Komatsu Articulated Dump Truck HM250 Repair Service Manual + Operation & Maintenance Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Articulated Dump Truck HM250, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Articulated Dump Truck HM250 workshop service repair manual includes:
* 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: 5,022 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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MAIN SECTIONS
COVER...1
00 Index and foreword...0
100 Index...3
Composition of shop manual...4
Table of contents...6
200 Foreword and general information...19
Safety notice...20
How to read the shop manual...25
Explanation of terms for maintenance standard...27
Handling of electric equipment and hydraulic component...29
Handling of connectors newly used for engines...38
How to read electric wire code...41
Precautions when carrying out operation...44
Method of disassembling and connecting push-pull type coupler...47
Standard tightening torque table...50
Conversion table...54
01 Specification...0
100 Specification and technical data...61
Specification drawings...62
Specifications...63
Weight table...66
Fuel, coolant and lubricants...67
10 Structure, function and maintenance standard...0
100 Engine and cooling system...71
Radiator, oil cooler, aftercooler...72
Output shaft...73
201 Power train, Part 1...77
Power train skeleton...78
Torque converter and transmission hydraulic piping...80
Brake cooling oil control valve (BCV)...82
Power train pump...83
Torque converter...86
Transmission...92
Transmission control valve...120
ECMV...122
Main relief, torque converter relief valve...129
202 Power train, Part 2...133
Drive shaft...134
Axle...135
Differential...138
Limited slip differential...144
Final drive...148
300 Steering system...155
Steering column...156
400 Brake system...159
Brake piping...160
Brake valve...162
Accumulator charge valve...165
Accumulator...169
Slack adjuster...170
Brake...172
Proportional reducing valve...177
Brake system tank...178
Parking brake...180
Parking brake solenoid...184
500 Undercarriage and frame...187
Suspension...188
Suspension cylinder...194
Oscillation hitch...196
600 Hydraulic system...201
Steering, hoist oil pressure piping diagram...202
Dump body control...203
Hydraulic tank and filter...204
Flow amp valve...205
Steering valve...208
Steering cylinder...212
Hoist valve...214
EPC valve...220
Hoist cylinder...222
Hydraulic pump...223
700 Cab and its attachments...227
ROPS cab...228
Cab tilt...229
Rear view monitor...230
Controller related...233
801 Electrical system, Part 1...235
Machine monitor system...236
802 Electrical system, Part 2...257
Automatic shift control system...258
Retarder control system...290
Auto emergency steering system...302
Battery disconnector switch...304
Dump control lever...306
803 Electrical system, Part 3...311
Sensors, switches...312
KOMTRAX terminal system (If equipped)...320
20 Standard value table...0
100 Standard service value table...323
Standard value table for engine...324
Standard value table for chassis...325
30 Testing and adjusting...0
101 Testing and adjusting, Part 1...331
Tools for testing, adjusting, and troubleshooting...333
Testing engine speed...336
Testing intake air pressure (boost pressure)...337
Testing exhaust temperature...338
Testing exhaust gas color...340
Adjusting valve clearance...341
Testing compression pressure...343
Testing blow-by pressure...345
Testing engine oil pressure...346
Testing EGR valve and bypass valve drive oil pressure...347
Handling of fuel system devices...348
Releasing residual pressure from fuel system...348
Testing fuel pressure...349
Handling of reduced cylinder mode operation...350
Handling of no injection cranking operation...350
Testing fuel return and leak amount...351
Bleeding air from fuel circuit...354
Testing the fuel circuit for leakage...355
Testing and adjusting alternator belt tension...356
Testing and adjusting air conditioner compressor belt tension...356
Adjusting the body mount...357
102 Testing and adjusting, Part 2...359
Testing torque converter stall speed...361
Testing power train oil pressure...362
Adjusting transmission speed sensor...370
Testing and adjusting brake oil pressure...372
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas...375
Testing brake performance...378
Bleeding air from brake circuit...379
Testing wear of wheel brake disc...380
Testing wear of parking brake pad...381
Method for emergency release of parking brake...383
Testing and adjusting steering circuit oil pressure...384
Testing and adjusting suspension cylinder...386
Method of tilting cab up...390
Testing and adjusting dump circuit oil pressure...392
Adjusting body positioner sensor...395
Procedure for adjusting length of spring in body heating spherical joint...396
Handling engine controller high voltage circuit...396
Adjusting transmission controller...397
Method for emergency escape at electrical system failure...398
103 Testing and adjusting, Part 3...403
Setting and adjusting various equipments...404
Special function of machine monitor (EMMS)...416
How to start operation of KOMTRAX terminal...453
Lamp display of KOMTRAX terminal...458
Pm Clinic check sheet...461
40 Troubleshooting...0
100 Failure code table and fuse locations...465
Failure codes table...466
Fuse locations...473
200 General information on troubleshooting...479
Points to remember when troubleshooting...480
Sequence of events in troubleshooting...481
Check before troubleshooting...482
Classification and procedures for troubleshooting...483
Information in troubleshooting table...484
Connection table for connector pin numbers...486
T-branch box and T-branch adapter table...522
301 Troubleshooting by failure code, Part 1...527
Failure code [1500L0] Double engagement...529
Failure code [15B0NX] Transmission oil filter: Clogged...530
Failure code [15F0KM] R ? F shifting abuse 1...532
Failure code [15F0MB] R ? F shifting abuse 2...532
Failure code [15F7KM] Transmission forward clutch abuse...533
Failure code [15G0MW] Trouble in reverse clutch system (Slip)...534
Failure code [15G7KM] Transmission reverse clutch abuse...536
Failure code [15H0MW] Trouble in Hi clutch system (Slip)...538
Failure code [15J0MW] Trouble in Lo clutch system (Slip)...540
Failure code [15K0MW] Trouble in 1st clutch system (Slip)...542
Failure code [15L0MW] Trouble in 2nd clutch system (Slip)...544
Failure code [15M0MW] Trouble in 3rd clutch system (Slip)...546
Failure code [15SBL1] Trouble in reverse clutch pressure control valve I...548
Failure code [15SBMA] Trouble in reverse clutch pressure control valve II...551
Failure code [15SCL1] Trouble in Hi clutch pressure control valve I...552
Failure code [15SCMA] Trouble in Hi clutch pressure control valve II...555
Failure code [15SDL1] Trouble in Lo clutch pressure control valve I...556
Failure code [15SDMA] Trouble in Lo clutch pressure control valve II...559
302 Troubleshooting by failure code, Part 2...561
Failure code [15SEL1] Trouble in 1st clutch pressure control valve I...563
Failure code [15SEMA] Trouble in 1st clutch pressure control valve II...566
Failure code [15SFL1] Trouble in 2nd clutch pressure control valve I...567
Failure code [15SFMA] Trouble in 2nd clutch pressure control valve II...570
Failure code [15SGL1] Trouble in 3rd clutch pressure control valve I...571
Failure code [15SGMA] Trouble in 3rd clutch pressure control valve II...574
Failure code [15SJMA] Trouble in lockup clutch pressure control valve II...576
Failure code [15SKMA] Trouble in interaxle differential lock clutch pressure control valve II...578
Failure code [2C4MNX] Clogging of retarder cooling oil filter...580
Failure code [2F00KM] Dragging of parking brake...582
Failure code [2G42ZG] Lowering of accumulator oil pressure (front)...584
Failure code [2G43ZG] Lowering of accumulator oil pressure (rear)...584
Failure code [989A00] Operation of engine overrun prevention system...585
Failure code [989D00] Rear section tipping over alarm (Raising operation on slope)...585
Failure code [A570NX] Clogging of engine oil filter...586
Failure code [AA10NX] Clogging of air cleaner...588
Failure code [AB00MA] Trouble in battery charge circuit...590
Failure code [B@BAZG] Lowering of engine oil pressure...591
Failure code [B@BAZK] Lowering of engine oil level...592
Failure code [B@BCNS] Overheating of engine...593
Failure code [B@BCZK] Lowering of coolant level...594
Failure code [B@BFZK] Lowering of fuel level...596
Failure code [B@C6NS] Overheating of brake cooling oil (front)...597
Failure code [B@C8NS] Overheating of brake cooling oil (center)...597
Failure code [B@CENS] Overheating of torque converter oil...598
Failure code [B@HAZK] Hydraulic oil level low...599
Failure code [B@JANS] Overheating of steering oil...600
303 Troubleshooting by failure code, Part 3...603
Failure code [CA111] Trouble in engine controller...606
Failure code [CA115] Trouble in engine Ne and Bkup speed sensors...608
Failure code [CA122] Abnormally high charge pressure...610
Failure code [CA123] Abnormally low charge pressure...612
Failure code [CA131] Abnormally high throttle sensor signal...614
Failure code [CA132] Abnormally low throttle sensor signal...616
Failure code [CA135] Abnormally high engine oil pressure...618
Failure code [CA141] Abnormally low engine oil pressure...620
Failure code [CA144] Abnormally high coolant temperature...622
Failure code [CA145] Abnormally low coolant temperature...624
Failure code [CA153] Abnormally high charge temperature...626
Failure code [CA154] Abnormally low charge temperature...628
Failure code [CA187] Abnormally low voltage in sensor power supply 2...629
Failure code [CA221] Abnormally high ambient pressure...630
Failure code [CA222] Abnormally low ambient pressure...632
Failure code [CA227] Abnormally high voltage in sensor power supply 2...634
Failure code [CA234] Engine overspeed...636
