Komatsu HM300-1L Articulated Truck Shop Manual PDF

We provide you the shop manual with complete information about Komatsu HM300-1L Articulated Truck models. Hundreds of pages you can see precautions for maintenance information, structure and function section, testing, adjusting and troubleshooting instruction, repair procedures, many illustrations, different diagrams and schemes for Komatsu HM300-1L Articulated Truck models.

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Table of Contents:

01 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

10 STRUCTURE AND FUNCTI30

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
FINAL DRIVE SYSTEM
FRONT
CENTER
REAR
STEERING COLUMN
WHEEL BRAKING SYSTEM
PIPING DIAGRAM
BRAKE VALVE
ACCUMULATOR CHARGE VALVE
ACCUMULATOR
SLACK ADJUSTER
FRONT BRAKE
CENTER, REAR BRAKE
PROPORTIONAL REDUCING VALVE
BRAKE SYSTEM TANK
PARKING BRAKE
PARKING BRAKE CALIPER
SPRING CYLINDER
PARKING BRAKE SOLENOID
SUSPENSION SYSTEM
FRONT
REAR
SUSPENSION CYLINDER
OSCILLATION HITCH JOINT
STEERING, HOIST OIL PIPING DIAGRAM
DUMP BODY CONTROL
HYDRAULIC TANK AND FILTER
FLOW AMPLIFIER VALVE
STEERING VALVE
HAND PUMP AND SLEEVE CONNECTION
FUNCTION OF CENTER SPRING
STEERING CYLINDER
HOIST VALVE
HOIST VALVE AT HOLD POSITION
HOIST VALVE AT RAISE POSITION
HOIST VALVE AT FLOAT POSITION
HOIST VALVE AT LOWER POSITION
EPC VALVE
PILOT CHECK VALVE
HOIST CYLINDER
HYDRAULIC PUMP
STEERING, HOIST + PILOT PUMP
TRANSMISSION + FRONT BRAKE COOLING PUMP
BRAKE COOLING + BRAKE PUMP
AUXILIARY STEERING PUMP
CAB TILT SYSTEM VIEW
AIR CONDITIONING SYSTEM VIEW
AIR CONDITIONER UNIT
RECEIVER DRYER
CONDENSER
REFRIGERANT COMPRESSOR
MACHINE MONITOR SYSTEM
NETWORK DATA
MACHINE MONITOR PANEL
OPTION SETTING CONNECTOR DIAGRAM
ADJUSTING MACHINE MONITOR
MACHINE MONITOR NORMAL DISPLAY FUNCTIONS
SELF-DIAGNOSTIC FUNCTION WHEN OPERATING IGNITION SWITCH
CHECK FUNCTION OF MONITOR LAMPS AND METERS
SERVICE METER DISPLAY
ODOMETER
SERVICE MODE
OPERATION METHOD
AUTOMATIC SHIFT CONTROL SYSTEM
TRANSMISSION CONTROLLER
SHIFT LEVER POSITION AND AUTOMATIC GEAR SHIFTING RANGE
GEAR SHIFTING CHARACTERISTICS
AUTOMATIC GEAR SHIFTING GRAPH
GEARSHIFT LEVER POSITIONS AND SHIFTING METHOD
SHIFT HOLD FUNCTION
GEAR SHIFTING TIME DELAY
SAFETY FUNCTIONS
SELF-DIAGNOSTIC FUNCTION
EMERGENCY STEERING SYSTEM
SENSORS AND SWITCHES
ENGINE SPEED SENSOR
ACCELERATOR PEDAL SENSOR
ENGINE COOLANT / COOLING OIL TEMPERATURE SENSORS
STEERING OIL TEMPERATURE SENSOR
FUEL LEVEL SENSOR
TILT SENSOR
AIR CLEANER CLOGGING SENSOR
HYDRAULIC OIL LEVEL SENSOR
BODY POSITIONER SENSOR
RETARDER CONTROL SYSTEM
RETARDER CONTROLLER UNIT
RETARDER CONTROL FUNCTION
HOIST CONTROL FUNCTION
DIFFERENTIAL LOCK CONTROL FUNCTION
BRAKE CONTROL SYSTEM (E-SPEC)
BRAKE CONTROLLER (E-SPEC) UNIT
BRAKE CONTROL FUNCTION
HOIST CONTROL SYSTEM
DIFFERENTIAL LOCK CONTROL SYSTEM
DUMP CONTROL LEVER

20 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  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
MEASURING DUMP PILOT 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

30 DISASSEMBLY AND ASSEMBLY
HOW TO USE MANUAL
PRECAUTIONS WHEN CARRYING OUT REPAIR OPERATION
SPECIAL TOOL LIST
SKETCHES OF SPECIAL TOOLS
CONNECTOR REPAIR PROCEDURES
ENGINE
RADIATOR
OUTPUT SHAFT SYSTEM
TRANSMISSION AND FRONT DIFFERENTIAL
TORQUE CONVERTER
TRANSMISSION
FRONT DIFFERENTIAL
CENTER AXLE AND DIFFERENTIAL
DIFFERENTIAL
REAR AXLE AND DIFFERENTIAL
AXLE ASSEMBLY
DIFFERENTIAL ASSEMBLY
FRONT FINAL DRIVE AND BRAKE ASSEMBLY
90 DIAGRAMS AND SCHEMATICS
CAB
CHASSIS