORS AND SWITCHES...193
ENGINE SPEED SENSOR...193
ACCELERATOR PEDAL SENSOR...193
ENGINE COOLANT / COOLING OIL TEMPERATURE SENSORS...195
STEERING OIL TEMPERATURE SENSOR...195
FUEL LEVEL SENSOR...196
TILT SENSOR...197
AIR CLEANER CLOGGING SENSOR...198
HYDRAULIC OIL LEVEL SENSOR...199
BODY POSITIONER SENSOR...200
RETARDER CONTROL SYSTEM...201
RETARDER CONTROLLER UNIT...202
RETARDER CONTROL FUNCTION...206
HOIST CONTROL FUNCTION...208
DIFFERENTIAL LOCK CONTROL FUNCTION...210
BRAKE CONTROL SYSTEM (E-SPEC)...212
BRAKE CONTROLLER (E-SPEC) UNIT...213
BRAKE CONTROL FUNCTION...217
HOIST CONTROL SYSTEM...218
DIFFERENTIAL LOCK CONTROL SYSTEM...220
DUMP CONTROL LEVER...222
20 TESTING, ADJUSTING AND TROUBLESHOOTING...227
STANDARD VALUE TABLE FOR ENGINE...229
STANDARD VALUE TABLE FOR CHASSIS...230
STANDARD VALUE TABLE FOR ELECTRICAL COMPONENTS...234
TOOLS FOR TESTING AND ADJUSTING...248
ENGINE COMPONENTS...249
MEASURING EXHAUST SMOKE...249
MEASURING EXHAUST TEMPERATURE...249
ADJUSTING VALVE CLEARANCE...249
MEASURING COMPRESSION PRESSURE...249
MEASURING CRANKCASE PRESSURE...249
MEASURING ENGINE OIL PRESSURE...249
MEASURING BOOST PRESSURE...249
MEASURING FUEL PRESSURE...249
BLEEDING AIR FROM FUEL SYSTEM...249
ADJUSTING ENGINE SPEED SENSOR...250
ADJUSTING ALTERNATOR BELT...252
TESTING TORQUE CONVERTER STALL SPEED...253
POWER TRAIN OIL PRESSURES...254
MEASURING POWER TRAIN MAIN RELIEF PRESSURE...255
MEASURING TORQUE CONVERTER INLET OIL PRESSURE...255
MEASURING TORQUE CONVERTER OUTLET OIL PRESSURE...255
MEASURING TORQUE CONVERTER LOCK-UP CLUTCH PRESSURE...256
MEASURING TRANSMISSION LO CLUTCH PRESSURE...257
MEASURING TRANSMISSION HI CLUTCH PRESSURE...257
MEASURING TRANSMISSION 1ST CLUTCH PRESSURE...257
MEASURING TRANSMISSION 2ND CLUTCH PRESSURE...258
MEASURING TRANSMISSION 3RD CLUTCH PRESSURE...258
MEASURING TRANSMISSION R CLUTCH PRESSURE...259
MEASURING INTER-AXLE DIFFERENTIAL LOCK CLUTCH PRESSURE...259
ADJUSTING TRANSMISSION SPEED SENSOR...260
BRAKE OIL PRESSURE...262
MEASURING CHARGE VALVE CUT-IN AND CUT-OUT PRESSURE...262
MEASURING WHEEL BRAKE ACTUATION AND PRESSURE DROP...262
MEASURING ACTUATION PRESSURE ON PARKING BRAKE...263
MEASURING ACTUATION PRESSURE OF EXHAUST BRAKE SOLENOID...264
ADJUSTING CHARGE VALVE CUT-IN AND CUT-OUT PRESSURE...265
TESTING BRAKE PERFORMANCE...266
TESTING BRAKING PERFORMANCE OF FOOT BRAKE...266
TESTING BRAKING PERFORMANCE OF RETARDER BRAKE...266
TESTING PARKING BRAKE BRAKING PERFORMANCE...267
TESTING OVERRUN PROTECTION BRAKING PERFORMANCE...267
BLEEDING AIR FROM BRAKE CIRCUIT...268
BLEEDING AIR FROM SLACK ADJUSTER PORTION OF WHEEL BRAKE...268
BLEEDING AIR FROM WHEEL BRAKE...269
BLEEDING AIR FROM PARKING BRAKE CIRCUIT...269
CHECKING WEAR LIMIT ON WHEEL BRAKE DISC AND PAD...270
CHECKING BRAKE DISC...270
CHECKING BRAKE PAD...271
ADJUSTING PAD CLEARANCE...272
RELEASING EMERGENCY PARKING BRAKE...273
STEERING CIRCUIT PRESSURE...273
MEASURING STEERING RELIEF OIL PRESSURE...273
ADJUSTING STEERING RELIEF OIL PRESSURE...274
SUSPENSION CYLINDER...275
CHECKING CYLINDER LENGTH...275
RELEASING NITROGEN GAS...275
ADJUSTING OIL LEVEL...276
CHARGING WITH NITROGEN GAS...277
ADJUSTING CYLINDER LENGTH...278
TILTING THE CAB...279
PREPARATORY WORK...279
TILTING CAB UP...279
USING EXTERNAL CRANE...280
HOLDING CAB IN POSITION...280
LOWERING CAB DOWN...280
DUMP CIRCUIT PRESSURE...281
TESTING DUMP MAIN RELIEF OIL PRESSURE...281
ADJUSTING DUMP MAIN RELIEF OIL PRESSURE...282
MEASURING DUMP PILOT RELIEF OIL PRESSURE...282
ADJUSTING DUMP PILOT RELIEF OIL PRESSURE...283
BODY POSITIONER SENSOR...284
CHECKING SENSOR OUTPUT/INPUT VOLTAGE...284