Komatsu Articulated Dump Truck HM300-1L service & repair manual

Description Komatsu Articulated Dump Truck HM300-1L service & repair manual

Komatsu Articulated Dump Truck HM300-1L pdf workshop service repair manual + operation & maintenance manual

Serial number A10001 and up

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

MANUAL CONTENT:
GENERAL
SPECIFICATION DRAWING
SPECIFICATIONS
WEIGHT TABLE
FUEL, COOLANT AND LUBRICANTS
ENGINE OIL SPECIFICATIONS
NORMAL OPERATION
ARCTIC OPERATION
TRANSMISSION, TORQUE CONVERTER, TRANSFER CASE AND OIL COOLER, SERVICE
BRAKES AND HYDRAULIC SYSTEM OIL SPECIFICATIONS
FINAL DRIVE OIL SPECIFICATIONS
DRIVE AXLE OIL SPECIFICATIONS
DIESEL FUEL SPECIFICATIONS
COOLANT SPECIFICATIONS
GENERAL
WATER
ANTIFREEZE
SUPPLEMENTAL COOLANT ADDITIVES
COOLING SYSTEM TEST KIT

STRUCTURE AND FUNCTION
COOLING SYSTEMS
POWER TRAIN
DRIVE SYSTEM
OUTPUT SHAFT
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING
TORQUE CONVERTER
TRANSMISSION POWER FLOW
WHEN LOCK-UP CLUTCH IS DISENGAGED
WHEN LOCK-UP CLUTCH IS ENGAGED
OIL FLOW
TRANSMISSION
FL - R CLUTCH
FH - 1ST CLUTCH
2ND - 3RD CLUTCH
DIFFERENTIAL LOCK
CLUTCH AND TRANSMISSION OPERATIONS
FORWARD 1ST
FORWARD 2ND
FORWARD 3RD
FORWARD 4TH
FORWARD 5TH
FORWARD 6TH
REVERSE 1ST
TRANSMISSION VALVE
ECMV (ELECTRONIC CONTROL MODULATION VALVE)
ECMV LOCK-UP CLUTCH
DURING DIRECT TRAVEL
FROM TORQUE CONVERTER TRAVEL TO DIRECT TRAVEL
ECMV SPEED CLUTCH
ECMV OUTLINE
ECMV AND PROPORTIONAL SOLENOID
ECMV AND FILL SWITCH
ECMV OPERATION
ECMV FOR DIFFERENTIAL LOCK
MAIN AND TORQUE CONVERTER RELIEF VALVE
TORQUE CONVERTER RELIEF VALVE
MAIN RELIEF VALVE
DRIVE SHAFT
DRIVE AXLE
FRONT
CENTER
REAR
LOCKING DIFFERENTIAL
FRONT
CENTER
REAR
LIMITED SLIP DIFFERENTIAL

TESTING, ADJUSTING AND TROUBLESHOOTING
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR ELECTRICAL COMPONENTS
TOOLS FOR TESTING AND ADJUSTING
ENGINE COMPONENTS
MEASURING EXHAUST SMOKE
MEASURING EXHAUST TEMPERATURE
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
MEASURING CRANKCASE PRESSURE
MEASURING ENGINE OIL PRESSURE
MEASURING BOOST PRESSURE
MEASURING FUEL PRESSURE
BLEEDING AIR FROM FUEL SYSTEM
ADJUSTING ENGINE SPEED SENSOR
ADJUSTING ALTERNATOR BELT
TESTING TORQUE CONVERTER STALL SPEED
POWER TRAIN OIL PRESSURES
MEASURING POWER TRAIN MAIN RELIEF PRESSURE
MEASURING TORQUE CONVERTER INLET OIL PRESSURE
MEASURING TORQUE CONVERTER OUTLET OIL PRESSURE
MEASURING TORQUE CONVERTER LOCK-UP CLUTCH PRESSURE
MEASURING TRANSMISSION LO CLUTCH PRESSURE
MEASURING TRANSMISSION HI CLUTCH PRESSURE
MEASURING TRANSMISSION 1ST CLUTCH PRESSURE
MEASURING TRANSMISSION 2ND CLUTCH PRESSURE
MEASURING TRANSMISSION 3RD CLUTCH PRESSURE
MEASURING TRANSMISSION R CLUTCH PRESSURE
MEASURING INTER-AXLE DIFFERENTIAL LOCK CLUTCH PRESSURE
ADJUSTING TRANSMISSION SPEED SENSOR
BRAKE OIL PRESSURE
MEASURING CHARGE VALVE CUT-IN AND CUT-OUT PRESSURE
MEASURING WHEEL BRAKE ACTUATION AND PRESSURE DROP
MEASURING ACTUATION PRESSURE ON PARKING BRAKE
MEASURING ACTUATION PRESSURE OF EXHAUST BRAKE SOLENOID
ADJUSTING CHARGE VALVE CUT-IN AND CUT-OUT PRESSURE
TESTING BRAKE PERFORMANCE
TESTING BRAKING PERFORMANCE OF FOOT BRAKE
TESTING BRAKING PERFORMANCE OF RETARDER BRAKE
TESTING PARKING BRAKE BRAKING PERFORMANCE
TESTING OVERRUN PROTECTION BRAKING PERFORMANCE
BLEEDING AIR FROM BRAKE CIRCUIT
BLEEDING AIR FROM SLACK ADJUSTER PORTION OF WHEEL BRAKE
BLEEDING AIR FROM WHEEL BRAKE
BLEEDING AIR FROM PARKING BRAKE CIRCUIT
CHECKING WEAR LIMIT ON WHEEL BRAKE DISC AND PAD
CHECKING BRAKE DISC
CHECKING BRAKE PAD
ADJUSTING PAD CLEARANCE
RELEASING EMERGENCY PARKING BRAKE
STEERING CIRCUIT PRESSURE
MEASURING STEERING RELIEF OIL PRESSURE
ADJUSTING STEERING RELIEF OIL PRESSURE
SUSPENSION CYLINDER
CHECKING CYLINDER LENGTH
RELEASING NITROGEN GAS
ADJUSTING OIL LEVEL
CHARGING WITH NITROGEN GAS
ADJUSTING CYLINDER LENGTH
TILTING THE CAB
PREPARATORY WORK
TILTING CAB UP
USING EXTERNAL CRANE
HOLDING CAB IN POSITION
LOWERING CAB DOWN
DUMP CIRCUIT PRESSURE
TESTING DUMP MAIN RELIEF OIL PRESSURE
ADJUSTING DUMP MAIN RELIEF OIL PRESSURE
ADJUSTING DUMP PILOT RELIEF OIL PRESSURE
BODY POSITIONER SENSOR
CHECKING SENSOR OUTPUT/INPUT VOLTAGE
ADJUSTING LINK LENGTH
CALIBRATING SYSTEM
HANDLING ENGINE CONTROLLER HIGH-VOLTAGE CIRCUIT
TRANSMISSION CONTROLLER
SETTING ROTARY SWITCH
ADJUSTING TRANSMISSION
ESCAPE METHOD FOR ELECTRICAL SYSTEM
MACHINE MONITOR
FUNCTIONS OF MACHINE MONITOR
NORMAL AND THE SPECIAL FUNCTIONS OF MACHINE MONITOR
FLOW OF MODES AND FUNCTIONs
OPERATION AND DISPLAYS FOR OPERATOR MODE
SWITCHING TO SERVICE MODE AND SCREEN DISPLAY

DISASSEMBLY AND ASSEMBLY
Removal and Installation of Assemblies
Disassembly and Assembly of Assemblies
PRECAUTIONS WHEN CARRYING OUT REPAIR OPERATION
SPECIAL TOOL LIST
SKETCHES OF SPECIAL TOOLS
CONNECTOR REPAIR PROCEDURES
Stripping Insulation
Wire Inspection
Contact Terminal Removal (HD30 Type)
Crimping Contact Terminal (HD30 Type)
Insertion Of Contact Terminal (HD30 Type)
Contact Terminal Removal (DT Type)
Crimping Contact Terminal (DT Type)
Insertion Of Contact Terminal (DT Type)

ENGINE
RADIATOR
OUTPUT SHAFT SYSTEM
TRANSMISSION AND FRONT DIFFERENTIAL
SEPARATING FRONT DIFFERENTIAL FROM TRANSMISSION
TORQUE CONVERTER
TRANSMISSION
FRONT DIFFERENTIAL
CENTER AXLE AND DIFFERENTIAL
AXLE ASSEMBLY
DIFFERENTIAL
REAR AXLE AND DIFFERENTIAL
AXLE ASSEMBLY
DIFFERENTIAL ASSEMBLY
FRONT FINAL DRIVE AND BRAKE ASSEMBLY
CENTER FINAL DRIVE AND BRAKE ASSEMBLY
REAR FINAL DRIVE AND BRAKE ASSEMBLY
SUSPENSION SYSTEM
FRONT SUSPENSION
REAR SUSPENSION
EQUALIZER BEAM
HITCH FRAME SYSTEM
ORBITAL STEERING UNIT
UNIT BREAKDOWN VIEW
FLOW AMP VALVE
HOIST VALVE
HYDRAULIC CYLINDER
STEERING CYLINDER
HOIST CYLINDER
TRUCK BODY ASSEMBLY
OPERATORS SEAT

DIAGRAMS AND SCHEMATICS
CAB
CLIMATE CONTROL SYSTEM
CAB HARNESS INSIDE OF CAB AND ENGINE CONTROLLER
CAB HARNESS TO OUTSIDE OF CAB AND ENGINE CONTROLLER
LIGHTING, WIPER AND RELAY BANK
RELAY AND SWITCH CIRCUITS
MODE SWITCHES, INDICATORS AND ELECTRICAL MOTOR SYSTEMS
DISPLAY PANEL, RADIO SPEAKERS AND WORK LAMPS
DIFFERENTIAL LOCK, HOIST LEVER, DISPLAY PANEL AND LEVER KICK-OUT
RETARDER SYSTEM
RETARDER SYSTEM, RADIO, IGNITION SWITCH AND AUXILIARY STEERING
TRANSMISSION CONTROLLER, CONSOLE HARNESS AND ACCELERATOR PEDAL
TRANSMISSION CONTROLLER
TO HARNESS OUTSIDE OF CAB
TO HARNESS OUTSIDE OF CAB AND TO ENGINE
CHASSIS
SIGNAL LAMPS, PRESSURE SWITCH AND TO HARNESS INSIDE OD CAB
TO MAIN HARNESS OF INSIDE CAB AND FRONT LAMPS
TO MAIN HARNESS OF INSIDE CAB, HORN AND FRONT LAMPS
CHASSIS SENSORS, SWITCHES AND JOINT CONNECTIONS
CHASSIS SENSOR SYSTEMS
CONNECTORS OUTSIDE OF CAB
ALTERNATOR, DIFFERENTIAL LOCK, EXHAUST BRAKE, BRAKE WEAR INDICATOR AND
TAIL LAMPS
DIFFERENTIAL LOCK, FUEL INJECTORS, FUEL LEVEL SENSOR AND PRE-HEAT SYSTEM
BATTERY BOX, ENGINE SENSORS AND INCLINATION SENSOR
TRANSMISSION SELECTOR SYSTEM
BRAKE HYDRAULIC CIRCUIT DIAGRAM

Engine SAA6D125E-3 workshop service repair manual