PDF Shop Manual Komatsu HM250-2 Dump Truck - 6 MB
This extensive shop manual (SEN04733-10) is the definitive guide for repairing and maintaining the Komatsu HM250-2 articulated dump truck.
It provides manufacturer-approved procedures for diagnostics, testing, and disassembly/reassembly of all major systems.
Written for professional service technicians, this manual is packed with diagrams, specifications, and detailed instructions.
It's the only resource you'll need to handle any repair on your HM250-2.
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--- Page 1 ---
SEN04733-10
ARTICULATED HM250 -2
DUMP TRUCK
SERIAL NUMBERS 2001 and up
--- Page 3 ---
100 Index
SEN04735-10 Table of contents
90 Diagrams and drawings
100 Hydraulic diagrams and drawings SEN04756-00
Power train hydraulic circuit diagram .......................................................................................... 3
Steering and hoist hydraulic circuit diagram................................................................................ 5
Brake hydraulic circuit diagram ................................................................................................... 7
Brake cooling hydraulic circuit diagram....................................................................................... 9
200 Electrical diagrams and drawings SEN04757-03
Electrical circuit diagram for inside cab (1/4)............................................................................... 3
Electrical circuit diagram for inside cab (2/4)............................................................................... 5
Electrical circuit diagram for inside cab (3/4)............................................................................... 7
Electrical circuit diagram for inside cab (4/4)............................................................................... 9
Electrical circuit diagram for outside cab (1/3) ............................................................................ 11
Electrical circuit diagram for outside cab (2/3) ............................................................................ 13
Electrical circuit diagram for outside cab (3/3) ............................................................................ 15
Connectors table and arrangement drawing ............................................................................... 17
00-100 14 HM250-2
--- Page 4 ---
200 Foreword and general information
Handling of electric equipment and hydraulic component SEN04736-02
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector
The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-cir-
cuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.
5) Oil or dirt stuck to connector
If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
HM250-2 00-200 13
--- Page 5 ---
200 Foreword and general information
SEN04736-02 Precautions when carrying out operation
2. Precautions when carrying out installation work
q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 β 3 drops of adhesive.
q When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 β 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 β 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation
1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, βBleeding airβ.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see βDisassembly and assemblyβ.
3) Checking engine piping for damage and looseness
Intake and exhaust systemο
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.ο
If any part is loosened or damaged, retighten or repair it.
Cooling systemο
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.ο
If any part is loosened or damaged, retighten or repair it.
Fuel systemο
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.ο
If any part is loosened or damaged, retighten or repair it.
00-200 28 HM250-2
--- Page 6 ---
SEN04738-00
ARTICULATED DUMP TRUCK 1SHOP MANUAL
HM250-2
Machine model Serial number
HM250-2 2001 and up
01 Specification 1
100 Specification and technical data
Specification drawings .................................................................................................................................... 2
Specifications .................................................................................................................................................. 3
Weight table .................................................................................................................................................... 6
Fuel, coolant and lubricants ............................................................................................................................ 7
HM250-2 01-100 1
--- Page 7 ---
SEN04740-00
HM250-2 Articulated dump truck
Form No. SEN04740-00ο
ο
Β© 2008 KOMATSU
All Rights Reserved
Printed in Japan 09-08 (02)
10-100 6 HM250-2
--- Page 8 ---
201 Power train, Part 1
Torque converter SEN04741-00
Oil flow
β’ The oil flows through the main relief valve and its
pressure is reduced to below the set pressure by
the torque converter relief valve. It then flows
into inlet port (A), goes through the oil passages
of stator shaft (1), and flows into pump (2).
β’ The oil is given centrifugal force by pump (2) and
flows into turbine (3) to transfer its energy to tur-
bine (3).
β’ The oil from turbine (3) is sent to stator (4) and
flows into pump (2) again. However, part of the
oil passes between turbine (3) and stator (4) and
is sent from outlet port (B) to the oil cooler to be
cooled. It is then used to lubricate the transmis-
sion.
HM250-2 10-201 15
--- Page 9 ---
201 Power train, Part 1
SEN04741-00 Transmission
Power transmitting route
Forward 1st speed
a The diagram above shows the situation when the differential lock is "off".
10-201 30 HM250-2
--- Page 10 ---
201 Power train, Part 1
Transmission control valve SEN04741-00
Operation table of ECMV
ECMV
Gear FL FH R 1st 2nd 3rd L/U D/L
speed
F1 Q Q Q Q
F2 Q Q Q Q
F3 Q Q Q Q
F4 Q Q Q
F5 Q Q Q
F6 Q Q Q
R1 Q Q Q
R2 Q Q Q
N Q
L/U: Indicates the lockup clutch ECMV.ο
D/L: Indicates the differential lock clutch ECMV.
Outline
β’ Lockup clutch ECMV operates when traveling forward at the speed higher than the set speed of transmis-
sion controller.
β’ Differential lock clutch ECMV operates in the 3rd or lower gear speeds.
β’ The oil from the pump flows through the oil filter to the transmission case. ο
The oil is then diverged to the main relief circuit and clutch actuation circuit.
β’ The pressure of the oil sent to the clutch actuation circuit is regulated by the main relief valve, and then used
to actuate the clutch through the last chance filter. ο
The oil relieved from the main relief valve is supplied to the torque converter.
β’ When the transmission gear is shifted, the ECMV increases the clutch oil pressure smoothly according to
the command current from the transmission controller to reduce the gear shifting shocks. ο
The ECMV keeps the clutch pressure constant during travel.
β’ If the FL, FR or R, and one out of 1st β 3rd clutch ECMVs are selected, the regulated oil pressure is supplied
to the selected clutches to set the transmission to the desired travel direction and gear speed.
β’ ECMV's of 3 kinds are used, which are identified and have differences as shown below.
Fill switch
Printing on name plate (A) Identification color (B) Clutch used
(operating pressure: MPa {kg/cm2})
Installed
L******* β FL, FR, R, 1st
(0.20 {2.0})
Installed
A******* Yellow 2nd, 3rd
(0.26 {2.7})
K******* β Not installed L/U, D/L
L/U: Indicates the lockup clutch ECMV.ο
D/L: Indicates the differential lock clutch ECMV.
HM250-2 10-201 45
--- Page 11 ---
202 Power train, Part 2
SEN04742-00 Axle
Center
1. Center axle housing
2. Center differential
3. Brake
4. Final drive
5. Oil filler port used as oil level plug
6. Drain plug
10-202 4 HM250-2
--- Page 12 ---
202 Power train, Part 2
Final drive SEN04742-00
Rear
1. Shaft 4. Planetary carrier
2. Ring gear (Number of teeth: 66) 5. Sun gear (Number of teeth: 18)
3. Planetary gear (Number of teeth: 23) 6. Drain plug
Unit: mm
No. Check item Criteria Remedy
Backlash between planetary
7 0.17 β 0.41
gear and sun gear
Replace
Backlash between planetary
8 0.20 β 0.55
gear and ring gear
9 Curvature of shaft Repair limit: 1.5TIR Repair or replace
Standard size Tolerance Repair limit
10 Thickness of spacer Replace
28 Β± 0.1 27.5
Wear of outside diameter of
+0.040
11 portion of ring gear hub 170 170
+0.015
inserted into bearing
Repair
Wear of outside diameter of
-0.030
12 portion of axle tube inserted 140 139.83
-0.055
into bearing
HM250-2 10-202 19
--- Page 13 ---
400 Brake system
SEN04744-00 Accumulator charge valve
1. Main relief valve (R3) 4. Relief valve (H1)
2. Valve body 5. Filter
3. Relief valve (R1) 6. Filter
10-400 8 HM250-2
--- Page 14 ---
400 Brake system
Parking brake SEN04744-00
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit Repair or
4 Face runout of disc
0.4 0.8 replace
Rebuid
(Thickness of
Min. 20
5 Thickness of disc 25 disc must not be
under 20 mm)
Max. 20
Thickness of pad (including Replace
6 20 10
thickness of plate)
Standard dimen- Standard Clearance
Tolerance
sion of blade clearance limit
-0.3
22.3
-0.3
Clearance between blade and Repair or
7 Standard
brake assembly Tolerance replace
dimension of 1.0 Β± 0.4 1.5
brake assembly
+0.4
23
-0.1
HM250-2 10-400 23
--- Page 15 ---
500 Undercarriage and frame
SEN04745-00 Oscillation hitch
Oscillation hitch 1
1. Steering cylinder 7. Disc
2. Front frame 8. Coupling
3. Center drive shaft 9. Shaft
4. Rear frame 10. Coupling
5. Pin 11. Pin
6. Hitch frame
10-500 10 HM250-2
--- Page 16 ---
600 Hydraulic system
Steering valve SEN04746-00
Function of center spring
β’ Centering spring (2) consists of four layers of
leaf springs crossed to form an X shape.
The springs are assembled in spool (9) and
sleeve (8) as shown in the diagram on the right.
When the steering wheel is turned, the spring is
compressed and a difference in rotation (angle
variation (a) arises between the spool and the
sleeve.
Because of this, the ports in the spool and
sleeve are connected and oil is sent to the cylin-
der. When the turning of the steering wheel is
stopped, the Girotor also stops turning, so no
more oil is sent to the cylinder and the oil pres-
sure rises.
To prevent this, when the turning of the steering
wheel is stopped, the action of the centering
spring only allows it to turn by an amount equal
to the difference in angle of rotation (angle vari-
ation (a) of the sleeve and spool, so the steer-
ing wheel returns to the NEUTRAL position.
HM250-2 10-600 11
--- Page 17 ---
SEN04746-00
HM250-2 Articulated dump truck
Form No. SEN04746-00ο
ο
Β© 2008 KOMATSU
All Rights Reserved
Printed in Japan 09-08 (02)
10-600 26 HM250-2
--- Page 18 ---
801 Electrical system, Part 1
Machine monitor system SEN04748-00
Related actuation Immediately
Display Display range/ after
No Display item category Device Color conditions Method of display Central Alarm starting Remarks
warning buzzer switch is
lamp turned ON
When abnormality or orWhen abnormality
failure occurs on failure occurs on Note: Top line displays
machine machine, top line "KOMATSU", bottom
Action code Action code * Displayed on top and shows action code; β β Note displays "SYSTEM
bottom lines of bottom line CHECK"
character display displays remedy or
nature of failure
Top line displays
failure code (6
When there is digit) and
abnormality or failure, controller that See Operation &
Failure code Failure press mode switch ">". detected problem; β β Maintenance Manual for
code * Displayed on top bottom line details of failure display
and bottom lines of displays system
character display that is abnormal or
nature of
7 abnormality
Reverse
travel
distance
meter, filter, Operate machine
oil Press machine monitor monitor mode See Operation &
Other displays replacement mode selector switch selector switch ">" Maintenance Manual for
time reset, "U" or "<" to switch details of failure display
telephone screen
No. setting,
language
selection
Brightness
Night lighting Backlight LED Green When small lamps reduced one level β β Q
light up when small lamps
light up
When operated:
Right turn Lights up
8 signal LED Green When operated When not β β Q
operated: Goes
out
When operated:
Lights up
9 Left turn signal LED Green When operated When not β β Q
operated: Goes
out
When operated:
Lights up
10 High beam LED Blue When operated When not β β Q
operated: Goes
out
11 Gear shift lever LED Green When gear shift lever is Lights up (*) β β Q * Flashes when neutral
(R2) position R2 at R2 safety is actuated
11 Gear shift lever LED Green When gear shift lever is Lights up (*) β β Q * Flashes when neutral
(R1) position R1 at R1 safety is actuated
11 Gear shift lever LED Orange When gear shift lever is Lights up β β Q
(N) position N at N
11 Gear shift lever LED Green When gear shift lever is Lights up (*) β β Q * Flashes when neutral
(D) position D Pilot at D safety is actuated
11 Gear shift lever LED Green When gear shift lever is Lights up (*) β β Q * Flashes when neutral
(5) position 5 at 5 safety is actuated
11 Gear shift lever LED Green When gear shift lever is Lights up (*) β β Q * Flashes when neutral
(4) position 4 at 4 safety is actuated
11 Gear shift lever LED Green When gear shift lever is Lights up (*) β β Q * Flashes when neutral
(3) position 3 at 3 safety is actuated
11 Gear shift lever LED Green When gear shift lever is Lights up (*) β β Q * Flashes when neutral
(2) position 2 at 2 safety is actuated
11 Gear shift lever LED Green When gear shift lever is Lights up (*) β β Q * Flashes when neutral
(1) position 1 at 1 safety is actuated
F1,F2,F3,F4,F5,F6,N,
R1,R2
* According to shift
Back- range signal received When shift range
ground from transmission signal is received Q
Shift indicator LED color: controller from transmission β β All light up
12 * When alarm is
Gray actuated when making controller
emergency escape, "E-"
and "N" are displayed in
turn
Night lighting LED Amber
HM250-2 10-801 7
--- Page 19 ---
SEN04748-00
HM250-2 Articulated dump truck
Form No. SEN04748-00
Β© 2008 KOMATSU
All Rights Reserved
Printed in Japan 09-08 (02)
10-801 22 HM250-2
--- Page 20 ---
802 Electrical system, Part 2
Automatic shift control system SEN04749-00
Data range Remarks
x1 [mV] (0.00 β 5.00 [V])
---- [Other than above]
4.72 V = 0?
4.33 V = 30?
3.55 V = 60?
2.20 V = 100?
1.61 V = 120?
x1 [?] (0 β 150 [?])
---- [Other than above]
x1 [mV] (0.00 β 5.00 [V])
---- [Other than above]
4.72 V = 0?
4.33 V = 30?
3.55 V = 60?
2.20 V = 100?
1.61 V = 120?
x1 [MPa] (0.00 β 5.00 [MPa])
---- [Other than above]
x1 [mV] (0.00 β 5.00 [V])
---- [Other than above]
Corresponding data is displayed by [1 (ON), 0 (OFF)] just H: H Fill SW recognition [1:ON, 0:OFF]
under HLR123. L: L Fill SW recognition [1:ON, 0:OFF]
R: R Fill SW recognition [1:ON, 0:OFF]
Example 1: One Fill SW recognition [1:ON, 0:OFF]
010100: When in F1 2: Two Fill SW recognition [1:ON, 0:OFF]
001010: When in R2 3: Three Fill SW recognition [1:ON, 0:OFF]
000000: When in N
100010: When in F4
x1 [mA] (0 β 1000 [mA])
---- [Other than above]
HM250-2 10-802 15
--- Page 21 ---
802 Electrical system, Part 2
SEN04749-00 Automatic shift control system
No. Item ID number Displayed spec. Data contents
60 Input signal D_IN_24-31 40908 D-IN-24-----31 Input signal condition is output
61 Input signal D_IN_32 40942 D-IN-32 Input signal condition is output
62 Output signal 40949 D-OUT-0------7 ON/OFF output state of SOL_OUT_0 - 7.
D_OUT_0-7 When power supply output is set, 0 is displayed.
63 Output signal 40950 D-OUT-8-----15 Corresponds to SOL_OUT_8, 9, 10A, 10B, 11A, 11B,
D_OUT_8-15 SIG_OUT_0 and SIG_OUT1.
When power supply output is set, 0 is displayed.
64 Output signal 40951 D-OUT-16----23 Corresponds to SIG_OUT_2, 3, HSW_OUT_0, 1,
D_OUT_16-23 BATT_RY_OUT.