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KOMATSU HD1200M-1 SHOP MANUAL SEBM0562A09 – PDF DOWNLOAD
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Description
KOMATSU HD1200M-1 SHOP MANUAL SEBM0562A09 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU HD1200M-1 SHOP MANUAL SEBM0562A09 – PDF DOWNLOAD
Language : English
Pages : 1041
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU HD1200M-1 SHOP MANUAL SEBM0562A09 – PDF DOWNLOAD
COVER............................................................................................................ 1 CONTENTS......................................................................................................... 8 GENERAL.......................................................................................................... 28 01 GENERAL INSTRUCTION....................................................................................... 28 GENERAL INSTRUCTION...................................................................................... 29 GENERAL VIEW(SERIAL NO.:1002-1100)................................................................... 30 DIMENSION(SERIAL NO.:1002-1100)...................................................................... 31 GENERAL VIEW(SERIAL NO.:1101 AND UP)................................................................. 32 DIMENSION(SERIAL NO.:1101 AND UP).................................................................... 33 SPECIFICATIONS....................................................................................... 34 ENGINE GENERAL VIEW.................................................................................. 36 WEIGHT TABLE......................................................................................... 37 02 TESTING AND ADJUSTING..................................................................................... 38 TESTING AND ADJUSTING.................................................................................... 39 STANDARD FOR TESTING AND ADJUSTING................................................................... 40 03 GENERAL DISASSEMBLY AND ASSEMBLY.......................................................................... 47 GENERAL DISASSEMBLY AND ASSEMBLY......................................................................... 48 GENERAL,DISASSEMBLY.................................................................................. 49 GENERAL,ASSEMBLY..................................................................................... 58 ENGINE RELATED COMPONENT......................................................................................... 69 12 TESTING AND ADJUSTING..................................................................................... 69 TESTING AND ADJUSTING.................................................................................... 70 STANDARD VALUE FOR TESTING AND ADJUSTING............................................................. 71 TOOLS FOR TESTING AND ADJUSTING...................................................................... 72 BARRING.............................................................................................. 73 EXHAUST AND INTAKE SYSTEM............................................................................ 73 ENGINE BODY.......................................................................................... 75 LUBRICATION SYSTEM................................................................................... 77 FUEL SYSTEM.......................................................................................... 79 COOLING SYSTEM....................................................................................... 80 13 DISASSEMBLY AND ASSEMBLY.................................................................................. 83 DISASSEMBLY AND ASSEMBLY................................................................................. 84 RADIATOR,DISMOUNTING................................................................................. 85 RADIATOR,MOUNTING.................................................................................... 88 ENGINE,DISMOUNTING................................................................................... 91 ENGINE,MOUNTING...................................................................................... 98 BRAKE OIL COOLER,DISMOUNTING......................................................................... 105 BRAKE OIL COOLER,MOUNTING............................................................................ 106 TORQUE CONVERTER OIL COOLER,DISMOUNTING AND MOUNTING................................................. 107 16 AIR STARTER............................................................................................... 108 AIR STARTER.............................................................................................. 109 WARNING.............................................................................................. 110 MOUNTING DIMENSIONS.................................................................................. 110 LUBRICATION.......................................................................................... 111 INSTALLATION......................................................................................... 111 BARRING OVER THE ENGINE.............................................................................. 113 DISASSEMBLY OF THE STARTER........................................................................... 115 ASSEMBLY OF THE STARTER.............................................................................. 116 TEST AND INSPECTION PROCEDURE........................................................................ 118 TROUBLESHOOTING GUIDE................................................................................ 119 POWER TRAIN...................................................................................................... 120 21 STRUCTURE AND FUNCTION.................................................................................... 120 STRUCTURE AND FUNCTION................................................................................... 121 GENERAL.............................................................................................. 122 OUTPUT SHAFT......................................................................................... 123 TORQUE CONVERTER AND TRANSMISSION.................................................................... 125 TORQUE CONVERTER..................................................................................... 126 TORQUE CONVERTER VALVE............................................................................... 137 TORQUE CONVERTER REGULATOR VALVE..................................................................... 144 TORQFLOW TRANSMISSION................................................................................ 145 TRANSMISSION CONTROL VALVE........................................................................... 156 SOLENOID VALVE....................................................................................... 167 TRANSMISSION LUBRICATION VALVE....................................................................... 168 TRANSMISSION OIL PUMP................................................................................ 169 TORQUE CONVERTER AND TRANSMISSION OIL CIRCUIT(SERIAL NO.:1002-1100).................................. 170 TORQUE CONVERTER,TRANSMISSION AND BRAKE COOLING OIL CIRCUIT(SERIAL NO.:1101-1129).................... 171 POWER TRAIN HYDRAULIC CIRCUIT SCHEMATIC(SERIAL NO.:1101-1129)........................................ 172 HYDRAULIC CIRCUIT DIAGRAM(SERIAL NO.:1130-1142)...................................................... 176 HYDRAULIC CIRCUIT SCHEMATICS(SERIAL NO.:1130-1142)................................................... 177 HYDRAULIC CIRCUIT DIAGRAM(SERIAL NO.:1143 AND UP).................................................... 178 HYDRAULIC CIRCUIT SCHEMATICS(SERIAL NO.:1143 AND UP)................................................. 179 TORQFLOW HYDRAULIC PIPING............................................................................ 180 PROPELLER SHAFT...................................................................................... 181 REAR AXLE ASSEMBLY................................................................................... 182 DIFFERENTIAL......................................................................................... 185 DIFFERENTIAL LOCK CONTROL............................................................................ 187 FINAL DRIVE SYSTEM................................................................................... 189 SERVICE BRAKE........................................................................................ 193 PARKING BRAKE........................................................................................ 199 22 TESTING AND ADJUSTING..................................................................................... 204 TESTING AND ADJUSTING.................................................................................... 205 STANDARD VALUE FOR TESTING AND ADJUSTING............................................................. 206 MEASUREMENT OF OPERATING FORCE AND STROKE OF VARIOUS LEVERS.......................................... 207 MEASUREMENT OF OIL QUANTITY.......................................................................... 208 MEASUREMENT OF OIL TEMPERATURE AND PRESSURE ......................................................... 209 ADJUSTMENT OF PARKING BRAKE.......................................................................... 212 TESTING WEAR OF SERVICE BRAKE........................................................................ 214 STALL PERFORMANCE.................................................................................... 215 TROUBLE SHOOTING..................................................................................... 216 TROUBLE SHOOTING................................................................................. 217 1. MACHINE FAILS TO START.................................................................... 217 2. MACHINE LACKS TRAVEL SPEED OR TRACTION FORCE(AT CERTAIN SPEED RANGES)..................... 218 3. MACHINE LACKS TRAVEL SPEED OR TRACTION FORCE(AT ALL SPEEDS RANGES)........................ 220 4. LARGE TIME LAG WHEN STARTING OR SHIFTING.................................................. 221 5. OIL TEMPERATURE OF TORQUE CONVERTER IS TOO HIGH........................................... 222 6. LARGE SHOCK WHEN STARTING OR SHIFTING..................................................... 223 7. OIL PRESSURE OF TORQUE CONVERTER IS TOO LOW............................................... 223 8. MACHINE FAILS TO RUN OR TRAVEL WITHOUT RESILIENCY IN DIRECT DRIVE RANGE................... 223 23 DISASSEMBLY AND ASSEMBLY.................................................................................. 224 DISASSEMBLY AND ASSEMBLY................................................................................. 225 TORQUE CONVERTER AND TORQFLOW TRANSMISSION,DISMOUNTING............................................... 226 TORQUE CONVERTER AND TORQFLOW TRANSMISSION,MOUNTING.................................................. 231 TORQUE CONVERTER AND TORQFLOW TRANSMISSION,DISCONNECTING............................................. 236 TORQUE CONVERTER AND TORQFLOW TRANSMISSION,CONNECTING................................................ 240 TORQUE CONVERTER,DISASSEMBLY......................................................................... 244 TORQUE CONVERTER,ASSEMBLY............................................................................ 257 TRANSMISSION,DISASSEMBLY............................................................................. 277 TRANSMISSION,ASSEMBLY................................................................................ 289 DIFFERENTIAL,DISMOUNTING............................................................................. 303 DIFFERENTIAL,MOUNTING................................................................................ 305 DIFFERENTIAL,DISASSEMBLY............................................................................. 307 DIFFERENTIAL,ASSEMBLY................................................................................ 312 SERVICE BRAKE,DISASSEMBLY............................................................................ 325 SERVICE BRAKE,ASSEMBLY............................................................................... 330 PARKING BRAKE........................................................................................ 341 PARKING BRAKE,DISMOUNTING........................................................................ 342 PARKING BRAKE,MOUNTING........................................................................... 343 PARKING BRAKE,DISASSEMBLY............................................................................ 345 PARKING BRAKE,ASSEMBLY............................................................................... 348 FINAL DRIVE,DISMOUNTING.............................................................................. 354 FINAL DRIVE,MOUNTING................................................................................. 358 OUTPUT SHAFT,REMOVAL AND INSTALLATION................................................................ 364 OUTPUT SHAFT,DISASSEMBLY............................................................................. 365 OUTPUT SHAFT,ASSEMBLY................................................................................ 366 PROPELLER SHAFT(FRONT),DISMOUNTING AND MOUNTING...................................................... 367 PROPELLER SHAFT(REAR),DISMOUNTING AND MOUNTING....................................................... 368 24 MAINTENANCE STANDARD...................................................................................... 369 MAINTENANCE STANDARD..................................................................................... 370 OUTPUT SHAFT......................................................................................... 371 TORQUE CONVERTER..................................................................................... 372 TORQUE CONVERTER CONTROL VALVE....................................................................... 376 TORQUE CONVERTER VALVE............................................................................... 378 TORQUE CONVERTER REGULATOR VALVE..................................................................... 380 TORQFLOW TRANSMISSION................................................................................ 381 TRANSMISSION CONTROL VALVE........................................................................... 387 DIFFERENTIAL......................................................................................... 391 FINAL DRIVE.......................................................................................... 393 SERVICE BRAKE........................................................................................ 395 PARKING BRAKE........................................................................................ 400 STEERING SYSTEM.................................................................................................. 403 41 STRUCTURE AND FUNCTION.................................................................................... 403 STRUCTURE AND FUNCTION................................................................................... 404 FRONT AXLE........................................................................................... 405 FRONT WHEELS......................................................................................... 406 REAR WHEELS.......................................................................................... 407 STEERING SYSTEM...................................................................................... 408 STEERING GEAR BOX.................................................................................... 413 CHASSIS SUSPENSION SYSTEM............................................................................ 414 FUNCTIONS OF CHASSIS SUSPENSION SYSTEM............................................................... 415 SUSPENSION CYLINDER.................................................................................. 417 42 TESTING AND ADJUSTING..................................................................................... 418 TESTING AND ADJUSTING.................................................................................... 419 STANDARD VALUE FOR TESTING AND ADJUSTING............................................................. 420 MEASUREMENT OF VARIOUS OIL QUANTITIES................................................................ 425 ADJUSTING OF STEERING OIL PRESSURE................................................................... 429 STEERING PERFORMANCE................................................................................. 430 BRAKE PERFORMANCE.................................................................................... 431 TROUBLE SHOOTING..................................................................................... 433 1. HEAVY STEERING................................................................................ 434 2. STEERING WHEEL DOESN'T WORK................................................................... 435 3. EXCESSIVE PLAY IN STEERING WHEEL.............................................................. 436 4. INSUFFICIENT OR UNBALANCED TURNING ANGLES..................................................... 436 5. SWAY IN STEERING WHEEL........................................................................ 437 6. STEERING WHEEL IS TOO LIGHT................................................................... 437 7. EXCESSIVE BOUNCING ON ROUGH GROUND............................................................ 438 8. INEFFECTIVE OR UNBALANCED REAR(FRONT) BRAKE................................................... 439 9. CAUTION LAMP FOR BRAKE OIL TEMPERATURE LIGHTS DURING NORMAL OPERATION......................... 440 10. AIR PRESSURE DOES NOT RISE................................................................... 441 43 DISASSEMBLY AND ASSEMBLY.................................................................................. 442 DISASSEMBLY AND ASSEMBLY................................................................................. 443 FRONT AXLE,DISASSEMBLY............................................................................... 444 FRONT AXLE,ASSEMBLY.................................................................................. 446 FRONT WHEEL,DISMOUNTING.............................................................................. 448 FRONT WHEEL,MOUNTING................................................................................. 449 REAR WHEEL,DISMOUNTING............................................................................... 450 REAR WHEEL,MOUNTING.................................................................................. 452 FRONT SUSPENSION CYLINDER,DISMOUNTING................................................................ 454 FRONT SUSPENSION CYLINDER,MOUNTING................................................................... 456 FRONT SUSPENSION CYLINDER,DISASSEMBLY................................................................ 458 FRONT SUSPENSION CYLINDER,ASSEMBLY................................................................... 460 REAR SUSPENSION,DISMOUNTING.......................................................................... 463 REAR SUSPENSION,MOUNTING............................................................................. 464 REAR SUSPENSION,DISASSEMBLY.......................................................................... 465 REAR SUSPENSION,ASSEMBLY............................................................................. 466 STEERING LINKAGE,DISASSEMBLY AND ASSEMBLY............................................................ 468 44 MAINTENANCE STANDARD...................................................................................... 469 MAINTENANCE STANDARD..................................................................................... 470 WHEEL................................................................................................ 471 STEERING LINKAGE..................................................................................... 472 FOLLOW-UP LINKAGE.................................................................................... 473 STEERING GEAR BOX.................................................................................... 474 SUSPENSION CYLINDER.................................................................................. 476 AIR SYSTEM....................................................................................................... 477 51 STRUCTURE AND FUNCTION.................................................................................... 477 STRUCTURE AND FUNCTION................................................................................... 478 AIR CIRCUIT DIAGRAM.................................................................................. 479 AIR PIPING........................................................................................... 495 BRAKE CIRCUIT........................................................................................ 504 AIR COMPRESSOR....................................................................................... 504 ENGINE OVERRUN PREVENTION SYSTEM..................................................................... 535 AIR STARTER AIR CIRCUIT.............................................................................. 541 HOIST CONTROL AIR CIRCUIT............................................................................ 542 HAND BRAKE VALVE(RETARDER CONTROL VALVE)............................................................. 544 2-WAY CONTROL VALVE.................................................................................. 547 CHAMBER CYLINDER..................................................................................... 550 PARKING BRAKE CHAMBER................................................................................ 553 SLACK ADJUSTER....................................................................................... 555 BRAKE VALVES......................................................................................... 560 DOUBLE-CHECK VALVE................................................................................... 567 EMERGENCY RELAY VALVE................................................................................ 569 RELAY VALVE.......................................................................................... 572 QUICK-RELEASE VALVE.................................................................................. 575 PRESSURE SETTING VALVE............................................................................... 577 CHECK VALVE.......................................................................................... 578 LOW-PRESSURE BUZZER,PARKING CAUTION SWITCH........................................................... 579 AIR GOVERNOR......................................................................................... 581 SAFETY VALVE......................................................................................... 584 SOLENOID VALVE(FOR ENGINE OVERRUN PREVENTION)........................................................ 585 SOLENOID VALVE(FOR AIR STARTER AND AUTOMATIC RETARDER)............................................... 586 STOP LAMP SWITCH..................................................................................... 589 HORN VALVE........................................................................................... 590 THROTTLE CONTROL AIR CYLINDER........................................................................ 591 AFTER-COOLER......................................................................................... 592 RELAY VALVE(FOR AIR STARTER)......................................................................... 594 LUBRICATOR........................................................................................... 595 DUMP CONTROL VALVE................................................................................... 596 PRESSURE SWITCH...................................................................................... 597 PROTECTION VALVE..................................................................................... 599 53 DISASSEMBLY AND ASSEMBLY.................................................................................. 601 DISASSEMBLY AND ASSEMBLY................................................................................. 602 BRAKE CHAMBER(FRONT AND REAR),DISMOUNTING AND MOUNTING............................................... 603 BRAKE CHAMBER(FRONT AND REAR),DISASSEMBLY............................................................ 605 BRAKE CHAMBER(FRONT AND REAR),ASSEMBLY............................................................... 608 BRAKE CHAMBER,DISASSEMBLY............................................................................ 611 BRAKE CHAMBER,ASSEMBLY............................................................................... 612 BRAKE VALVE,DISMOUNTING AND MOUNTING................................................................. 613 BRAKE VALVE,DISASSEMBLY.............................................................................. 614 BRAKE VALVE,ASSEMBLY................................................................................. 617 AIR GOVERNOR,DISMOUNTING AND MOUNTING................................................................ 620 AIR GOVERNOR,DISASSEMBLY AND ASSEMBLY................................................................ 621 SLACK ADJUSTER,DISASSEMBLY AND ASSEMBLY.............................................................. 622 PARKING BRAKE CHAMBER,REMOVAL AND INSTALLATION....................................................... 623 PARKING BRAKE CHAMBER,DISASSEMBLY.................................................................... 624 PARKING BRAKE CHAMBER,ASSEMBLY....................................................................... 625 54 MAINTENANCE STANDARD...................................................................................... 627 MAINTENANCE STANDARD..................................................................................... 628 AIR GOVERNOR......................................................................................... 629 BRAKE CHAMBER........................................................................................ 630 SLACK ADJUSTER....................................................................................... 631 HYDRAULIC CONTROL................................................................................................ 633 61 STRUCTURE AND FUNCTION.................................................................................... 633 STRUCTURE AND FUNCTION................................................................................... 634 HYDRAULIC CIRCUIT FOR STEERING CYLINDERS,HOIST CYLINDERS AND DEMAND VLAVE(SERIAL NO.:1002-1100)...... 635 STEERING,HOIST AND BRAKE COOLING CIRCUIT(SERIAL NO.:1002-1100)....................................... 636 HYDRAULIC PIPING(HOIST AND BRAKE COOLING CIRCUIT)(SERIAL NO.:1002-1100).............................. 637 HYDRAULIC PIPING(STEERING CIRCUIT)(SERIAL NO.:1002-1100)............................................. 638 HYDRAULIC CIRCUIT FOR STEERING CYLINDERS,HOIST CYLINDERS AND DEMAND VLAVE(SERIAL NO.:1101 AND UP).... 639 STEERING AND HOIST CIRCUIT(SERIAL NO.:1101 AND UP)................................................... 640 BRAKE COOLING CIRCUIT................................................................................ 641 HYDRAULIC PIPING(STEERING AND HOIST CIRCUIT)(SERIAL NO.:1101 AND UP)................................. 643 HYDRAULIC PIPING(BRAKE COOLING)...................................................................... 644 HOIST VALVE(SERIAL NO.:1002-1100).................................................................... 647 HOIST CONTROL SYSTEM(SERIAL NO.:1002-1100)........................................................... 648 HOIST VALVE(CCV50)................................................................................... 652 HOIST CONTROL SYSTEM(SERIAL NO.:1101 AND UP)......................................................... 656 STEERING VALVE....................................................................................... 660 DEMAND VALVE......................................................................................... 661 STEERING DEMAND VALVE(SDV40)......................................................................... 664 STEERING VALVE(SDV40)................................................................................ 665 DOUBLE SHUTTLE VALVE................................................................................. 668 RELIEF VALVE GROUP................................................................................... 670 HYDRAULIC PUMP(FOR HYDRAULIC SYSTEM)................................................................. 671 HYDRAULIC PUMP(FOR EMERGENCY STEERING)............................................................... 672 HYDRAULIC PUMP(FOR STEERING HOIST AND BRAKE COOLING TRANSMISSION CIRCUIT)............................ 673 HYDRAULIC PUMP SAL020................................................................................ 674 CHECK VALVE FOR STEERING PUMP........................................................................ 675 BRAKE COOLING VALVE(BCV60)........................................................................... 676 SLOW RETURN VALVE.................................................................................... 678 HYDRAULIC TANK(SERIAL NO.:1002-1100)................................................................. 681 HYDRAULIC TANK BRACKET............................................................................... 683 HYDRAULIC TANK(SERIAL NO.:1101 AND UP)............................................................... 685 HOIST CYLINDER....................................................................................... 687 STEERING CYLINDER.................................................................................... 687 62 TESTING AND ADJUSTING..................................................................................... 688 TESTING AND ADJUSTING.................................................................................... 689 OIL QUANTITY AND OIL TEMPERATURE MEASUREMENT......................................................... 690 HYDRAULIC PUMP....................................................................................... 691 DUMP CONTROL AIR CYLINDER............................................................................ 692 TROUBLE SHOOTING..................................................................................... 694 1. HOIST CYLINDER LACKS LIFTING FORCE(LIFTING SPEED)............................................. 695 2. HOIST CYLINDER FAILS TO ACT................................................................... 696 3. EXCESSIVE SPONTANEOUS LOWERING OF DUMP BODY................................................... 697 63 DISASSEMBLY AND ASSEMBLY.................................................................................. 698 DISASSEMBLY AND ASSEMBLY................................................................................. 699 STEERING VALVE,DISMOUNTING AND MOUNTING.............................................................. 700 STEERING DEMAND VALVE,DISMOUNTING AND MOUNTING....................................................... 701 STEERING VALVE,DISASSEMBLY........................................................................... 702 STEERING VALVE,ASSEMBLY.............................................................................. 703 STEERING DEMAND VALVE(SDV40),DISASSEMBLY AND ASSEMBLY................................................ 706 STEERING CYLINDER,DISMOUNTING........................................................................ 708 STEERING CYLINDER,MOUNTING........................................................................... 709 STEERING CYLINDER,DISASSEMBLY........................................................................ 710 STEERING CYLINDER,ASSEMBLY........................................................................... 714 DEMAND VALVE,DISMOUNTING AND MOUNTING................................................................ 716 HOIST VALVE,DISMOUNTING AND MOUNTING(SERIAL NO.:1002-1100)........................................... 717 HOIST VALVE,DISASSEMBLY(SERIAL NO.:1002-1100)........................................................ 718 HOIST VALVE,ASSEMBLY(SERIAL NO.:1002-1100)........................................................... 720 HOIST VALVE,DISMOUNTING AND MOUNTING(SERIAL NO.:1101 AND UP)......................................... 723 HOIST VALVE(CCV50),DISASSEMBLY AND ASSEMBLY(SERIAL NO.:1101 AND UP).................................. 724 HOIST CYLINDER,DISMOUNTING AND MOUNTING.............................................................. 726 HOIST CYLINDER,DISASSEMBLY........................................................................... 728 HOIST CYLINDER,ASSEMBLY.............................................................................. 731 HYDRAULIC PUMP(LEFT AND RIGHT),DISMOUNTING AND MOUNTING.............................................. 741 64 MAINTENANCE STANDARD...................................................................................... 742 MAINTENANCE STANDARD..................................................................................... 743 HYDRAULIC PUMP(FOR STEERING AND HOIST)............................................................... 744 HYDRAULIC PUMP(FOR DIFFERENTIAL LOCK)................................................................ 745 TRANSMISSION PUMP.................................................................................... 746 HOIST VALVE.......................................................................................... 747 HOIST VALVE(CCV50)................................................................................... 749 STEERING VALVE....................................................................................... 751 DEMAND VALVE......................................................................................... 755 RELIEF VALVE......................................................................................... 756 HOIST CYLINDER....................................................................................... 757 STEERING CYLINDER.................................................................................... 758 HYDRAULIC FILTER..................................................................................... 759 BRAKE COOLING VALVE(BCV60)........................................................................... 760 WORK EQUIPMENT................................................................................................... 761 71 STRUCTURE AND FUNCTION.................................................................................... 761 STRUCTURE AND FUNCTION................................................................................... 762 MAIN FRAME AND DUMP BODY............................................................................. 763 72 TESTING AND ADJUSTING..................................................................................... 764 TESTING AND ADJUSTING.................................................................................... 765 STANDARD VALUE FOR TESTING AND ADJUSTING............................................................. 766 OIL PRESSURE MEASUREMENT............................................................................. 767 DUMP BODY............................................................................................ 768 73 DISASSEMBLY AND ASSEMBLY.................................................................................. 769 DISASSEMBLY AND ASSEMBLY................................................................................. 770 DUMP BODY,DISMOUNTING................................................................................ 771 DUMP BODY,MOUNTING................................................................................... 772 74 MAINTENANCE STANDARD...................................................................................... 773 MAINTENANCE STANDARD..................................................................................... 774 MAIN FRAME........................................................................................... 775 DUMP BODY............................................................................................ 776 REPAIR OF DUMP BODY BY WELDING....................................................................... 777 OTHERS........................................................................................................... 779 91 ELECTRICAL SYSTEM......................................................................................... 779 ELECTRICAL SYSTEM........................................................................................ 780 ELECTRICAL CIRCUIT DIAGRAM(SERIAL NO.:1002-1100)..................................................... 781 ELECTRICAL PARTS ARRANGEMENT DRAWING(SERIAL NO.:1002-1100)........................................... 782 ELECTRICAL CIRCUIT DIAGRAM(SERIAL NO.:1101-1131)..................................................... 783 ELECTRICAL PARTS ARRANGEMENT DRAWING(SERIAL NO.:1101 AND UP)......................................... 784 WARNING DEVICE....................................................................................... 788 WARNING DEVICE WIRING DIAGRAM........................................................................ 789 AUTOMATIC SHIFT CONTROL(SERIAL NO.:1002-1100)........................................................ 791 AUTOMATIC SHIFT CONTROLLER CHECKING(SERIAL NO.:1002-1100)............................................ 797 AUTOMATIC SHIFT CONTROL SYSTEM(SERIAL NO.:1101-1131)................................................. 817 TOOL FOR TROUBLESHOOTING OF AUTOMATIC CONTROLLER..................................................... 827 TROUBLESHOOTING OF AUTOMATIC SHIFT CONTROL SYSTEM.................................................... 837 METHOD OF DETECTING INPUT SIGNAL OF SHIFT CONTROLLER................................................. 857 AUTOMATIC SHIFT CONTROL SYSTEM(SERIAL NO.:1132 AND UP)............................................... 859 TROUBLESHOOTING...................................................................................... 871 TROUBLESHOOTING PROCEDURE........................................................................ 872 CHECKS BEFORE TROUBLESHOOTING.................................................................... 873 JUDGEMENT TABLE.................................................................................. 875 LOCATION OF CONNECTORS........................................................................... 883 ELECTRICAL CIRCUIT DIAGRAM FOR AUTOMATIC SHIFT CONTROL SYSTEM.................................... 884 CONNECTION TABLE FOR CONNECTOR PINS.............................................................. 886 TROUBLESHOOTING CHART(E1 TO E-11,H-1 TO H-9)..................................................... 892 E-1: ENGINE DOES NOT START................................................................... 893 E-2: ENGINE DOES NOT START................................................................... 902 E-3: MACHINE DOES NOT START.................................................................. 904 E-4: ABNORMALITY IN OPERATION OF MACHINE WHEN STARTING....................................... 917 E-5: GEAR SHIFT ABNORMALITY.................................................................. 917 E-6: ABNORMALITY IN MACHINE MOVEMENT WHEN TRAVELING.......................................... 918 E-7: TRANSMISSION SUDDENLY RETURNS TO NEUTRAL WHEN TRAVELING................................. 926 E-8: LONG TIME TAKEN TO SHIFT UP............................................................. 936 E-9: SKIP SHIFT ACTION IS ABNORMAL........................................................... 943 E-10: KICK-DOWN OPERATES ABNORMALLY.......................................................... 949 E-11: ABNORMALITY IN MACHINE MOVEMENT WHEN RETARDED IS OPERATED.............................. 953 H-1: MACHINE FAILS TO START.................................................................. 954 H-2: MACHINE DOES NOT TRAVEL SMOOTHLY........................................................ 955 H-3: CAN NOT DISENGAGE LOCK-UP CLUTCH(ENGINE STALL).......................................... 955 H-4: LARGE SHOCK WHEN STARTING OF SHIFTING................................................... 956 H-5: DOES NOT SHIFT UP OR SHIFT UP SPEED IS HIGH............................................. 956 H-6: MACHINE LACKS TRAVEL SPEED OR TRACTION FORCE............................................ 957 H-7: LARGE TIME LAG WHEN STARTING OR SHIFTING................................................ 961 H-8: OIL TEMPERATURE OF TORQUE CONVERTER IS TOO HIGH......................................... 962 H-9: TORQUE CONVERTER OIL PRESSURE IS LOW.................................................... 963 EMERGENCY STEERING................................................................................... 964 TAIL GATE............................................................................................ 966 FIRE EXTINGUISHERS................................................................................... 968 PAYLOAD METER(IF EQUIPPED)........................................................................... 978 STRUCTURE AND FUNCTION........................................................................... 979 STRUCTURE.................................................................................... 980 PRINCIPLE OF MEASUREMENT..................................................................... 981 CHARACTERISTICS OF COMPONENT................................................................. 983 FUNCTION OF PAYLOAD METER(PLM)............................................................... 986 FUNCTION OF PAYLOAD PRINTER(PLP)............................................................. 991 FORCED CHANGE IN DISPLAY LOAD................................................................ 996 TROUBLESHOOTING.................................................................................. 997 CHECK BEFORE TROUBLESHOOTING................................................................. 998 PRECAUTIONS BEFORE STARTING TROUBLESHOOTING.................................................. 999 METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART............................................1000 PRECAUTION WHEN HANDLING CONNECTOR...........................................................1001 CONNECTOR TERMINAL NUMBERS...................................................................1003 CIRCUIT DIAGRAM..............................................................................1007 LOCATION OF PARTS AND CONNECTOR NUMBERS......................................................1008 TROUBLESHOOTING..............................................................................1009 P-1 NO DISPLAY GIVEN WHEN STARTING SWITCH IS TURNED ON...................................1010 P-2 AFTER POWER SOURCE IS RESET,CALIBRATION DEMAND(CAL FLASHING)STAYS ON.................1011 P-3 CALIBRATION CANNOT BE CARRIED OUT....................................................1012 P-4 WHEN POWER SOURCE IS RESET,NOT ALL EXTERNAL DISPLAY LAMPS LIGHT UP...................1013 a) WHEN POWER SOURCE IS RESET,NOT ALL PLM CONTROLLER DISPLAY LAMPS LIGHT UP..........1013 b) WHEN POWER SOURCE IS RESET,ALL PLM CONTROLLER DISPLAY LAMPS LIGHT UP..............1013 c) FUSE OF EXTERNAL DISPLAY LAMP BROKEN..............................................1013 P-5 IT IS NOT CONDITION FOR LAMPS TO LIGHT UP,BUT EXTERNAL DISPLAY LAMPS LIGHT UP........1014 P-6 LEVEL OF LIGHT UP OF EXTERNAL DISPLAY LAMPS IS NOT CORRECT...........................1015 P-7 ABNORMALITY IN DISPLAY LOGIC.........................................................1016 a) DISPLAY DOES NOT SHOW O TO WHEN DUMP BODY IS OPERATED.............................1016 b) DISPLAY STAYS AT O TON AND DOES NOT CHANGE........................................1017 c) DISPLAY CHANGES WHEN MACHINE IS TRAVELING(PARKING RELEASED).......................1018 d) DISPLAY DOES NOT CHANGE WHEN TRUCK IS LOADED......................................1019 P-8 DISPLAY SHOWS E01-E08................................................................1020 P-9 DISPLAY SHOWS E11-E18................................................................1021 P-10 SENSOR CHECK GIVES DISPLAY OF E21-E28...............................................1021 P-11 DISPLAY SHOWS E31...................................................................1022 P-12 DISPLAY SHOWS E32...................................................................1024 P-13 DISPLAY SHOWS E41...................................................................1025 P-14 DISPLAY SHOWS E42...................................................................1026 P-15 PAYLOAD PRINTER GIVES NO DISPLAY....................................................1027 P-16 PAYLOAD PRINTER CLOCK IS WRONG......................................................1028 P-17 PAYLOAD PRINTER DOES NOT PRINT......................................................1029 P-18 PAYLOAD PRINTER PAPER IS STUCK......................................................1030 HD1200M-1 SHOP MANUAL INDEX......................................................................................1031 PROPOSAL FOR MANUAL REVISION.....................................................................................1037
DESCRIPTION:
KOMATSU HD1200M-1 SHOP MANUAL SEBM0562A09 – PDF DOWNLOAD
Introduction
This shop manual has been prepared as an aid to improve the quality of repairs by providing servicemen with an accurate understanding of the product and guidance on performing repairs and making informed judgments. Ensure you understand the contents of this manual and use it effectively at every available opportunity.
This shop manual has been prepared as an aid to improve the quality of repairs by providing servicemen with an accurate understanding of the product and guidance on performing repairs and making informed judgments. Ensure you understand the contents of this manual and use it effectively at every available opportunity.
Organization
This shop manual primarily contains the essential technical information required for operations performed in a service workshop.
This shop manual primarily contains the essential technical information required for operations performed in a service workshop.
For ease of understanding, the manual is divided into chapters covering the main groups of components. These chapters are further divided into the following sections:
1. Structure and Function
This section explains the structure and function of each component. It aims not only to provide an understanding of the structure but also serves as reference material for troubleshooting.
2. Testing and Adjusting
This section explains the checks to be made before and after performing repairs, as well as adjustments to be made upon completion of these checks and repairs. Troubleshooting charts correlating “Diagnoses” to “Causes” are also included in this section.
3. Disassembly and Assembly
This section outlines the procedures to follow when removing, installing, disassembling, or assembling each component. It also highlights the precautions to be taken during these operations.
4. Maintenance Standards
This section provides judgment standards for inspecting disassembled parts.
S.S 29/12/24
