Komatsu Articulated Dump Truck HM250-2 service & repair manual

Description Komatsu Articulated Dump Truck HM250-2 service & repair manual

Komatsu Articulated Dump Truck HM250-2 pdf workshop service repair manual

Serial numbers:
2001 and up

Technical data, specifications, maintenance, testing, troubleshooting, electrical wiring diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
Index and foreword
Foreword and general information
Safety notice
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table

Specification
Specification and technical data
Specification drawings
Weight table
Fuel, coolant and lubricants

Structure, function and maintenance standard
Engine and cooling system
Radiator, oil cooler, aftercooler
Output shaft
Power train
Power train skeleton
Torque converter and transmission hydraulic piping
Brake cooling oil control valve (BCV)
Power train pump
Torque converter
Transmission
Transmission control valve
ECMV
Main relief, torque converter relief valve
Drive shaft
Axle
Differential
Limited slip differential
Final drive
Steering system
Steering column
Brake system
Brake piping
Brake valve
Accumulator charge valve
Accumulator
Slack adjuster
Brake
Proportional reducing valve
Brake system tank
Parking brake
Parking brake solenoid
Undercarriage and frame
Suspension
Suspension cylinder
Oscillation hitch
Hydraulic system
Steering, hoist oil pressure piping diagram
Dump body control
Hydraulic tank and filter
Flow amp valve
Steering valve
Steering cylinder
Hoist valve
EPC valve
Hoist cylinder
Hydraulic pump
Cab and its attachments
ROPS cab
Cab tilt
Rear view monitor
Controller related
Electrical system
Machine monitor system
Automatic shift control system
Retarder control system
Auto emergency steering system
Battery disconnector switch
Dump control lever
Sensors, switches
KOMTRAX terminal system (If equipped)

Standard value table
Standard service value table
Standard value table for engine
Standard value table for chassis

Testing and adjusting
Precautions before work
Tools for testing, adjusting, and troubleshooting
Testing engine speed
Testing intake air pressure (boost pressure)
Testing exhaust temperature
Testing exhaust gas color
Adjusting valve clearance
Testing compression pressure
Testing blow-by pressure
Testing engine oil pressure
Testing EGR valve and bypass valve drive oil pressure
Handling of fuel system devices
Releasing residual pressure from fuel system
Testing fuel pressure
Handling of reduced cylinder mode operation
Handling of no injection cranking operation
Testing fuel return and leak amount
Bleeding air from fuel circuit
Testing the fuel circuit for leakage
Testing and adjusting alternator belt tension
Testing and adjusting air conditioner compressor belt tension
Adjusting the body mount
Testing torque converter stall speed
Testing power train oil pressure
Adjusting transmission speed sensor
Testing and adjusting brake oil pressure
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas
Testing brake performance
Releasing remaining pressure in brake circuit
Bleeding air from brake circuit
Testing wear of wheel brake disc
Testing wear of parking brake pad
Method for emergency release of parking brake
Testing and adjusting steering circuit oil pressure
Testing and adjusting suspension cylinder
Method of tilting cab up
Testing and adjusting dump circuit oil pressure
Adjusting body positioner sensor
Procedure for adjusting length of spring in body heating spherical joint
Adjustment of tilt lock lever of steering wheel
Handling engine controller high voltage circuit
Adjusting transmission controller
Method for emergency escape at electrical system failure
Setting and adjusting various equipments
Special function of machine monitor (EMMS)
How to start operation of KOMTRAX terminal
Lamp display of KOMTRAX terminal
Pm Clinic check sheet

Troubleshooting
Failure code table and fuse locations
Fuse locations
General information on troubleshooting
Precautions before work
Points to remember when performing troubleshooting
How to proceed in troubleshooting
Check before troubleshooting
Classification and procedures of troubleshooting
Information in troubleshooting table
Troubleshooting method for disconnecting wiring harness of pressure sensor system
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Troubleshooting by failure code
Troubleshooting of electrical system (E-mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of engine (S-mode)

Disassembly and assembly
General information on disassembly and assembly
Precautions before work
How to read this manual
Coating materials list
Special tool list
Sketches of special tools
Engine and cooling system
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of engine front oil seal
Removal and installation of engine rear oil seal
Removal and installation of cylinder head assembly
Removal and installation of engine assembly
Removal and installation of radiator assembly
Removal and installation of cooling assembly
Removal and installation of aftercooler assembly
Removal and installation of output shaft assembly
Disassembly and assembly of output shaft assembly
Power train, Part 1
Removal and installation of transmission and front differential assembly
Disconnection and connection of front differential assembly and transmission assembly
Disassembly and assembly of front differential assembly
Disassembly and assembly of torque converter assembly
Power train, Part 2
Disassembly and assembly of transmission assembly
Power train, Part 3
Removal and installation of center differential assembly
Disassembly and assembly of center differential assembly
Removal and installation of rear differential assembly
Disassembly and assembly of rear differential assembly
Power train, Part 4
Removal and installation of front final drive and brake assembly
Disassembly and assembly of front final drive and brake assembly
Removal and installation of center final drive and brake assembly
Disassembly and assembly of center final drive and brake assembly
Power train, Part 5
Disassembly and assembly of rear final drive assembly
Removal and installation of center axle assembly
Removal and installation of rear axle assembly
Undercarriage and frame
Removal and installation of front suspension cylinder assembly
Removal and installation of rear suspension cylinder assembly
Disassembly and assembly of front and rear suspension cylinder assembly
Removal and installation of equalizer bar
Removal and installation of hitch frame assembly
Disassembly and assembly of hitch frame assembly
Hydraulic system
Removal and installation of flow amp valve
Removal and installation of hoist valve assembly
Disassembly and assembly of hydraulic cylinder assembly
Body
Removal and installation of body assembly
Cab and its attachments
Method of tilting cab up
Removal and installation of cab assembly
Removal and installation of operator's cab glass (Stuck glass)
Disassembly and assembly of operator's seat assembly
Removal and installation of air conditioner unit assembly
Electrical system
Removal and installation of engine controller
Removal and installation of retarder controller
Removal and installation of transmission
Removal and installation of KOMTRAX terminal assembly

Air conditioner
Structure, function, testing, adjusting, and troubleshooting
Precautions before work
Structure and function
Air conditioner component
Configuration and function of refrigerating cycle
Outline of refrigerating cycle
Air conditioner unit
Function of major components in the air conditioner unit
Blower and intake unit
Compressor
Condenser
Receiver drier
Air conditioner control panel
Testing, adjusting and troubleshooting
Caution about refrigerant
Troubleshooting procedure
Block diagram and circuit diagram of control system
Detail of air conditioner unit
Arrangement of connector pins
Part and connector locations
Cab tilting
Testing air leakage (ducts)
Testing with self-diagnosis function (indication on control panel)
Testing temperature control
Testing vent (mode) changeover
Testing Recirc/Fresh changeover
Testing evaporator temperature sensor
Testing relays
Troubleshooting chart
Troubleshooting for electrical system (E mode)
E-1 Power supply system (Air conditioner does not operate)
E-2 Compressor system (Air is not cooled)
E-3 Blower motor system (No air comes out or air flow is abnormal)
E-4 Temperature cannot be controlled
E-5 Vent (mode) cannot be changed over
E-6 Recirc/Fresh air cannot be changed over
Troubleshooting with gauge pressure
Connection of service tool
Precautions for connecting air conditioner piping
Handling of compressor oil
Control of compressor oil
Adding of compressor oil
Compressor replacement
Applying compressor oil for O-ring

Diagrams and drawings
Hydraulic diagrams and drawings
Power train hydraulic circuit diagram
Steering and hoist hydraulic circuit diagram
Brake hydraulic circuit diagram
Brake cooling hydraulic circuit diagram
Electrical diagrams and drawings
Electrical circuit diagram for inside cab
Electrical circuit diagram for outside cab
Connectors table and arrangement drawing

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