Complete service repair manual with Electrical Wiring Diagrams for Komatsu Articulated Dump Truck HM300-2R, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Articulated Dump Truck HM300-2R 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: 2,023 pages
File Format: PDF
Language: English
SEN02269-06 – Articulated Dump Truck HM300-2R Shop Manual.pdf
GEN00091-00 – Articulated Dump Truck HM300-2R Field Assembly Instruction.pdf
PEN00193-09 – Articulated Dump Truck HM300-2R Operation & Maintenance Manual.pdf
PEN00470-11 – Articulated Dump Truck HM300-2R Operation & Maintenance Manual.pdf
MAIN SECTIONS
GEN00091-00 – Articulated Dump Truck HM300-2R Field Assembly Instruction…2
COVER…2
Contents…3
1 Drawings of removed units…5
2 Dimensions of removed units…5
3 Assembly procedure, necessary equipments, and schedule…6
4 Necessary tools and equipments…6
5 Assembly procedure No…7
0100 Positioning bare machine…7
0150 Installation of rear monitor…8
0200 Installing engine hood mirrors…9
0250 Installation of right and left mudguards…10
0300 Adjusting N2 gas of front and rear suspensions…11
Attached sheet: Mirror adjustment for reference…12
PEN00193-09 – Articulated Dump Truck HM300-2R Operation & Maintenance Manual…15
COVER…15
FOREWORD…16
BEFORE READING THIS MANUAL…17
SAFETY INFORMATION…18
INTENDED USE…19
USE OF MACHINE…19
DIRECTIONS OF MACHINE…19
VISIBILITY FROM OPERATOR'S SEAT…19
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…20
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…20
ENGINE SERIAL NO. PLATE…20
SERVICE METER POSITION…21
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…21
CONTENTS…22
SAFETY…26
SAFETY…27
SAFETY LABELS…30
POSITION FOR ATTACHING SAFETY LABELS…31
SAFETY LABELS…32
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…38
PRECAUTIONS BEFORE STARTING OPERATION…38
PREPARATIONS FOR SAFE OPERATION…38
FIRE PREVENTION…40
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…41
DO NOT GET CAUGHT IN ARTICULATING PORTION AND DUMP BODY…43
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…43
UNAUTHORIZED MODIFICATION…43
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…44
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…44
PRECAUTIONS FOR OPERATION…45
PRECAUTIONS FOR JOBSITE…45
STARTING ENGINE…47
OPERATION…50
TRANSPORTATION…54
TOWING…55
PRECAUTIONS FOR MAINTENANCE…56
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…56
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…61
TIRES…66
OPERATION…68
GENERAL VIEW…69
GENERAL VIEW OF MACHINE…69
GENERAL VIEW OF CONTROLS AND GAUGES…70
EXPLANATION OF COMPONENTS…72
MACHINE MONITOR…72
OTHER FUNCTIONS OF MACHINE MONITOR…93
SWITCHES…97
CONTROL LEVERS AND PEDALS…107
BODY PIVOT PIN…112
ARTICULATE LOCK…112
LOCATION OF FIRE EXTINGUISHER…113
DUST INDICATOR…113
CIRCUIT BREAKER…113
FUSES…114
CAR RADIO…117
CAR STEREO…123
AIR CONDITIONER…131
OPERATION…136
CHECK BEFORE STARTING ENGINE…136
STARTING ENGINE…153
OPERATIONS, CHECKS AFTER STARTING ENGINE…155
STOPPING ENGINE…156
CHECKS AFTER STOPPING ENGINE…156
MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING…157
SHIFTING GEAR…162
TRAVELING DOWNHILL…164
STEERING THE MACHINE…170
OPERATION USING DIFFERENTIAL LOCK…171
LOADING OPERATIONS…172
DUMP OPERATIONS…174
CAB TILT OPERATION…176
PRECAUTIONS FOR OPERATION…179
PARKING MACHINE…180
CHECKS AFTER COMPLETION OF WORK…181
LOCKING…181
HANDLING TIRES…182
DETERMINING AND MAINTAINING TRAVEL ROAD…183
DETERMINING TRAVEL ROAD…183
MAINTAINING TRAVEL ROAD…183
TRANSPORTATION…184
PRECAUTIONS WHEN TRANSPORTING…184
STEPS FOR TRANSPORTATION…184
METHOD OF SECURING MACHINE…185
METHOD OF LIFTING MACHINE…186
COLD WEATHER OPERATION…190
PRECAUTIONS FOR LOW TEMPERATURE…190
PRECAUTIONS AFTER COMPLETION OF WORK…191
AFTER COLD WEATHER…192
LONG-TERM STORAGE…193
BEFORE STORAGE…193
DURING STORAGE…193
AFTER STORAGE…193
PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE…193
TROUBLESHOOTING…194
AFTER RUNNING OUT OF FUEL…194
IF TRANSMISSION HAS TROUBLE…194
METHOD OF LOWERING DUMP BODY IN EMERGENCY…194
METHOD OF TOWING MACHINE…195
IF BATTERY IS DISCHARGED…199
OTHER TROUBLE…203
MAINTENANCE…210
GUIDES TO MAINTENANCE…211
OUTLINE OF SERVICE…213
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…213
OUTLINE OF ELECTRIC SYSTEM…217
WEAR PARTS…218
WEAR PARTS LIST…218
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…219
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…220
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…221
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…222
TORQUE LIST…222
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…224
SAFETY CRITICAL PARTS…225
MAINTENANCE SCHEDULE CHART…226
MAINTENANCE SCHEDULE CHART…226
SERVICE PROCEDURE…229
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…229
WHEN REQUIRED…230
CHECK BEFORE STARTING…254
EVERY 50 HOURS SERVICE…255
EVERY 250 HOURS SERVICE…256
EVERY 500 HOURS SERVICE…267
EVERY 1000 HOURS SERVICE…274
EVERY 2000 HOURS SERVICE…284
EVERY 4000 HOURS SERVICE…291
EVERY 6000 HOURS SERVICE…294
EVERY 8000 HOURS SERVICE…295
SPECIFICATIONS…296
SPECIFICATIONS…297
ATTACHMENTS, OPTIONS…298
HANDLING AUTOMATIC RETARDER, ACCELERATOR CONTROL(ARAC)…299
EXPLANATION OF COMPONENTS…299
METHOD OF OPERATION…300
HANDLING PAYLOAD METER HM…301
FEATURES OF PAYLOAD METER HM…301
METHOD OF USING ACCURATELY…302
GENERAL LOCATIONS…304
CONTENT OF DISPLAY (CONTROLLER, EXTERNAL DISPLAY LAMPS)…307
EXTERNAL DISPLAY LAMPS…309
DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER…311
OPERATION OF SWITCHES…314
ABNORMALITY AND WARNING DISPLAY (ERROR CODE)…327
WHEN ERROR CODE F-09 IS DISPLAYED…328
PROCEDURE WHEN DOWNLOADING…329
OTHERS…332
USE OF REAR VIEW MONITOR…333
NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR…333
SETTING OF REAR VIEW MONITOR…336
CAUTIONS WHEN USING REAR VIEW MONITOR…336
HANDLING DUMPING COUNTER…337
HANDLING BATTERY DISCONNECTOR SWITCH…338
HANDLING MACHINES EQUIPPED WITH KOMTRAX…340
BASIC PRECAUTIONS…340
INDEX…342
PEN00470-11 – Articulated Dump Truck HM300-2R Operation & Maintenance Manual…346
COVER…346
FOREWORD…347
BEFORE READING THIS MANUAL…348
SAFETY INFORMATION…349
INTENDED USE…350
USE OF MACHINE…350
DIRECTIONS OF MACHINE…350
VISIBILITY FROM OPERATOR'S SEAT…351
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…352
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…352
ENGINE SERIAL NO. PLATE…352
SERVICE METER POSITION…353
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…353
CONTENTS…354
SAFETY…359
SAFETY…360
SAFETY LABELS…363
POSITION FOR ATTACHING SAFETY LABELS…364
SAFETY LABELS…365
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…372
PREPARATIONS FOR SAFE OPERATION…372
EPARATIONS FOR SAFE OPERATION…372
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…375
DO NOT GET CAUGHT IN ARTICULATING PORTION AND DUMP BODY…377
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…377
UNAUTHORIZED MODIFICATION…377
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…378
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…378
PRECAUTIONS FOR OPERATION…379
PRECAUTIONS FOR JOBSITE…379
STARTING ENGINE…381
OPERATION…384
TRANSPORTATION…388
TOWING…389
PRECAUTIONS FOR MAINTENANCE…390
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…390
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…395
TIRES…400
OPERATION…403
GENERAL VIEW…404
GENERAL VIEW OF MACHINE…404
GENERAL VIEW OF CONTROLS AND GAUGES…405
EXPLANATION OF COMPONENTS…407
MACHINE MONITOR…407
OTHER FUNCTIONS OF MACHINE MONITOR…428
SWITCHES…432
CONTROL LEVERS AND PEDALS…443
BODY PIVOT PIN…448
ARTICULATE LOCK…448
LOCATION OF FIRE EXTINGUISHER…449
DUST INDICATOR…449
CIRCUIT BREAKER…449
FUSES…450
CAR RADIO…453
CAR STEREO…459
AIR CONDITIONER…467
OPERATION…472
CHECK BEFORE STARTING ENGINE…472
STARTING ENGINE…490
OPERATIONS, CHECKS AFTER STARTING ENGINE…492
CANCELING DUMP BODY HOLD CONDITION…493
MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING…494
SHIFTING GEAR…499
TRAVELING DOWNHILL…501
STEERING THE MACHINE…507
OPERATION USING DIFFERENTIAL LOCK…508
LOADING OPERATIONS…509
DUMP OPERATIONS…511
CAB TILT OPERATION…513
PRECAUTIONS FOR OPERATION…516
PARKING MACHINE…517
CHECKS AFTER COMPLETION OF WORK…518
LOCKING…518
HANDLING TIRES…519
DETERMINING AND MAINTAINING TRAVEL ROAD…520
DETERMINING TRAVEL ROAD…520
MAINTAINING TRAVEL ROAD…520
TRANSPORTATION…521
PRECAUTIONS WHEN TRANSPORTING…521
STEPS FOR TRANSPORTATION…521
METHOD OF SECURING MACHINE…522
METHOD OF LIFTING MACHINE…523
COLD WEATHER OPERATION…527
PRECAUTIONS FOR LOW TEMPERATURE…527
PRECAUTIONS AFTER COMPLETION OF WORK…528
AFTER COLD WEATHER…529
LONG-TERM STORAGE…530
BEFORE STORAGE…530
DURING STORAGE…530
AFTER STORAGE…530
PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE…530
TROUBLESHOOTING…531
AFTER RUNNING OUT OF FUEL…531
IF TRANSMISSION HAS TROUBLE…532
METHOD OF LOWERING DUMP BODY IN EMERGENCY…532
METHOD OF TOWING MACHINE…533
IF BATTERY IS DISCHARGED…537
OTHER TROUBLE…541
MAINTENANCE…547
GUIDES TO MAINTENANCE…548
OUTLINE OF SERVICE…550
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…550
OUTLINE OF ELECTRIC SYSTEM…554
WEAR PARTS…555
WEAR PARTS LIST…555
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…556
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…557
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…559
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…560
TORQUE LIST…560
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…562
SAFETY CRITICAL PARTS…563
MAINTENANCE SCHEDULE CHART…564
MAINTENANCE SCHEDULE CHART…564
SERVICE PROCEDURE…567
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…567
WHEN REQUIRED…568
CHECK BEFORE STARTING…590
EVERY 50 HOURS SERVICE…591
EVERY 250 HOURS SERVICE…592
EVERY 500 HOURS SERVICE…603
EVERY 1000 HOURS SERVICE…610
EVERY 2000 HOURS SERVICE…628
EVERY 4000 HOURS SERVICE…635
EVERY 6000 HOURS SERVICE…638
EVERY 8000 HOURS SERVICE…639
SPECIFICATIONS…641
SPECIFICATIONS…642
ATTACHMENTS, OPTIONS…645
HANDLING AUTOMATIC RETARDER, ACCELERATOR CONTROL(ARAC)…646
EXPLANATION OF COMPONENTS…646
METHOD OF OPERATION…647
HANDLING PAYLOAD METER HM…648
FEATURES OF PAYLOAD METER HM…648
METHOD OF USING ACCURATELY…649
GENERAL LOCATIONS…651
CONTENT OF DISPLAY (CONTROLLER, EXTERNAL DISPLAY LAMPS)…654
EXTERNAL DISPLAY LAMPS…656
DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER…658
OPERATION OF SWITCHES…661
ABNORMALITY AND WARNING DISPLAY (ERROR CODE)…674
WHEN ERROR CODE F-09 IS DISPLAYED…675
PROCEDURE WHEN DOWNLOADING…676
OTHERS…679
USE OF REAR VIEW MONITOR…680
NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR…680
SETTING OF REAR VIEW MONITOR…683
CAUTIONS WHEN USING REAR VIEW MONITOR…683
HANDLING DUMPING COUNTER…684
HANDLING BATTERY DISCONNECTOR SWITCH…685
HANDLING MACHINES EQUIPPED WITH KOMTRAX…687
BASIC PRECAUTIONS…687
INDEX…689
SEN02269-06 – Articulated Dump Truck HM300-2R Shop Manual…693
COVER…693
00 Index and foreword…0
Index…695
Composition of shop manual…696
Table of contents…698
Foreword and general information…709
Safety notice…710
How to read the shop manual…715
Explanation of terms for maintenance standard…717
Handling of electric equipment and hydraulic component…719
Handling of connectors newly used for engines…728
How to read electric wire code…731
Precautions when carrying out operation…734
Method of disassembling and connecting push-pull type coupler…737
Standard tightening torque table…740
Conversion table…744
01 Specification…0
Specification and technical data…751
Specification drawings…752
Specifications…753
Weight table…756
Fuel, coolant and lubricants…757
10 Structure, function and maintenance standard…0
Engine and cooling system…761
Radiator, oil cooler, aftercooler…762
Output shaft…763
Power train, Part 1…767
Power train skeleton…768
Torque converter and transmission hydraulic piping…770
Brake cooling oil control valve (BCV)…772
Power train pump…773
Torque converter…776
Transmission…782
Transmission control valve…810
ECMV…811
Main relief, torque converter relief valve…818
Power train, Part 2…821
Drive shaft…822
Axle…823
Differential…826
Limited slip differential…832
Final drive…836
Steering system…843
Steering column…844
Brake system…847
Brake piping…848
Brake valve…850
Accumulator charge valve…853
Accumulator…857
Slack adjuster…858
Brake…860
Proportional reducing valve…865
Brake system tank…866
Parking brake…868
Parking brake solenoid…872
Undercarriage and frame…875
Suspension…876
Suspension cylinder…882
Oscillation hitch…884
Hydraulic system…889
Steering, hoist oil pressure piping diagram…890
Dump body control…891
Hydraulic tank and filter…892
Flow amp valve…893
Steering valve…896
Steering cylinder…900
Hoist valve…902
EPC valve…908
Hoist cylinder…909
Hydraulic pump…910
Cab and its attachments…913
ROPS cab…914
Cab tilt…915
Air conditioner…916
Rear view monitor…924
Controller related…927
Electrical system, Part 1…929
Machine monitor system…930
Electrical system, Part 2…951
Automatic shift control system…952
Retarder control system…984
Auto emergency steering system…996
Dump control lever…997
Electrical system, Part 3…1003
Payload meter (Card type)…1004
Electrical system, Part 4…1037
Sensors, switches…1038
KOMTRAX terminal system (If equipped)…1046
20 Standard value table…0
Standard service value table…1049
Standard value table for engine…1050
Standard value table for chassis…1051
30 Testing and adjusting…0
Testing and adjusting, Part 1…1059
Tools for testing, adjusting, and troubleshooting…1061
Sketches of special tools…1066
Measuring engine speed…1067
Measuring intake air pressure (boost pressure)…1068
Measuring exhaust temperature…1069
Measuring exhaust gas color…1071
Adjusting valve clearance…1072
Measuring compression pressure…1074
Measuring blow-by pressure…1076
Measuring engine oil pressure…1077
Handling of fuel system devices…1078
Releasing residual pressure from fuel system…1078
Testing fuel pressure…1079
Testing fuel return and leak amount…1080
Bleeding air from fuel circuit…1083
Testing fuel circuit for leakage…1085
Testing and adjusting alternator belt tension…1086
Testing and adjusting air conditioner compressor belt tension…1086
Adjusting the body mount…1087
Testing and adjusting, Part 2…1089
Measuring torque converter stall speed…1091
Measuring power train oil pressure…1092
Adjusting transmission speed sensor…1100
Testing and adjusting brake oil pressure…1102
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas…1106
Testing brake performance…1109
Bleeding air from brake circuit…1110
Measuring wear of wheel brake disc…1111
Measuring wear of parking brake pad…1112
Method for emergency release of parking brake…1114
Testing and adjusting steering circuit oil pressure…1115
Testing and adjusting suspension cylinder…1117
Method of tilting cab up…1121
Testing and adjusting dump circuit oil pressure…1123
Adjusting body positioner sensor…1126
Procedure for adjusting length of spring in body heating spherical joint…1127
Handling engine controller high voltage circuit…1127
Adjusting transmission controller…1128
Method for emergency escape at electrical system failure…1129
Testing and adjusting, Part 3…1135
Setting and adjusting various equipments…1136
Special function of machine monitor (EMMS)…1147
How to start operation of KOMTRAX terminal…1181
Lamp display of KOMTRAX terminal…1184
Pm Clinic check sheet…1187
40 Troubleshooting…0
Failure code table and fuse locations…1191
Failure code table…1192
Before troubleshooting by failure codes…1199
General information on troubleshooting…1203
Points to remember when troubleshooting…1204
Sequence of events in troubleshooting…1205
Checks before troubleshooting…1206
Classification and procedures for troubleshooting…1207
Information in troubleshooting table…1208
Connection table for connector pin numbers…1210
T-branch box and T- branch adapter table…1246
Troubleshooting by failure code (Display of code), Part 1…1251
Failure code [1500L0] (Dual engagement)…1253
Failure code [15B0NX] (Transmission oil filter: Clogged)…1254
Failure code [15F0KM] (R → F shifting abuse 1: Operational error or incorrect setting)…1256
Failure code [15F0MB] (R → F shifting abuse 2: Functional deterioration)…1256
Failure code [15F7KM] (forward clutch disc abuse)…1257
Failure code [15G0MW] (R clutch: Slipping)…1258
Failure code [15G7KM] (reverse clutch disc abuse)…1260
Failure code [15H0MW] (Hi clutch: Slipping)…1261
Failure code [15J0MW] (Lo clutch: Slipping)…1264
Failure code [15K0MW] (1st clutch: Slipping)…1266
Failure code [15L0MW] (2nd clutch: Slipping)…1268
Failure code [15M0MW] (3rd clutch: Slipping)…1270
Failure code [15SBL1] (R clutch solenoid: Fill signal is ON when command current is OFF.)…1272
Failure code [15SBMA] (R clutch solenoid: Malfunction)…1276
Failure code [15SCL1] (Hi clutch solenoid: Fill signal is ON when command current is OFF.)…1278
Failure code [15SCMA] (Hi clutch solenoid: Malfunction)…1282
Failure code [15SDL1] (Lo clutch solenoid: Fill signal is ON when command current is OFF.)…1284
Failure code [15SDMA] (Lo clutch solenoid: Malfunction)…1286
Failure code [15SEL1] (1st clutch solenoid: Fill signal is ON when command current is OFF)…1290
Failure code [15SEMA] (1st clutch solenoid: Malfunction)…1294
Failure code [15SFL1] (2nd clutch solenoid: Fill signal is ON when command current is OFF.)…1296
Failure code [15SFMA] (2nd clutch solenoid: Malfunction)…1300
Failure code [15SGL1] (3rd clutch solenoid: Fill signal is ON when command current is OFF.)…1302
Failure code [15SGMA] (3rd clutch solenoid: Malfunction)…1306
Failure code [15SJMA] (Lockup clutch solenoid: Malfunction)…1308
Failure code [15SKMA] (Inter-axle differential lockup pressure control valve: Malfunction)…1310
Failure code [2F00KM] (Parking brake: Error in operation or setting)…1312
Failure code [2G42ZG] (Front accumulator: Oil pressure too low)…1314
Failure code [2G43ZG] (Rear accumulator: Oil pressure too low)…1314
Troubleshooting by failure code (Display of code), Part 2…1317
Failure code [989A00] (Engine over run prevention command signal: Operating)…1319
Failure code [989D00] (Rear section tipping over alarm: Alarm is activated.)…1319
Failure code [AA10NX] (Air cleaner element: Clogged)…1320
Failure code [AB00MA] (Alternator: Malfunction)…1322
Failure code [B@BAZK] (Engine oil : Level too low)…1323
Failure code [B@BCNS] (Eng overheat)…1324
Failure code [B@BCZK] (Radiator coolant: Level too low)…1325
Failure code [B@BFZK] (Fuel level: Level too low)…1326
Failure code [B@C6NS] (Front brake oil: Overheat)…1327
Failure code [B@C8NS] (Center brake oil: Overheat)…1327
Failure code [B@CENS] (Torque converter: Overheat)…1328
Failure code [B@HAZK] (Hydraulic tank oil: Level too low)…1329
Failure code [B@JANS] (Steering oil: Overheat)…1330
Failure code [CA111] (Abnormality in engine controller)…1331
Failure code [CA115] (Abnormal engine Ne and Bkup sensors)…1332
Failure code [CA122] (Charge pressure sensor too high)…1334
Failure code [CA123] (Charge pressure sensor too low)…1336
Failure code [CA131] (Throttle sensor tool high)…1338
Failure code [CA132] (Throttle sensor tool low)…1340
Failure code [CA135] (Oil pressure sensor too high)…1342
Failure code [CA141] (Oil pressure sensor too low)…1344
Failure code [CA144] (Coolant temperature sensor too high)…1346
Failure code [CA145] (Coolant temperature sensor too low)…1348
Failure code [CA153] (Charge temperature sensor too high)…1350
Failure code [CA154] (Charge temperature sensor too low)…1352
Failure code [CA187] (Sensor power source 2 too low)…1352
Failure code [CA221] (Atmospheric sensor too high)…1354
Failure code [CA222] (Atmospheric sensor too low)…1356
Failure code [CA227] (Sensor power source 2 too high)…1358
Failure code [CA234] (Engine over speed)…1360
Failure code [CA238] (Abnormal power source for Ne speed sensor)…1362
Failure code [CA263] (Fuel temperature sensor too high)…1364
Failure code [CA265] (Fuel temperature sensor too low)…1366
Failure code [CA271] (PCV1 short circuit)…1367
Failure code [CA272] (PCV1 disconnection)…1368
Failure code [CA273] (PCV2 short circuit)…1369
Failure code [CA274] (PCV2 disconnection)…1370
Failure code [CA322] (Injector No. 1 system disconnection or short circuit)…1372
Failure code [CA323] (Injector No. 5 system disconnection or short circuit)…1374
Failure code [CA324] (Injector No. 3 system disconnection or short circuit)…1376
Failure code [CA325] (Injector No. 6 system disconnection or short circuit)…1378
Failure code [CA331] (Injector No. 2 system disconnection or short circuit)…1380
Failure code [CA332] (Injector No. 4 system disconnection or short circuit)…1382
Troubleshooting by failure code (Display of code), Part 3…1385
Failure code [CA342] (Abnormal engine controller data consistency)…1387
Failure code [CA351] (Abnormal injector drive circuit)…1388
Failure code [CA352] (Sensor power source 1 too low)…1389
Failure code [CA386] (Sensor power source 1 too high)…1390
Failure code [CA431] Idle validation switch error…1392
Failure code [CA432] (Abnormal process with idle validation switch)…1396
Failure code [CA441] (Power source voltage too low)…1397
Failure code [CA442] (Power source voltage too high)…1397
Failure code [CA449] (Common rail pressure too high 2)…1398
Failure code [CA451] (Common rail pressure sensor too high)…1400
Failure code [CA452] (Common rail pressure sensor too low)…1402
Failure code [CA553] (Common rail pressure too high 1)…1402
Failure code [CA554] (In-range error of common rail pressure sensor)…1403
Failure code [CA559] (Loss of pressure feed from supply pump 1)…1404
Failure code [CA689] (Abnormal engine Ne speed sensor)…1408
Failure code [CA731] (Abnormal engine Bkup speed sensor phase)…1410
Failure code [CA757] (Loss of all engine controller data)…1410
Failure code [CA778] (Abnormal engine Bkup speed sensor)…1412
Failure code [CA1633] (Abnormal KOMNET)…1414
Failure code [CA2185] (Throttle sensor power source too high)…1416
Failure code [CA2186] (Throttle sensor power source too low)…1418
Failure code [CA2249] (Loss of pressure feed from supply pump 2)…1418
Failure code [CA2555] (Disconnection in intake air heater relay)…1419
Failure code [CA2556] (Intake air heater relay short circuit)…1420
Failure code [DAF9KM] (Machine monitor connector: Error in operation or setting)…1422
Failure code [DAFRKR] (Abnormal CAN communication (machine monitor): Abnormal communication)…1424
Failure code [DAQ0KK] (Transmission controller: Power source voltage too low)…1426
Failure code [DAQ0KT] (Transmission nonvolatile memory: Abnormality in controller)…1428
Failure code [DAQ2KK] (Transmission controller solenoid power source: Voltage too low)…1429
Failure code [DAQRKR] (COMMUNICATION LOST: Defective communication)…1430
Failure code [DAQRMA] (Transmission controller option setting: Malfunction)…1432
Failure code [DB10KT] (Retarder controller nonvolatile memory: Abnormality in controller)…1432
Failure code [DB12KK] (Retarder controller solenoid power source: Power source voltage too low)…1433
Failure code [DB13KK] (Retarder controller battery direct power source: Power source voltage too low)…1434
Failure code [DB19KQ] (Retarder controller model select signal: Inconsistent model selection signal)…1435
Failure code [DB1QMA] (Retarder controller option setting: Malfunction)…1435
Failure code [DB1RKR] (CAN communication (retarder controller): Communication disabled)…1436
Failure code [DB2RKR] (CAN communication (engine controller): Communication disabled)…1438
Failure code [DDTHKA] (Fill switch for Hi clutch: Disconnection)…1440
Failure code [DDTJKA] (Fill switch for Lo clutch: Disconnection)…1442
Failure code [DDTKKA] (Fill switch for 1st clutch: Disconnection)…1444
Failure code [DDTLKA] (Fill switch for 2nd clutch: Disconnection)…1445
Failure code [DDTMKA] (Fill switch for 3rd clutch: Disconnection)…1446
Failure code [DDTNKA] (Fill switch for R clutch: Disconnection)…1447
Failure code [DF10KA] (Gear shift lever: Disconnection)…1448
Failure code [DF10KB] (Gear shift lever: Short circuit)…1451
Troubleshooting by failure code (Display of code), Part 4…1455
Failure code [DGF1KX] (Transmission oil temperature sensor: Input signal out of range)…1458
Failure code [DGR3KZ] (Center brake oil temperature sensor: Disconnection or short circuit)…1460
Failure code [DGR3L8] (Center brake oil temperature sensor: Inconsistent analog signals)…1462
Failure code [DGR4KZ] (Front brake oil temperature sensor: Disconnection or short circuit)…1464
Failure code [DGR4L8] (Front brake oil temperature sensor: Inconsistent analog signals)…1466
Failure code [DGR6KX] (Steering oil temperature sensor: Input signal out of range)…1468
Failure code [DGT1KX] (Torque converter oil temperature sensor: Input signal out of range)…1470
Failure code [DHT5KX] (Torque converter oil pressure sensor: Input signal out of range)…1472
Failure code [DHT5L6] (Torque converter oil pressure sensor: Inconsistent signals during a travel and stop)…1474
Failure code [DHU2KX] (Front accumulator oil pressure sensor: Input signal out of range)…1476
Failure code [DHU3KX] (Rear accumulator oil pressure sensor: Input signal out of range)…1478
Failure code [DJF1KA] (Fuel level sensor: Disconnection)…1480
Failure code [DK51L5] (Retarder lever potentiometer: Potentiometer signal is inconsistent with switch signal)…1482
Failure code [DK52KX] (Dump lever potentiometer failure 1: Input signal out of range)…1484
Failure code [DK53L8] (Dump lever potentiometer failure 2: Inconsistent analog signal)…1486
Failure code [DK54KX] (Body positioner sensor: Input signal out of range)…1488
Failure code [DKH0KX] (Inclination sensor: Inclination out of range)…1490
Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection)…1492
Failure code [DLF1LC] (Transmission input shaft speed sensor: Inconsistent rotation speed signal)…1493
Failure code [DLF2KA] (Transmission intermediate shaft speed sensor: Disconnection)…1494
Failure code [DLF2LC] (Transmission intermediate shaft speed sensor: Inconsistent speed signal)…1495
Failure code [DLF4KA] (Differential speed sensor: Disconnection)…1496
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)…1497
Failure code [DV00KB] (Alarm buzzer output: Short circuit)…1498
Failure code [DW72KZ] (Kick-out solenoid output system: Disconnection or short circuit)…1500
Failure code [DW73KZ] (Hoist selector valve output system: Disconnection or short circuit)…1502
Failure code [DW78KZ] (Rear brake BCV command output system: Disconnection or short circuit)…1504
Failure code [DW79KZ] (Front brake BCV command output system: Disconnection or short circuit)…1506
Failure code [DX11K4] Trouble in rear wheel proportional solenoid pressure reducing valve 1…1508
Failure code [DX11KA] (Rear brake proportional pressure reducing solenoid valve output circuit: Disconnection)…1510
Failure code [DX11KB] (Rear brake proportional pressure reducing solenoid valve: Short circuit)…1511
Failure code [DX11KY] (Rear brake proportional pressure reducing solenoid valve: Short circuit to power source line)…1512
Failure code [DX11MA] (Rear brake proportional pressure reducing solenoid valve: Malfunction)…1514
Failure code [DX12K4] (Front brake proportional pressure reducing solenoid valve: Out of control)…1516
Failure code [DX12KA] (Front brake proportional pressure reducing solenoid valve output circuit: Disconnection)…1518
Failure code [DX12KB] (Front brake proportional pressure reducing solenoid valve: Short circuit)…1519
Troubleshooting by failure code (Display of code), Part 5…1521
Failure code [DX12KY] (Front brake proportional pressure reducing solenoid valve: Short circuit to power source line)…1523
Failure code [DX12MA] (Front brake proportional pressure reducing solenoid valve: Malfunction)…1524
Failure code [DX13KA] (Hoist EPC valve output circuit: Disconnection)…1526
Failure code [DX13KB] (Hoist EPC valve output circuit: Short circuit)…1527
Failure code [DX13KY] (Hoist EPC valve output circuit: Short circuit in power source line)…1528
Failure code [DXH0KA] (Inter-axle differential lock pressure control valve: Disconnection)…1529
Failure code [DXH0KB] (Inter-axle differential lock pressure control valve: Short circuit)…1530
Failure code [DXH0KY] (Inter-axle differential lockup pressure control valve: Short circuit to power source line)…1531
Failure code [DXH1KA] (Lockup clutch solenoid output circuit: Disconnection)…1532
Failure code [DXH1KB] (Lockup clutch solenoid output circuit: Short circuit)…1533
Failure code [DXH1KY] (Lockup clutch solenoid output circuit: Short circuit to power source line)…1534
Failure code [DXH2KA] (Hi clutch solenoid output circuit: Disconnection)…1536
Failure code [DXH2KB] (Hi clutch solenoid output circuit: Short circuit)…1538
Failure code [DXH2KY] (Hi clutch solenoid output circuit: Short circuit to power source line)…1540
Failure code [DXH3KA] (Lo clutch solenoid output circuit: Disconnection)…1544
Failure code [DXH3KB] (Lo clutch solenoid output circuit: Short circuit)…1546
Failure code [DXH3KY] (Lo clutch solenoid output circuit: Short circuit in power source line)…1548
Failure code [DXH4KA] (1st clutch solenoid output circuit: Disconnection)…1552
Failure code [DXH4KB] (1st clutch solenoid output circuit: Short circuit)…1554
Failure code [DXH4KY] (1st clutch solenoid output circuit: Short circuit to power source line)…1556
Failure code [DXH5KA] (2nd clutch solenoid output circuit: Disconnection)…1560
Failure code [DXH5KB] (2nd clutch solenoid output circuit: Short circuit)…1562
Failure code [DXH5KY] (2nd clutch solenoid output circuit: Short circuit in power source line)…1564
Failure code [DXH6KA] (3rd clutch solenoid output circuit: Disconnection)…1568
Failure code [DXH6KB] (3rd clutch solenoid output circuit: Short circuit)…1570
Failure code [DXH6KY] (3rd clutch solenoid output circuit: Short circuit to power source line)…1572
Failure code [DXH7KA] (R clutch solenoid output circuit: Disconnection)…1576
Failure code [DXH7KB] (R clutch solenoid output circuit: Short circuit)…1578
Failure code [DXH7KY] (R clutch solenoid output circuit: Short circuit to power source line)…1580
Troubleshooting of electrical system (E-mode)…1585
Before troubleshooting of electrical system…1587
Contents of troubleshooting table…1590
E-1 Engine does not start…1591
E-2 Automatic preheating does not operate…1594
E-3 Machine monitor does not display all, when starting switch is turned ON…1598
E-4 Machine monitor does not operate when starting switch is OFF…1600
E-5 Alarm buzzer does not sound…1602
E-6 Gauges of machine monitor, caution lamps or character display section do not display properly…1603
E-7 Selection of display in character display section cannot be changed…1604
E-8 Power mode selecting function does not operate properly…1608
E-9 AISS function does not operate properly…1609
E-10 Seat belt caution lamp does not display properly…1610
E-11 Turn signal lamp or turning lamp (hazard lamp) does not work properly…1611
E-12 Night illumination (lighting) does not work properly…1614
E-13 Emergency steering does not operate…1621
E-14 Dump lever does not operate normally…1626
E-15 KOMTRAX system does not operate normally…1628
E-16 Electric priming pump does not operate or does not stop automatically…1632
E-17 Air conditioner does not operate normally…1634
Troubleshooting of hydraulic and mechanical system (H-mode)…1641
Contents of troubleshooting table…1643
H-1 Machine does not start…1644
H-2 Machine does not travel smoothly (machine jerks)…1646
H-3 Lockup cannot be cancelled…1646
H-4 Excessive shock when starting or shifting…1647
H-5 Transmission does not shift up…1648
H-6 Machine lacks power or speed when traveling…1649
H-7 Time lag is excessive when starting or shifting gear…1651
H-8 Torque converter oil temperature is high…1652
H-9 Torque converter oil pressure is low…1653
H-10 Front brake is ineffective…1654
H-11 Center brake is ineffective…1655
H-12 Steering wheel is heavy…1656
H-13 Steering wheel does not work…1657
H-14 Steering wheel vibrates…1658
H-15 Dump body lifting speed is slow…1659
H-16 Dump body does not work…1660
H-17 Excessive hydraulic drift of dump body…1661
Troubleshooting of engine (S-mode)…1663
How to use a troubleshooting chart…1665
S-1 Engine is hard to start…1668
S-2 Engine does not start…1669
S-3 Engine does not pick up smoothly…1672
S-4 Engine stops during operations…1673
S-5 Engine does not rotate smoothly…1674
S-6 Engine lacks output (or lacks power)…1675
S-7 Exhaust gas color is black (incomplete combustion)…1676
S-8 Oil consumption is excessive (or exhaust gas color is blue)…1677
S-9 Oil gets contaminated prematurely…1678
S-10 Fuel consumption is excessive…1679
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)…1680
S-12 Oil pressure drops…1681
S-13 Oil level rises (coolant or fuel mixes)…1682
S-14 Coolant temperature rises too high (overheat)…1683
S-15 Abnormal noise comes out…1684
S-16 Vibration is excessive…1685
S-17 Air cannot be bled from fuel circuit…1686
50 Disassembly and assembly…0
General information on disassembly and assembly…1689
How to read this manual…1690
Coating materials list…1692
Special tool list…1695
Sketches of special tools…1700
Engine and cooling system (SAA6D125E-5)…1715
Removal and installation of fuel supply pump assembly…1716
Removal and installation of fuel injector assembly…1721
Removal and installation of cylinder head assembly…1726
Removal and installation of engine front seal…1738
Removal and installation of engine rear seal…1740
Removal and installation of engine assembly…1744
Removal and installation of radiator assembly…1752
Removal and installation of cooling assembly…1754
Removal and installation of output shaft assembly…1757
Disassembly and assembly of output shaft assembly…1762
Power train, Part 1…1767
Removal and installation of transmission and front differential assembly…1768
Disconnection and connection of front differential assembly and transmission assembly…1774
Disassembly and assembly of front differential assembly…1776
Disassembly and assembly of torque converter assembly…1791
Power train, Part 2…1799
Disassembly and assembly of transmission assembly…1800
Power train, Part 3…1843
Removal and installation of center differential assembly…1844
Disassembly and assembly of center differential assembly…1848
Removal and installation of rear differential assembly…1865
Disassembly and assembly of rear differential assembly…1867
Power train, Part 4…1883
Removal and installation of front final drive and brake assembly…1884
Disassembly and assembly of front final drive and brake assembly…1887
Removal and installation of center final drive and brake assembly…1897
Disassembly and assembly of center final drive and brake assembly…1899
Power train, Part 5…1909
Disassembly and assembly of rear final drive assembly…1910
Removal and installation of center axle assembly…1917
Removal and installation of rear axle assembly…1920
Undercarriage and frame…1923
Removal and installation of front suspension cylinder assembly…1924
Removal and installation of rear suspension cylinder assembly…1926
Removal and installation of equalizer bar…1927
Removal and installation of hitch frame assembly…1929
Disassembly and assembly of hitch frame assembly…1939
Hydraulic system…1947
Removal and installation of flow amp valve…1948
Removal and installation of hoist valve assembly…1950
Disassembly and assembly of steering cylinder assembly…1953
Disassembly and assembly of hoist cylinder assembly…1957
Body…1963
Removal and installation of body assembly…1964
Cab and its attachments…1967
Removal and installation of operator’s cab…1968
Removal and installation of operator’s cab glass (Stuck glass)…1973
Disassembly and assembly of operator’s seat assembly (If equipped)…1980
Electrical system…1991
Removal and installation of air conditioner unit assembly…1992
Removal and installation of engine controller…1997
Removal and installation of retarder controller…1999
Removal and installation of transmission controller assembly…2001
90 Diagrams and drawings…0
Hydraulic diagrams and drawings…2003
Power train hydraulic circuit diagram…2005
Steering and hoist hydraulic circuit diagram…2006
Brake hydraulic circuit diagram…2008
Brake cooling hydraulic circuit diagram…2009
Electrical diagrams and drawings…2011
Electrical circuit diagram for inside cab (1/4)…2013
Electrical circuit diagram for inside cab (2/4)…2014
Electrical circuit diagram for inside cab (3/4)…2015
Electrical circuit diagram for inside cab (4/4)…2016
Electrical circuit diagram for outside cab (1/3)…2017
Electrical circuit diagram for outside cab (2/3)…2018
Electrical circuit diagram for outside cab (3/3)…2019
Electrical circuit diagram for payload meter…2020
Connectors table and arrangement drawing…2021
Komatsu Articulated Dump Truck HM300-2R Repair Service Manuals