HM300-2 Shop Manual

SEN02269-04
ARTICULATED HM300 -2R

DUMP TRUCK
SERIAL NUMBERS 7001 and up
SEN02271-04
ARTICULATED DUMP TRUCK 1SHOP MANUAL
HM300-2R
Machine model Serial number

HM300-2R 7001 and up
00 Index and foreword 1

Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4
HM300-2R 1
SEN02271-04 00 Index and foreword
Composition of shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN02269-04
00 Index and foreword SEN02270-04

Index SEN02271-04 q
Foreword and general information SEN02272-02
01 Specification SEN02273-00
Specification and technical data SEN02274-00
10 Structure, function and maintenance standard SEN02275-01

Engine and cooling system SEN02664-00
Power train, Part 1 SEN02665-00
Steering system SEN02667-00
Brake system SEN02668-00
Undercarriage and frame SEN02669-00
Hydraulic system SEN02670-00
Cab and its attachments SEN02671-00
Electrical system, Part 1 SEN02672-00
20 Standard value table SEN02276-01

Standard service value table SEN03418-01
30 Testing and adjusting SEN02277-01

Testing and adjusting, Part 1 SEN03419-01
40 Troubleshooting SEN02278-02
Failure code table and fuse locations SEN03422-00
General information on troubleshooting SEN03423-01
Troubleshooting by failure code (Display of code), Part 1 SEN03424-00
2 HM300-2R

Troubleshooting by failure code (Display of code), Part 4 SEN03427-02 q
Troubleshooting by failure code (Display of code), Part 5 SEN03428-01 q
Troubleshooting of electrical system (E-mode) SEN03429-01
Troubleshooting of hydraulic and mechanical system (H-mode) SEN03430-00
Troubleshooting of engine (S-mode) SEN03431-01
50 Disassembly and assembly SEN02279-01

General information on disassembly and assembly SEN04028-01
Engine and cooling system (SAA6D125E-5) SEN04029-01
Body SEN04038-00
Electrical system SEN04040-00
90 Diagrams and drawings SEN02280-03

Hydraulic diagrams and drawings SEN02281-00
Electrical diagrams and drawings SEN02282-03 q
HM300-2R 3
Table of contents 1
00 Index and foreword
Index SEN02271-04
Composition of shop manual....................................................................................................... 2
Table of contents ......................................................................................................................... 4
Foreword and general information SEN02272-02

Safety notice................................................................................................................................ 2
How to read the shop manual ..................................................................................................... 7
Explanation of terms for maintenance standard.......................................................................... 9
Handling of electric equipment and hydraulic component........................................................... 11
Handling of connectors newly used for engines.......................................................................... 20
How to read electric wire code .................................................................................................... 23
Precautions when carrying out operation .................................................................................... 26
Method of disassembling and connecting push-pull type coupler ............................................... 29
Standard tightening torque table ................................................................................................. 32
Conversion table ......................................................................................................................... 36
01 Specification
Specification and technical data SEN02274-00
Specification drawings................................................................................................................. 2
Specifications .............................................................................................................................. 3
Weight table ................................................................................................................................ 6
Fuel, coolant and lubricants ........................................................................................................ 7
10 Structure, function and maintenance standard

Engine and cooling system SEN02664-00
Radiator, oil cooler, aftercooler.................................................................................................... 2
Output shaft................................................................................................................................. 3
Power train skeleton.................................................................................................................... 2
Torque converter and transmission hydraulic piping ................................................................... 4
Brake cooling oil control valve (BCV) .......................................................................................... 6
Power train pump ........................................................................................................................ 7
Torque converter ......................................................................................................................... 10
Transmission ............................................................................................................................... 16
Transmission control valve .......................................................................................................... 44
ECMV .......................................................................................................................................... 45
Main relief, torque converter relief valve ..................................................................................... 52
Drive shaft ................................................................................................................................... 2
Axle ............................................................................................................................................. 3
Differential ................................................................................................................................... 6
Limited slip differential................................................................................................................. 12
Final drive.................................................................................................................................... 16
Steering system SEN02667-00
Steering column........................................................................................................................... 2
Brake system SEN02668-00
Brake piping ................................................................................................................................ 2
Brake valve.................................................................................................................................. 4
Accumulator charge valve ........................................................................................................... 7
Accumulator ................................................................................................................................ 11
Slack adjuster.............................................................................................................................. 12
Brake ........................................................................................................................................... 14
4 HM300-2R
Proportional reducing valve......................................................................................................... 19

Brake system tank....................................................................................................................... 20
Parking brake .............................................................................................................................. 22
Parking brake solenoid................................................................................................................ 26
Suspension ................................................................................................................................. 2
Suspension cylinder .................................................................................................................... 8
Oscillation hitch ........................................................................................................................... 10
Steering, hoist oil pressure piping diagram ................................................................................. 2
Dump body control ...................................................................................................................... 3
Hydraulic tank and filter............................................................................................................... 4
Flow amp valve ........................................................................................................................... 5
Steering valve.............................................................................................................................. 8
Steering cylinder.......................................................................................................................... 12
Hoist valve................................................................................................................................... 14
EPC valve ................................................................................................................................... 20
Hoist cylinder............................................................................................................................... 21
Hydraulic pump ........................................................................................................................... 22
ROPS cab ................................................................................................................................... 2
Cab tilt ......................................................................................................................................... 3
Air conditioner ............................................................................................................................. 4
Rear view monitor ....................................................................................................................... 12
Controller related......................................................................................................................... 15
Machine monitor system ............................................................................................................. 2
Automatic shift control system .................................................................................................... 2
Retarder control system .............................................................................................................. 34
Auto emergency steering system................................................................................................ 46
Dump control lever ...................................................................................................................... 47
Payload meter (Card type) .......................................................................................................... 2
Sensors, switches ....................................................................................................................... 2
KOMTRAX terminal system (If equipped) ................................................................................... 10
20 Standard value table

Standard service value table SEN03418-01
Standard value table for engine .................................................................................................. 2
Standard value table for chassis ................................................................................................. 3
30 Testing and adjusting

Tools for testing, adjusting, and troubleshooting ......................................................................... 3
Sketches of special tools............................................................................................................. 8
Measuring engine speed............................................................................................................. 9
Measuring intake air pressure (boost pressure).......................................................................... 10
Measuring exhaust temperature ................................................................................................. 11
Measuring exhaust gas color ...................................................................................................... 13
Adjusting valve clearance ........................................................................................................... 14
Measuring compression pressure ............................................................................................... 16
Measuring blow-by pressure ....................................................................................................... 18
Measuring engine oil pressure .................................................................................................... 19
HM300-2R 5
Handling of fuel system devices.................................................................................................. 20

Releasing residual pressure from fuel system ............................................................................ 20
Testing fuel pressure ................................................................................................................... 21
Testing fuel return and leak amount ............................................................................................ 22
Bleeding air from fuel circuit ........................................................................................................ 25
Testing fuel circuit for leakage ..................................................................................................... 27
Testing and adjusting alternator belt tension ............................................................................... 28
Testing and adjusting air conditioner compressor belt tension.................................................... 28
Measuring torque converter stall speed ...................................................................................... 3
Measuring power train oil pressure ............................................................................................. 4
Adjusting transmission speed sensor.......................................................................................... 12
Testing and adjusting brake oil pressure ..................................................................................... 14
Testing of accumulator nitrogen gas pressure and procedure for charging
accumulator with nitrogen gas ................................................................................................. 18
Testing brake performance.......................................................................................................... 21
Bleeding air from brake circuit..................................................................................................... 22
Measuring wear of wheel brake disc ........................................................................................... 23
Measuring wear of parking brake pad ......................................................................................... 24
Method for emergency release of parking brake......................................................................... 26
Testing and adjusting steering circuit oil pressure....................................................................... 27
Testing and adjusting suspension cylinder .................................................................................. 29
Method of tilting cab up ............................................................................................................... 33
Testing and adjusting dump circuit oil pressure........................................................................... 35
Adjusting body positioner sensor ................................................................................................ 38
Procedure for adjusting length of spring in body heating spherical joint ..................................... 39
Handling engine controller high voltage circuit............................................................................ 39
Adjusting transmission controller................................................................................................. 40
Method for emergency escape at electrical system failure ......................................................... 41
Setting and adjusting various equipments................................................................................... 2
Special function of machine monitor (EMMS) ............................................................................. 13
How to start operation of KOMTRAX terminal............................................................................. 47
Lamp display of KOMTRAX terminal........................................................................................... 50
Pm Clinic check sheet ................................................................................................................. 53
40 Troubleshooting
Failure code table and fuse locations SEN03422-00
Failure code table........................................................................................................................ 2
Before troubleshooting by failure codes ...................................................................................... 9
General information on troubleshooting SEN03423-01
Points to remember when troubleshooting .................................................................................. 2
Sequence of events in troubleshooting ....................................................................................... 3
Checks before troubleshooting.................................................................................................... 4
Classification and procedures for troubleshooting ...................................................................... 5
Information in troubleshooting table ............................................................................................ 6
Connection table for connector pin numbers............................................................................... 8
T-branch box and T- branch adapter table .................................................................................. 44
Failure code [1500L0] (Dual engagement).................................................................................. 3
Failure code [15B0NX] (Transmission oil filter: Clogged)............................................................ 4
Failure code [15F0KM] (R o F shifting abuse 1: Operational error or incorrect setting)............. 6
Failure code [15F0MB] (R o F shifting abuse 2: Functional deterioration)................................. 6
Failure code [15F7KM] (forward clutch disc abuse) .................................................................... 7
Failure code [15G0MW] (R clutch: Slipping) ............................................................................... 8
Failure code [15G7KM] (reverse clutch disc abuse) ................................................................... 10
6 HM300-2R
Failure code [15H0MW] (Hi clutch: Slipping) .............................................................................. 11

Failure code [15J0MW] (Lo clutch: Slipping)............................................................................... 14
Failure code [15K0MW] (1st clutch: Slipping) ............................................................................. 16
Failure code [15L0MW] (2nd clutch: Slipping) ............................................................................ 18
Failure code [15M0MW] (3rd clutch: Slipping) ............................................................................ 20
Failure code [15SBL1] (R clutch solenoid: Fill signal is ON when command current is OFF.) .... 22
Failure code [15SBMA] (R clutch solenoid: Malfunction) ............................................................ 26
Failure code [15SCL1] (Hi clutch solenoid: Fill signal is ON when command current is OFF.) ... 28
Failure code [15SCMA] (Hi clutch solenoid: Malfunction) ........................................................... 32
Failure code [15SDL1] (Lo clutch solenoid:
Fill signal is ON when command current is OFF.) ................................................................... 34
Failure code [15SDMA] (Lo clutch solenoid: Malfunction) .......................................................... 36
Failure code [15SEL1] (1st clutch solenoid:
Fill signal is ON when command current is OFF) .................................................................... 40
Failure code [15SEMA] (1st clutch solenoid: Malfunction) .......................................................... 44
Failure code [15SFL1] (2nd clutch solenoid:
Failure code [15SFMA] (2nd clutch solenoid: Malfunction) ......................................................... 50
Failure code [15SGL1] (3rd clutch solenoid:
Failure code [15SGMA] (3rd clutch solenoid: Malfunction) ......................................................... 56
Failure code [15SJMA] (Lockup clutch solenoid: Malfunction).................................................... 58
Failure code [15SKMA] (Inter-axle differential lockup pressure control valve: Malfunction) ....... 60
Failure code [2F00KM] (Parking brake: Error in operation or setting)......................................... 62
Failure code [2G42ZG] (Front accumulator: Oil pressure too low) ............................................. 64
Failure code [2G43ZG] (Rear accumulator: Oil pressure too low) .............................................. 64
Failure code [989A00] (Engine over run prevention command signal: Operating) ..................... 3
Failure code [989D00] (Rear section tipping over alarm: Alarm is activated.) ............................ 3
Failure code [AA10NX] (Air cleaner element: Clogged).............................................................. 4
Failure code [AB00MA] (Alternator: Malfunction)........................................................................ 6
Failure code [B@BAZK] (Engine oil : Level too low)................................................................... 7
Failure code [B@BCNS] (Eng water overheat)........................................................................... 8
Failure code [B@BCZK] (Radiator coolant: Level too low) ......................................................... 9
Failure code [B@BFZK] (Fuel level: Level too low) .................................................................... 10
Failure code [B@C6NS] (Front brake oil: Overheat)................................................................... 11
Failure code [B@C8NS] (Center brake oil: Overheat) ................................................................ 11
Failure code [B@CENS] (Torque converter: Overheat) .............................................................. 12
Failure code [B@HAZK] (Hydraulic tank oil: Level too low) ........................................................ 13
Failure code [B@JANS] (Steering oil: Overheat) ........................................................................ 14
Failure code [CA111] (Abnormality in engine controller) ............................................................. 15
Failure code [CA115] (Abnormal engine Ne and Bkup sensors)................................................. 16
Failure code [CA122] (Charge pressure sensor too high)........................................................... 18
Failure code [CA123] (Charge pressure sensor too low) ............................................................ 20
Failure code [CA131] (Throttle sensor tool high) ........................................................................ 22
Failure code [CA132] (Throttle sensor tool low) .......................................................................... 24
Failure code [CA135] (Oil pressure sensor too high) .................................................................. 26
Failure code [CA141] (Oil pressure sensor too low) ................................................................... 28
Failure code [CA144] (Coolant temperature sensor too high)..................................................... 30
Failure code [CA145] (Coolant temperature sensor too low) ...................................................... 32
Failure code [CA153] (Charge temperature sensor too high) ..................................................... 34
Failure code [CA154] (Charge temperature sensor too low)....................................................... 36
Failure code [CA187] (Sensor power source 2 too low).............................................................. 36
Failure code [CA221] (Atmospheric sensor too high) ................................................................. 38
Failure code [CA222] (Atmospheric sensor too low) ................................................................... 40
Failure code [CA227] (Sensor power source 2 too high) ............................................................ 42
Failure code [CA234] (Engine over speed) ................................................................................. 44
Failure code [CA238] (Abnormal power source for Ne speed sensor)........................................ 46
HM300-2R 7
Failure code [CA263] (Fuel temperature sensor too high) .......................................................... 48

Failure code [CA265] (Fuel temperature sensor too low)............................................................ 50
Failure code [CA271] (PCV1 short circuit) .................................................................................. 51
Failure code [CA272] (PCV1 disconnection)............................................................................... 52
Failure code [CA273] (PCV2 short circuit) .................................................................................. 53
Failure code [CA274] (PCV2 disconnection)............................................................................... 54
Failure code [CA322] (Injector No. 1 system disconnection or short circuit)............................... 56
Failure code [CA342] (Abnormal engine controller data consistency) ........................................ 3
Failure code [CA351] (Abnormal injector drive circuit) ................................................................ 4
Failure code [CA352] (Sensor power source 1 too low).............................................................. 5
Failure code [CA386] (Sensor power source 1 too high) ............................................................ 6
Failure code [CA431] Idle validation switch error ........................................................................ 8
Failure code [CA432] (Abnormal process with idle validation switch) ......................................... 12
Failure code [CA441] (Power source voltage too low) ................................................................ 13
Failure code [CA442] (Power source voltage too high)............................................................... 13
Failure code [CA449] (Common rail pressure too high 2) ........................................................... 14
Failure code [CA451] (Common rail pressure sensor too high) .................................................. 16
Failure code [CA452] (Common rail pressure sensor too low).................................................... 18
Failure code [CA553] (Common rail pressure too high 1) ........................................................... 18
Failure code [CA554] (In-range error of common rail pressure sensor)...................................... 19
Failure code [CA559] (Loss of pressure feed from supply pump 1) ............................................ 20
Failure code [CA689] (Abnormal engine Ne speed sensor)........................................................ 24
Failure code [CA731] (Abnormal engine Bkup speed sensor phase) ......................................... 26
Failure code [CA757] (Loss of all engine controller data) ........................................................... 26
Failure code [CA778] (Abnormal engine Bkup speed sensor) .................................................... 28
Failure code [CA1633] (Abnormal KOMNET) ............................................................................. 30
Failure code [CA2185] (Throttle sensor power source too high)................................................. 32
Failure code [CA2186] (Throttle sensor power source too low) .................................................. 34
Failure code [CA2249] (Loss of pressure feed from supply pump 2) .......................................... 34
Failure code [CA2555] (Disconnection in intake air heater relay) ............................................... 35
Failure code [CA2556] (Intake air heater relay short circuit) ....................................................... 36
Failure code [DAF9KM] (Machine monitor connector: Error in operation or setting)................... 38
Failure code [DAFRKR] (Abnormal CAN communication (machine monitor):
Abnormal communication) ....................................................................................................... 40
Failure code [DAQ0KK] (Transmission controller: Power source voltage too low)...................... 42
Failure code [DAQ0KT] (Transmission nonvolatile memory: Abnormality in controller).............. 44
Failure code [DAQ2KK] (Transmission controller solenoid power source: Voltage too low) ....... 45
Failure code [DAQRKR] (COMMUNICATION LOST: Defective communication)........................ 46
Failure code [DAQRMA] (Transmission controller option setting: Malfunction)........................... 48
Failure code [DB10KT] (Retarder controller nonvolatile memory: Abnormality in controller) ...... 48
Failure code [DB12KK] (Retarder controller solenoid power source:
Power source voltage too low)................................................................................................. 49
Failure code [DB13KK] (Retarder controller battery direct power source:
Power source voltage too low)................................................................................................. 50
Failure code [DB19KQ] (Retarder controller model select signal:
Inconsistent model selection signal) ........................................................................................ 51
Failure code [DB1QMA] (Retarder controller option setting: Malfunction) .................................. 51
Failure code [DB1RKR] (CAN communication (retarder controller): Communication disabled).. 52
Failure code [DB2RKR] (CAN communication (engine controller): Communication disabled) ... 54
Failure code [DDTHKA] (Fill switch for Hi clutch: Disconnection) ............................................... 56
Failure code [DDTJKA] (Fill switch for Lo clutch: Disconnection ) .............................................. 58
Failure code [DDTKKA] (Fill switch for 1st clutch: Disconnection) .............................................. 60
8 HM300-2R
Failure code [DDTLKA] (Fill switch for 2nd clutch: Disconnection) ............................................. 61
Failure code [DDTMKA] (Fill switch for 3rd clutch: Disconnection) ............................................. 62
Failure code [DDTNKA] (Fill switch for R clutch: Disconnection) ................................................ 63
Failure code [DF10KA] (Gear shift lever: Disconnection) ........................................................... 64
Failure code [DF10KB] (Gear shift lever: Short circuit) ............................................................... 67
Failure code [DGF1KX] (Transmission oil temperature sensor: Input signal out of range) ......... 4
Failure code [DGR3KZ] (Center brake oil temperature sensor: Disconnection or short circuit).. 6
Failure code [DGR3L8] (Center brake oil temperature sensor: Inconsistent analog signals) ..... 8
Failure code [DGR4KZ] (Front brake oil temperature sensor: Disconnection or short circuit) .... 10
Failure code [DGR4L8] (Front brake oil temperature sensor: Inconsistent analog signals)........ 12
Failure code [DGR6KX] (Steering oil temperature sensor: Input signal out of range)................. 14
Failure code [DGT1KX] (Torque converter oil temperature sensor: Input signal out of range).... 16
Failure code [DHT5KX] (Torque converter oil pressure sensor: Input signal out of range) ......... 18
Failure code [DHT5L6] (Torque converter oil pressure sensor:
Inconsistent signals during a travel and stop) ......................................................................... 20
Failure code [DHU2KX] (Front accumulator oil pressure sensor: Input signal out of range) ...... 22
Failure code [DHU3KX] (Rear accumulator oil pressure sensor: Input signal out of range) ....... 24
Failure code [DJF1KA] (Fuel level sensor: Disconnection) ......................................................... 26
Failure code [DK51L5] (Retarder lever potentiometer:
Potentiometer signal is inconsistent with switch signal) .......................................................... 28
Failure code [DK52KX] (Dump lever potentiometer failure 1: Input signal out of range) ............ 30
Failure code [DK53L8] (Dump lever potentiometer failure 2: Inconsistent analog signal) .......... 32
Failure code [DK54KX] (Body positioner sensor: Input signal out of range) ............................... 34
Failure code [DKH0KX] (Inclination sensor: Inclination out of range) ......................................... 36
Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection) ...................... 38
Failure code [DLF1LC] (Transmission input shaft speed sensor:
Inconsistent rotation speed signal) .......................................................................................... 39
Failure code [DLF2KA] (Transmission intermediate shaft speed sensor: Disconnection) .......... 40
Failure code [DLF2LC] (Transmission intermediate shaft speed sensor:
Inconsistent speed signal) ....................................................................................................... 41
Failure code [DLF4KA] (Differential speed sensor: Disconnection) ............................................ 42
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection) .................... 43
Failure code [DV00KB] (Alarm buzzer output: Short circuit) ....................................................... 44
Failure code [DW72KZ] (Kick-out solenoid output system: Disconnection or short circuit) ........ 46
Failure code [DW73KZ] (Hoist selector valve output system: Disconnection or short circuit)..... 48
Failure code [DW78KZ] (Rear brake BCV command output system:
Disconnection or short circuit) ................................................................................................. 50
Failure code [DW79KZ] (Front brake BCV command output system:
Disconnection or short circuit) ................................................................................................. 52
Failure code [DX11K4] Trouble in rear wheel proportional solenoid
pressure reducing valve 1 ....................................................................................................... 54
Failure code [DX11KA] (Rear brake proportional pressure reducing solenoid valve output circuit:
Disconnection)......................................................................................................................... 56
Failure code [DX11KB] (Rear brake proportional pressure reducing solenoid valve:
Short circuit) ............................................................................................................................ 57
Failure code [DX11KY] (Rear brake proportional pressure reducing solenoid valve:
Short circuit to power source line) ........................................................................................... 58
Failure code [DX11MA] (Rear brake proportional pressure reducing solenoid valve:
Malfunction) ............................................................................................................................. 60
Failure code [DX12K4] (Front brake proportional pressure reducing solenoid valve:
Out of control).......................................................................................................................... 62
Failure code [DX12KA] (Front brake proportional pressure reducing solenoid valve output circuit:
Disconnection)......................................................................................................................... 64
Failure code [DX12KB] (Front brake proportional pressure reducing solenoid valve:
Short circuit) ............................................................................................................................ 65
HM300-2R 9

Failure code [DX12KY] (Front brake proportional pressure reducing solenoid valve:
Failure code [DX12MA] (Front brake proportional pressure reducing solenoid valve:
Malfunction) ............................................................................................................................. 4
Failure code [DX13KA] (Hoist EPC valve output circuit: Disconnection) .................................... 6
Failure code [DX13KB] (Hoist EPC valve output circuit: Short circuit) ........................................ 7
Failure code [DX13KY] (Hoist EPC valve output circuit: Short circuit in power source line) ....... 8
Failure code [DXH0KA] (Inter-axle differential lock pressure control valve: Disconnection) ....... 9
Failure code [DXH0KB] (Inter-axle differential lock pressure control valve: Short circuit)........... 10
Failure code [DXH0KY] (Inter-axle differential lockup pressure control valve:
Failure code [DXH1KA] (Lockup clutch solenoid output circuit: Disconnection) ......................... 12
Failure code [DXH1KB] (Lockup clutch solenoid output circuit: Short circuit) ............................. 13
Failure code [DXH1KY] (Lockup clutch solenoid output circuit:
Failure code [DXH2KA] (Hi clutch solenoid output circuit: Disconnection).................................. 16
Failure code [DXH2KB] (Hi clutch solenoid output circuit: Short circuit) ..................................... 18
Failure code [DXH2KY] (Hi clutch solenoid output circuit: Short circuit to power source line) .... 20
Failure code [DXH3KA] (Lo clutch solenoid output circuit: Disconnection) ................................. 24
Failure code [DXH3KB] (Lo clutch solenoid output circuit: Short circuit)..................................... 26
Failure code [DXH3KY] (Lo clutch solenoid output circuit: Short circuit in power source line).... 28
Failure code [DXH4KA] (1st clutch solenoid output circuit: Disconnection) ................................ 32
Failure code [DXH4KB] (1st clutch solenoid output circuit: Short circuit).................................... 34
Failure code [DXH4KY] (1st clutch solenoid output circuit: Short circuit to power source line)... 36
Failure code [DXH5KA] (2nd clutch solenoid output circuit: Disconnection) ............................... 40
Failure code [DXH5KB] (2nd clutch solenoid output circuit: Short circuit)................................... 42
Failure code [DXH5KY] (2nd clutch solenoid output circuit: Short circuit in power source line).. 44
Failure code [DXH6KA] (3rd clutch solenoid output circuit: Disconnection)................................ 48
Failure code [DXH6KB] (3rd clutch solenoid output circuit: Short circuit) ................................... 50
Failure code [DXH6KY] (3rd clutch solenoid output circuit: Short circuit to power source line) .. 52
Failure code [DXH7KA] (R clutch solenoid output circuit: Disconnection) .................................. 56
Failure code [DXH7KB] (R clutch solenoid output circuit: Short circuit) ...................................... 58
Failure code [DXH7KY] (R clutch solenoid output circuit: Short circuit to power source line)..... 60
Troubleshooting of electrical system (E-mode) SEN03429-01
Before troubleshooting of electrical system................................................................................. 3
Contents of troubleshooting table................................................................................................ 6
E-1 Engine does not start............................................................................................................ 7
E-2 Automatic preheating does not operate................................................................................ 10
E-3 Machine monitor does not display all, when starting switch is turned ON ............................ 14
E-4 Machine monitor does not operate when starting switch is OFF .......................................... 16
E-5 Alarm buzzer does not sound ............................................................................................... 18
E-6 Gauges of machine monitor, caution lamps or character display section
do not display properly. ............................................................................................................ 19
E-7 Selection of display in character display section cannot be changed................................... 20
E-8 Power mode selecting function does not operate properly................................................... 24
E-9 AISS function does not operate properly .............................................................................. 25
E-10 Seat belt caution lamp does not display properly ............................................................... 26
E-11 Turn signal lamp or turning lamp (hazard lamp) does not work properly ............................ 27
E-12 Night illumination (lighting) does not work properly ............................................................ 30
E-13 Emergency steering does not operate................................................................................ 37
E-14 Dump lever does not operate normally............................................................................... 42
E-15 KOMTRAX system does not operate normally ................................................................... 44
E-16 Electric priming pump does not operate or does not stop automatically ............................ 48
E-17 Air conditioner does not operate normally .......................................................................... 50
Troubleshooting of hydraulic and mechanical system (H-mode) SEN03430-00
Contents of troubleshooting table................................................................................................ 3
10 HM300-2R
H-1 Machine does not start ......................................................................................................... 4

H-2 Machine does not travel smoothly (machine jerks) .............................................................. 6
H-3 Lockup cannot be cancelled................................................................................................. 6
H-4 Excessive shock when starting or shifting ............................................................................ 7
H-5 Transmission does not shift up............................................................................................. 8
H-6 Machine lacks power or speed when traveling..................................................................... 9
H-7 Time lag is excessive when starting or shifting gear ............................................................ 11
H-8 Torque converter oil temperature is high .............................................................................. 12
H-9 Torque converter oil pressure is low..................................................................................... 13
H-10 Front brake is ineffective .................................................................................................... 14
H-11 Center brake is ineffective .................................................................................................. 15
H-12 Steering wheel is heavy...................................................................................................... 16
H-13 Steering wheel does not work ............................................................................................ 17
H-14 Steering wheel vibrates ...................................................................................................... 18
H-15 Dump body lifting speed is slow ......................................................................................... 19
H-16 Dump body does not work.................................................................................................. 20
H-17 Excessive hydraulic drift of dump body .............................................................................. 21
Troubleshooting of engine (S-mode) SEN03431-01
How to use a troubleshooting chart............................................................................................. 3
S-1 Engine is hard to start........................................................................................................... 6
S-2 Engine does not start............................................................................................................ 7
S-3 Engine does not pick up smoothly........................................................................................ 10
S-4 Engine stops during operations ............................................................................................ 11
S-5 Engine does not rotate smoothly .......................................................................................... 12
S-6 Engine lacks output (or lacks power).................................................................................... 13
S-7 Exhaust gas color is black (incomplete combustion) ............................................................ 14
S-8 Oil consumption is excessive (or exhaust gas color is blue) ................................................ 15
S-9 Oil gets contaminated prematurely ....................................................................................... 16
S-10 Fuel consumption is excessive........................................................................................... 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................. 18
S-12 Oil pressure drops .............................................................................................................. 19
S-13 Oil level rises (coolant or fuel mixes).................................................................................. 20
S-14 Coolant temperature rises too high (overheat) ................................................................... 21
S-15 Abnormal noise comes out ................................................................................................. 22
S-16 Vibration is excessive ......................................................................................................... 23
S-17 Air cannot be bled from fuel circuit ..................................................................................... 24
50 Disassembly and assembly

General information on disassembly and assembly SEN04028-01
How to read this manual ............................................................................................................. 2
Coating materials list................................................................................................................... 4
Special tool list ............................................................................................................................ 7
Sketches of special tools............................................................................................................. 12
Engine and cooling system (SAA6D125E-5) SEN04029-01
Removal and installation of fuel supply pump assembly............................................................. 2
Removal and installation of fuel injector assembly ..................................................................... 7
Removal and installation of cylinder head assembly .................................................................. 12
Removal and installation of engine front seal ............................................................................. 24
Removal and installation of engine rear seal .............................................................................. 26
Removal and installation of engine assembly ............................................................................. 30
Removal and installation of radiator assembly............................................................................ 38
Removal and installation of cooling assembly ............................................................................ 40
Removal and installation of output shaft assembly ..................................................................... 43
Disassembly and assembly of output shaft assembly................................................................. 48
Removal and installation of transmission and front differential assembly ................................... 2
HM300-2R 11
Disconnection and connection of front differential assembly and transmission assembly .......... 8
Disassembly and assembly of front differential assembly ........................................................... 10
Disassembly and assembly of torque converter assembly ......................................................... 25
Disassembly and assembly of transmission assembly ............................................................... 2
Removal and installation of center differential assembly............................................................. 2
Disassembly and assembly of center differential assembly ........................................................ 6
Removal and installation of rear differential assembly ................................................................ 23
Disassembly and assembly of rear differential assembly............................................................ 25
Removal and installation of front final drive and brake assembly ............................................... 2
Disassembly and assembly of front final drive and brake assembly ........................................... 5
Removal and installation of center final drive and brake assembly............................................. 15
Disassembly and assembly of center final drive and brake assembly ........................................ 17
Disassembly and assembly of rear final drive assembly............................................................. 2
Removal and installation of center axle assembly ...................................................................... 9
Removal and installation of rear axle assembly .......................................................................... 12
Removal and installation of front suspension cylinder assembly ................................................ 2
Removal and installation of rear suspension cylinder assembly ................................................. 4
Removal and installation of equalizer bar ................................................................................... 5
Removal and installation of hitch frame assembly ...................................................................... 7
Disassembly and assembly of hitch frame assembly.................................................................. 17
Removal and installation of flow amp valve ................................................................................ 2
Removal and installation of hoist valve assembly ....................................................................... 4
Disassembly and assembly of steering cylinder assembly ......................................................... 7
Disassembly and assembly of hoist cylinder assembly............................................................... 11
Body SEN04038-00
Removal and installation of body assembly ................................................................................ 2
Removal and installation of operator's cab.................................................................................. 2
Removal and installation of operator's cab glass (Stuck glass)................................................... 7
Disassembly and assembly of operator's seat assembly (If equipped)....................................... 14
Electrical system SEN04040-00
Removal and installation of air conditioner unit assembly........................................................... 2
Removal and installation of engine controller.............................................................................. 7
Removal and installation of retarder controller ............................................................................ 9
Removal and installation of transmission controller assembly .................................................... 11
90 Diagrams and drawings

Hydraulic diagrams and drawings SEN02281-00
Power train hydraulic circuit diagram .......................................................................................... 3
Steering and hoist hydraulic circuit diagram................................................................................ 5
Brake hydraulic circuit diagram ................................................................................................... 7
Brake cooling hydraulic circuit diagram....................................................................................... 9
Electrical diagrams and drawings SEN02282-03
Electrical circuit diagram for inside cab (1/4)............................................................................... 3
Electrical circuit diagram for outside cab (1/3) ............................................................................ 11
12 HM300-2R

Electrical circuit diagram for payload meter ................................................................................ 17
Connectors table and arrangement drawing ............................................................................... 19
HM300-2R 13
HM300-2R Articulated dump truck

Form No. SEN02271-04
© 2010 KOMATSU
All Rights Reserved
Printed in Japan 04-10
14 HM300-2R
SEN02272-02
HM300-2R

00 Index and foreword 1

Foreword and general information
Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling of electric equipment and hydraulic component .............................................................................11
Handling of connectors newly used for engines ........................................................................................... 20
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
HM300-2R 1
Safety notice 1
(Rev. 2008/08)
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before weld in g wo rk , al way s wear wel din g
operating the machine. In addition, gloves, apron, shielding goggles, cap and
read this manual and understand its other clothes suited for welding work.
contents before starting the work. 8) Before starting work, warm up your body
1) Before carrying out any greasing or thoroughly to start work under good condi-
repairs, read all the safety labels stuck to tion.
the machine. For the locations of the 9) Avoid continuing work for long hours and
safety labels and detailed explanation of take rests at proper intervals to keep your
precautions, see the Operation and Main- body in good condition. Take rests in
tenance Manual. specified safe places.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always Safety points
keep the tools and parts in their correct
places. Always keep the work area clean 1 Good arrangement
and make sure that there is no dirt, water, 2 Correct work clothes
or oil on the floor. Smoke only in the areas 3 Following work standard
provided for smoking. Never smoke while
working. 4 Making and checking signs
3) When carrying out any operation, always Prohibition of operation and handling by
5
wear safety shoes and helmet. Do not unlicensed workers
wear loose work clothes, or clothes with 6 Safety check before starting work
buttons missing.
Wearing protective goggles
q Always wear safety glasses when hit- 7
(for cleaning or grinding work)
ting parts with a hammer.
q Always wear safety glasses when Wearing shielding goggles and protectors
8
grinding parts with a grinder, etc. (for welding work)
4) When carrying out any operation with 2 or 9 Good physical condition and preparation
more workers, always agree on the oper- Precautions against work which you are
ating procedure before starting. Always 10
not used to or you are used to too much
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, fork-
lift, service car, etc.
2 HM300-2R
2. Preparations for work 6) When removing a cover which is under

1) Before adding oil or making any repairs, internal pressure or under pressure from a
park the machine on a hard and level spring, always leave 2 bolts in diagonal
ground, and apply the parking brake and positions. Loosen those bolts gradually
block the wheels or tracks to prevent the and alternately to release the pressure,
machine from moving. and then remove the cover.
2) Before starting work, lower the work 7) When removing components, be careful
equipment (blade, ripper, bucket, etc.) to not to break or damage the electrical wir-
the ground. If this is not possible, insert ing. Damaged wiring may cause electrical
the lock pin or use blocks to prevent the fires.
work equipment from falling. In addition, 8) When removing piping, stop the fuel or oil
be sure to lock all the control levers and from spilling out. If any fuel or oil drips
hang warning signs on them. onto the floor, wipe it up immediately. Fuel
3) When disassembling or assembling, sup- or oil on the floor can cause you to slip
port the machine with blocks, jacks, or and can even start fires.
stands before starting work. 9) As a general rule, do not use gasoline to
4) Remove all mud and oil from the steps or wash parts. Do not use it to clean electri-
other places used to get on and off the cal parts, in particular.
machine. Always use the handrails, lad- 10) Be sure to assemble all parts again in their
ders or steps when getting on or off the original places. Replace any damaged
m a c h i n e . N e v e r j u m p o n o r o ff t h e parts and parts which must not be reused
machine. If it is impossible to use the with new parts. When installing hoses and
handrails, ladders or steps, use a stand to wires, be sure that they will not be dam-
provide safe footing. aged by contact with other parts when the
machine is operated.
3. Precautions during work 11) When installing high pressure hoses,
1) Before disconnecting or removing compo- make sure that they are not twisted. Dam-
nents of the oil, water, or air circuits, first aged tubes are dangerous, so be
release the pressure completely from the extremely careful when installing tubes for
circuit. When removing the oil filler cap, a high pressure circuits. In addition, check
drain plug, or an oil pressure pickup plug, t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
loosen it slowly to prevent the oil from installed.
spurting out. 12) When assembling or installing parts,
2) The coolant and oil in the circuits are hot always tighten them to the specified
when the engine is stopped, so be careful torques. When installing protective parts
not to get scalded. Wait for the oil and such as guards, or parts which vibrate vio-
coolant to cool before carrying out any lently or rotate at high speed, be particu-
work on the oil or water circuits. l a r ly c a r e fu l t o c he c k t h a t t h e y ar e
3) Before starting work, stop the engine. installed correctly.
When working on or around a rotating 13) When aligning 2 holes, never insert your
part, in particular, stop the engine. When fingers or hand. Be careful not to get your
checking the machine without stopping fingers caught in a hole.
the engine (measuring oil pressure, 14) When measuring hydraulic pressure,
revolving speed, temperature, etc.), take check that the measuring tools are cor-
extreme care not to get rolled or caught in rectly assembled.
rotating parts or moving parts. 15) Take care when removing or installing the
4) Before starting work, remove the leads tracks of track-type machines. When
from the battery. Always remove the lead removing the track, the track separates
from the negative (–) terminal first. suddenly, so never let anyone stand at
5) When raising a heavy component (heavier either end of the track.
than 25 kg), use a hoist or crane. Before 16) If the engine is operated for a long time in
starting work, check that the slings (wire a place which is not ventilated well, you
ropes, chains, and hooks) are free from may suffer from gas poisoning. Accord-
damage. Always use slings which have ingly, open the windows and doors to ven-
ample capacity and install them to proper tilate well.
places. Operate the hoist or crane slowly
to prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.
HM300-2R 3
4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is well seen
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
4 HM300-2R
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven- 18 28.6 2.9
tion earth leakage breaker, crane collision 20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
HM300-2R 5
8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
6 HM300-2R
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword

This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
HM300-2R 7
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 HM300-2R
Explanation of terms for maintenance standard 1

The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.
1. Standard size and tolerance

q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence from the standard size is called the
“tolerance”.
q The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.
Example:
Standard size Tolerance
–0.022
120
–0.126
a The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
HM300-2R 9
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the “standard clear- between them is increased to a certain
ance“, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the “clearance limit”.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
“standard value“, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value “interference limit”.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance table is smaller than that of the
mating shaft, the difference between those
diameters is called the “interference”.
q The range (A – B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the “standard interference”.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value or allow-

able dimension
q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
q If a part is worn to the repair limit, it must
be replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value which
the product can be used without causing a
problem is called the “allowable value” or
“allowable dimension”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
10 HM300-2R
Handling of electric equipment and hydraulic component 1

To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and
“Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
HM300-2R 11
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.
12 HM300-2R
3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.
q When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3] Action to take after removing connec-

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
HM300-2R 13
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
14 HM300-2R
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
HM300-2R 15
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oi l a nd wa ter fr om t he c om -
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
16 HM300-2R
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
HM300-2R 17
Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1. Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4. Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
18 HM300-2R
5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
HM300-2R 19
Handling of connectors newly used for engines 1

a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 95 – 170, 12V140 engines
q 95E-5 q Various temperature sensors
q 107E-1 Example)
q 114E-3 Intake air temperature sensor in
q 125E-5 intake manifold: TIM
q 140E-5 Fuel temperature sensor: TFUEL
q 170E-5 Oil temperature sensor: TOIL
q 12V140E-3 Coolant temperature sensor: TWTR,
etc.
1. Slide lock type Disconnect the connector by pulling lock
(FRAMATOME-3, FRAMATOME-2) (B) (on the wiring harness side) of connec-
q 95 – 170, 12V140 engines tor (2) outward.
q Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure sensor in intake
manifold: PIM
(125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(95, 107, 114 engines)
Ne speed sensor of flywheel housing:
NE (95 – 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
Disconnect connector (1) according to the fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.
20 HM300-2R
3. Push lock type

q 95, 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 engine
q 107, 114 engines

Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)
3) While pressing lock (D), pull out connector

(4) in the direction of the arrow.
q 107 engine
a If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
HM300-2R 21
q 95, 125 – 170, 12V140 engines 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure sensor in common rail: 1) Disconnect connector (6) according to the
PFUEL etc. (AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the

following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it “clicks”.
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 HM300-2R
How to read electric wire code 1

a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
HM300-2R 23
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
24 HM300-2R
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
HM300-2R 25
Precautions when carrying out operation 1

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work

q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising components, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376-70210 02789-20210
03 07376-70315 02789-20315
04 07376-70422 02789-20422
05 07376-70522 02789-20522
06 07376-70628 02789-20628
10 07376-71034 07221-21034
12 07376-71234 07221-21234
2) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
26 HM300-2R
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 – 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 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 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, “Bleeding air”.
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 “Disassembly and assembly”.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
HM300-2R 27
4) Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly
and assembly”.
28 HM300-2R
Method of disassembling and connecting push-pull type coupler 1

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
HM300-2R 29
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
30 HM300-2R
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
HM300-2R 31
Standard tightening torque table 1

1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below.
a The following table applies to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 157 – 196 16 – 20
16 24 245 – 309 25 – 31.5
18 27 343 – 427 35 – 43.5
20 30 490 – 608 50 – 62
22 32 662 – 829 67.5 – 84.5
24 36 824 – 1,030 84 – 105
27 41 1,180 – 1,470 120 – 150
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table applies to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
32 HM300-2R
2. Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.

mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. Table of tightening torques for O-ring boss piping joints

a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Thread diameter Width across flats Tightening torque Nm {kgm}

Nominal No.
mm mm Range Target
02 14 35 – 63 { 3.5 – 6.5} 44 { 4.5}
03,04 20 Varies depending 84 – 132 { 8.5 – 13.5} 103 {10.5}
05,06 24 on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
HM300-2R 33
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. –
No. of across Thread
Thread size Number of
hose flats Range Target diameter (mm)
(mm) threads, type of
(Reference)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. Table of tightening torques for face seal joints

a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to
be used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Outer Width Tightening torque Nm {kgm} Face seal

diameter across Nominal No. – Thread diameter
of pipe flats Range Target Number of threads, (mm)
(mm) (mm) type of thread (Reference)
8 19 14 – 16 {1.4 – 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 – 27 {2.4 – 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 (27) 43 – 47 {4.4 – 4.8} 45 {4.6} 13/16-16UN 20.6
15 (16) 30 (32) 60 – 68 {6.1 – 6.8} 64 {6.5} 1-14UN 25.4
22 (20) 36 90 – 95 {9.2 – 9.7} 92.5 {9.4} 1-3/16-12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
34 HM300-2R
8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
HM300-2R 35
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
36 HM300-2R
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
HM300-2R 37
Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
38 HM300-2R
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
HM300-2R 39
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
40 HM300-2R
HM300-2R 41

© 2008 KOMATSU
All Rights Reserved
Printed in Japan 09-08 (02)
42 HM300-2R
SEN02274-00
HM300-2R

01 Specification 1
Specification and technical data
Specification drawings .................................................................................................................................... 2
Specifications .................................................................................................................................................. 3
Weight table .................................................................................................................................................... 6
Fuel, coolant and lubricants ............................................................................................................................ 7
HM300-2R 1
SEN02274-00 01 Specification
Specification drawings 1
2 HM300-2R
Specifications 1
Machine model HM300-2R
Serial number 7001 and up
Unloaded kg 24,040
Max. payload kg 27,300
Overall weight kg 51,340
Unloaded (front wheel) kg 13,640
Weight
(center wheel) kg 5,860

(rear wheel) kg 5,120
Weight
Fully loaded (front wheel) kg 15,785
(center wheel) kg 18,430
(rear wheel) kg 17,705
Struck m3 12.9
Dump body capacity
Heaped (2:1) m3 16.6
Performance
Max. travel speed km/h 58.6

Gradeability (sin θ) 0.45
Min turning radius (front wheel/rear wheel) (S) mm 7,960/4,010
Dumping angle (angle to ground) deg. 70
Overall length (A) mm 10,440

Overall width (B) mm 2,900
Overall height (C) mm 3,520
Body width (D) mm 2,900
Front over bank (E) mm 2,935
Wheelbase (front wheel – center wheel) (F) mm 4,100
Wheelbase (center wheel – rear wheel) (G) mm 1,710
Flexural center – front wheel (H) mm 1,200
Front tires mm 2,280

Tread (J) Center tires mm 2,280
Rear tires mm 2,280
Front wheel mm 2,900

Entire width of tire (K) Center wheel mm 2,900
Dimensions
Rear wheel mm 2,900

Approach angle (L) deg. 24
Front wheel mm 585

Minimum ground clear-
Center wheel mm 525
ance (M)
Rear wheel mm 520
Ground clearance (N) (Articulate section) mm 510
Minimum ground clearance (dump body lower edge) (P) mm 600
Dump body loading height (when body is raised) (Q) mm 2,790

Dump body height (unloaded) (R) mm 6,430
Rear axis – axis pin (R2) mm 580
Rear axis – dump body rear edge mm 1,695
(when body is raised) (R3)
Cab width (T) mm 1,600

Body length (U) mm 4,965
HM300-2R 3
Model Komatsu SAA6D125E-5

Type 4-cycle, water-cooled, in-line 6 cylinder, direct
injection, with turbocharger and
air-cooled aftercooler
No. of cylinders – Bore x stroke mm 6–125 x 150
Piston displacement l{cc} 11.04{11,040}
Engine
Flywheel horsepower kW/rpm{HP/rpm} 254/2,000 {340/2,000}

Max. torque Nm/rpm{kgm/rpm} 1,706/1,400 {174/1,400}
Fuel consumption (rated) g/kWh{g/HPh} 209 {156}
Starting motor 7.5kW
Alternator 24V 50A
Battery 12V 136Ah x 2
Type 3-element, 1-stage, 2-phase

Torque converter Lock-up clutch Hydraulically-actuated, wet-type,
single-disc clutch
TORQFLOW multiple-axle transmission, fully

Type automatic, electrically-hydraulically actuated,
Transmission
Power train
force-feed type pump lubrication type

No. of speeds F6, R2
Type Spiral bevel gear, splash lubrication

Reduction gear Reduction ratio 3.154
Differential type Straight bevel gear, splash lubrication
Type Planetary gear, splash lubrication

Final drive
Reduction ratio 4.667
Travel system
Type Fully hydraulic
Front axle Full floating suspension (De Dion type)

Axle type Center axle Full floating suspension
Suspension
Rear axle Full floating suspension
Front axle Hydropneumatic type

Suspension method
Rear axle Hydropneumatic type
Front tire 23.5 R25 x 2

Size and No. Center tire 23.5 R25 x 2
Tires
Rear tire 23.5 R25 x 2
kPa
Tire inflation pressure 440 {4.5}
{kg/cm2}
4 HM300-2R
Front wheel Independent front and center system brake, sealed,

wet- type, multiple disc, hydraulically operated type
Main brake
Center wheel Independent front and center system brake, sealed,
Brakes
Parking brake Spring-boosted, caliper disc type
Independent front and center system brake, sealed,

Retarder
For steering, hoist

Type Gear pump
Discharge amount (l /min) 218 + 55
(when engine is at rated speed of 2000 rpm)
For hoist control

Type Gear pump
Discharge amount (l /min) 14.1
Hydraulic pump, motor
For transmission, brake cooling

Type Gear pump
Discharge amount (l /min) 168
Hydraulic system
For brake cooling

Type Gear pump
For brake
Type Gear pump
Hoist cylinder
Type 2-stage piston type
(only 2nd stage double-acting)
Cylinders
No. – bore (1st–2nd) x stroke 2–(140 mm-100 mm) x 2,897 mm

Steering cylinder
Type Piston type, double acting
No. – bore x stroke 2–110 mm x 420 mm
HM300-2R 5
Weight table 1
This weight table is a guide for use when transporting or handling components.
Unit: kg
Engine assembly 1,280

Output shaft assembly 65
Cooling assembly 228
Fuel tank (individual part) 219
Torque converter assembly 112
Transmission assembly 935
Drive shaft assembly 183
Front axle assembly 1,162
Differential 302
Final drive 802
Center axle assembly 1,451
Differential 301
Final drive 836
Rear axle assembly 895
Differential 194
Final drive 423
Front suspension cylinder 70
Rear suspension cylinder 54
Oscillation hitch assembly 634
Front frame 1,220
Rear frame 1,596
Cab (including interior components) 1,090
Operator’s seat 65
Steering cylinder (each) 56
Hoist cylinder (each) 183
Flow amp valve 29
Hoist valve 34
Hydraulic tank 187
Hydraulic pump (SDR(30) 100 + (20)25 + SB(1)6) 30
Hydraulic pump (SDR(30)75) 18
Hydraulic pump (SDR(30)80 + SA(1)18) 22
Hydraulic pump (SBL(1)26) 8
Body assembly 3,453
6 HM300-2R
Fuel, coolant and lubricants 1

a Regarding the details of notes (note 1, note 2, ...), refer to "Operation and maintenance manual".
• ASTM: American Society of Testing and Material
HM300-2R 7
Reservoir Transmission
Front Rear Front
Engine case Hydraulic
suspension suspension differential
oil pan (Incl. brake tank
(each) (each) Case
Capacity system tank)
l 44 165 171 3 2.2 14.0

Specified
US gal 11.62 43.59 45.18 0.79 0.58 3.70
l 37 77.5 120 3 2.2 14.0

Refill
US gal 9.78 20.48 31.70 0.79 0.58 3.70
Reservoir
Front final Center Center final Rear Rear final
Cooling
drive case differential drive case differential drive case Fuel tank
system
(each) case (each) case (each)
Capacity
l 4.5 25 4.0 25 5.0 384 65

Specified
US gal 1.19 6.61 1.06 6.61 1.32 101.45 17.17
l 4.0 24.5 3.5 25 4.5 – 59

Refill
US gal 1.06 6.47 0.92 6.61 1.19 – 15.59
Notice
Always use diesel oil for the fuel.
To ensure good fuel consumption characteristics and exhaust gas characteristics, the engine mounted
on this machine uses an electronically controlled high-pressure fuel injection device. This device
requires high precision parts and lubrication, so if low viscosity fuel with low lubricating ability is
used, the durability may drop markedly.
Note 1: HTHS (High-Temperature High-Shear Viscosity 150°C), specified by ASTM D4741 must be equal to or
higher than 3.5 mPa-S. Komatsu EOS0W30 and EOS5W40 are the most suitable oils.
Note 2: Powertrain oil has different properties from engine oil. Be sure to use the recommended oils.
Note 3: Hyper grease (G2-T, G2-TE) has a high performance.

When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking of
pins and bushings, the use of G2-T or G2-TE is recommended.
Note 4: Supercoolant (AF-NAC)

1) Coolant has the important function of anticorrosion as well as antifreeze.
Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential.
Komatsu machines are supplied with Komatsu Supercoolant AF-NAC. Komatsu Supercoolant AF-NAC
has excellent anticorrosion, antifreeze and cooling propertiesand can be used continuously for 2 years or
4000 hours.
Komatsu Supercoolant AF-NAC is strongly recommended wherever available.
2) For details of the ratio when diluting super coolant with water, see "Mixing rate of water and antifreeze".
Supercoolant AF-NAC may be supplied in premix. In this case, always top off with premix solution. (never
dilute with water)
3) To maintain the anticorrosion properties of Supercoolant AF-NAC, always keep the density of Supercool-
ant between 30% and 68%.
8 HM300-2R
Maxing rate of water and antifreeze
Min. atmospheric °C -10 -15 -20 -25 -30

temperature °F 14 5 -4 -13 -22
Liters 17.5 20.5 23.5 26.5 29.5
Amount of antifreeze
US gal 4.62 5.42 6.21 7.00 7.79
Liters 41.5 38.5 35.5 32.5 29.5
Amount of water
US gal 10.97 10.17 9.38 8.59 7.80
Volume ratio % 30 35 40 45 50
HM300-2R 9

© 2007 KOMATSU
All Rights Reserved
10 HM300-2R
SEN02664-00
HM300-2R

10 Structure, function and

maintenance standard 1
Engine and cooling system
Radiator, oil cooler, aftercooler ....................................................................................................................... 2
Output shaft .................................................................................................................................................... 3
HM300-2R 1
SEN02664-00 10 Structure, function and maintenance standard
Radiator, oil cooler, aftercooler 1
1. Reservoir tank Specifications

2. Radiator Radiator
3. Aftercooler • Core type: Aluminum louver four lines
4. Torque converter oil cooler • Total heat dissipation area: 80.36m2
5. Steering oil cooler Torque converter oil cooler
6. Upper tank • Core type: PTO-LS
7. Lower tank • Total heat dissipation area: 4.065m2
Steering oil cooler
A: To intake manifold • Core type: PTO-LS
B: From turbocharger • Total heat dissipation area: 0.497m2
C: From thermostat
D: To water pump
2 HM300-2R
Output shaft 1
1. Rubber cushion (large) Function

2. Rubber cushion (small) The output shaft is installed to the engine flywheel,
3. Coupling shaft and absorbs the twisting vibration caused by chang-
4. Breather es in the engine torque.
5. Flange
6. Outer body
7. Cover
8. Inner body
HM300-2R 3
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance

Clearance between bearing size Shaft Hole clearance limit
1
and inner body
+0.025 -0.020 -0.045 –
85 –
+0.003 -0.020 -0.013
Clearance between bearing -0.018 -0.020 -0.045 –
2 130 –
and flange -0.018 -0.045 -0.002
Clearance between retainer +0.006 +0.060 -0.014 –
3 130 –
and flange -0.034 +0.020 -0.094
Standard size Tolerance Repair limit
Wear of shaft and oil seal con- Replace
4 -0.074
tact surface 70 -0.12
-0.074
Standard backlash Backlash limit
5 Backlash at spline portion
0.071 – 0.177 0.35
Initial size Repair limit
Deterioration and cracks in
6 At min. width: Min. 63 mm
rubber 70
There must be no cracks
Deterioration and cracks in At min. width: Min. 48 mm
7 50
rubber There must be no cracks
4 HM300-2R
HM300-2R 5

© 2007 KOMATSU
All Rights Reserved
6 HM300-2R
SEN02665-00
HM300-2R


Power train, Part 1
Power train skeleton ....................................................................................................................................... 2
Torque converter and transmission hydraulic piping....................................................................................... 4
Brake cooling oil control valve (BCV).............................................................................................................. 6
Power train pump............................................................................................................................................ 7
Torque converter ........................................................................................................................................... 10
Transmission................................................................................................................................................. 16
Transmission control valve............................................................................................................................ 44
ECMV............................................................................................................................................................ 45
Main relief, torque converter relief valve ....................................................................................................... 52
HM300-2R 1
Power train skeleton 1
2 HM300-2R
1. Engine
2. Output shaft
3. Front drive shaft
4. Center brake cooling and brake system pump (SDR(30)80+SBR(1)18)
5. Power train, front brake cooling pump (SDR(30)75)
6. PTO
7. Torque converter
8. Steering, hoist control pump (SDR(30)100+(20)25+SAR(1)6)
9. Transmission
10. Center drive shaft
11. Oscillation hitch
12. Drive shaft (hitch)
13. Front limited slip differential
14. Front drive shaft
15. Tire
16. Final drive (front)
17. Brake (front)
18. Rear drive shaft (front)
19. Center limited slip differential
20. Tire
21. Final drive (center)
22. Brake (center)
23. Rear drive shaft (rear)
24. Rear limited slip differential
25. Tire
26. Final drive (rear)
27. Interaxle differential lock
HM300-2R 3
Torque converter and transmission hydraulic piping 1
4 HM300-2R
1. Engine
2. Oil cooler
3. Center brake cooling and brake system pump (SDR(30)80+SA(1)18)
4. Torque converter
5. Transmission
6. Transmission oil filter
7. Brake system tank
8. Power train, front brake cooling pump (SDR(30)75)
9. Transmission oil filter
10. Brake cooling oil control valve (center)
11. Brake cooling oil control valve (front)
HM300-2R 5
Brake cooling oil control valve (BCV) 1
1. Pilot relief valve assembly Function

2. Body • When the retarder is not being used, this valve
3. Solenoid valve bypasses part of the brake cooling oil to reduce
4. Main valve spool the power loss when traveling.
• The main valve spool is actuated by switching
S: To transmission the solenoid vavle ON/OFF.
Q: From transmission If any abnormal pressure is generated in the hy-
R: To oil cooler draulic circuit, the pilot relief valve is actusted,
and this actuates the main relief valve, so the
brake cooling valve also acts as an unload
valve.
6 HM300-2R
Power train pump 1

Power train, front brake cooling pump
Unit: mm
Model Tolerance Repair limit
1 Side clearance
SDR(30)-75 0.16 – 0.20 0.24
Clearance between inside
diameter of plain bearing and
2 SDR(30)-75 0.06 – 0.131 0.20
outside of diameter of gear Replace
shaft
Model Standard size Tolerance Repair limit
3 Depth for knocking in pin -0.5
SDR(30)-75 10 –
-0.5
4 Rotating torque of spline shaft 6.9 – 11.8 Nm {0.7 – 1.2 kgm}
Discharge
Rotating Standard Delivery
pressure
Delivery Model speed delivery limit
{MPa –
– Oil: EO10-CD (rpm) (l/min) (l/min)
(kg/cm2)}
Oil temperature: 45–55°C
20.6
SDR(30)-75 2,500 172.3 159.2
{210}
HM300-2R 7
Center brake cooling, brake cooling system pump
Unit: mm
1 Side clearance SDR(30)-80 0.16 – 0.20 0.24
SAR(1)-18 0.15 – 0.16 0.19
Clearance between inside SDR(30)-80 0.06 – 0.131
diameter of plain bearing and
2 0.20 Replace
outside of diameter of gear
SAR(1)-18 0.06 – 0.149
shaft
3 Depth for knocking in pin SDR(30)-80 -0.5
10 –
SAR(1)-18 -0.5
Discharge
pressure
Model speed delivery limit
{MPa
Delivery (rpm) (l/min) (l/min)
(kg/cm2)} –
– Oil: EO10-CD
20.6
Oil temperature: 45–55°C SDR(30)-80 184.5 170.4
{210}
2,500
24.5
SAR(1)-18 40.5 36.3
{250}
8 HM300-2R
HM300-2R 9
Torque converter 1
1
Unit: mm
Clearance between PTO gear size Shaft Hole clearance limit
1 and bearing +0.018 -0.012 -0.030 –
50 — Replace
+0.002 -0.012 -0.002
Clearance between bearing and -0.015 +0.004 -0.018 –
2 90 —
case -0.015 -0.018 0.019
3. Steering, hoist control pump Specifications

installation port Type: 3-element, 1-stage, 2-phase
4. Center brake cooling, brake system pump with modulation and lockup
installation port clutch
5. Power train, front brake cooling pump Lockup clutch: Wet type single-disc clutch
installation port hydraulic control
6. PTO gear (number of teeth: 66) (with modulation valve)
Stall torque ratio: 2.53
10 HM300-2R
1. Coupling 9. Stator shaft

2. Input shaft (number of teeth: 78) 10. Free wheel
3. Case 11. Stator
4. Drive case 12. Lockup clutch disc
5. Turbine 13. Lockup clutch piston
6. Race 14. Lockup clutch housing
7. Pump 15. Boss
8. Retainer 16. Retainer
HM300-2R 11
12 HM300-2R
Unit: mm
Outside diameter of oil seal
1 0
contact surface of coupling 95 94.8
-0.087
Inside diameter of seal ring +0.025
2 35 35.5
contact surface of input shaft 0
Inside diameter of seal ring
+0.089
3 contact surface of clutch hous- 365 365.5
0
ing
4 260 260.1
contact surface of clutch piston 0
5 140 140.5
contact surface of retainer 0
6 65 65.5
contact surface of stator shaft 0
-0.01
Wear of clutch hous- Width 5 4.5 Replace
7 -0.04
ing seal ring
Thickness 6 ±0.15 5.85
Inside diameter of
8 race free wheel transmission 102.555 ±0.008 102.585
surface
Outer diameter of
+0.004
9 stator shaft free wheel trans- 83.6 83.57
-0.009
mission surface
Inside diameter of sliding por- +0.015
10 83.71 83.79
tion of bushing 0
Thickness of sliding portion of
11 6 ±0.05 5.5
bushing
12 Thickness of clutch disc 5 ±0.1 4.5
Backlash between
13 0.18 – 0.46
input shaft and PTO gear
HM300-2R 13
Power transmission route
When lockup clutch is “disengaged“ When lockup clutch is “engaged“
Drive case (4) is disconnected from boss (8) and Drive case (4) is connected to boss (8) and turbine
turbine (7) and lockup torque converter works as an (7) and lockup torque converter is locked up.
ordinary torque converter.
The power from engine
The power from engine
O
O
Drive shaft
Drive shaft
O
O
Coupling (1)
Coupling (1)
O
O
Input shaft (2), clutch housing (3), drive case (4)
Input shaft (2), clutch housing (3), drive case (4)
and pump (5) rotate together
and pump (5) rotate together
O
O
Lockup clutch (6)
Oil is used as medium
O
O
Boss (8)
Turbine (7) and boss (8)
O
O
Transmission input shaft (9)
Transmission input shaft (9)
• The power transmitted to input shaft (2) is also
• The power transmitted to input shaft (2) is also
used as power for driving the pump after being
used as power for driving the pump after being
transmitted through PTO gear.
transmitted through PTO gear.
14 HM300-2R
Oil flow
• 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).
• The oil is given centrifugal force by pump (2) and
flows into turbine (3) to transfer its energy to tur-
bine (3).
• 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.
HM300-2R 15
Transmission 1
1
16 HM300-2R
A: To center brake cooling, Outline

brake system pump • The transmission adopted is a “forward 6-gear
B: To power train, speed and reverse 2-gear speed“ transmission
front brake cooling pump which consists of the counter-shaft type, con-
C: From transmission oil filter stant mesh spur gear mechanisms and the disc
D: Torque converter outlet oil pressure pick-up port clutches.
E: From return filter • The transmission selects one rotation direction
and rotation speed by fixing the counter-shaft
1. Transmission case (front) type, constant mesh spur gear mechanisms and
2. Transmission case (rear) 2 out of 6 sets disc clutch with the oil pressure by
3. Transmission intermediate shaft speed sensor ECMV operation.
4. Differential input speed sensor • The transmission transfers the power received
5. Oil filler tube mounting port by the transmission input shaft to the output
6. Differential output speed sensor shaft while changing the gear speed (forward
7. Torque converter outlet oil temperature sensor 1st-6th or reverse 1st-2nd) by any combination
8. Drain plug of the FL, FH, R clutches and 3 speed clutches.
9. Drain valve • The gear is automatically shifted with automatic
transmission based on the engine speed chang-
es.
Number of plates and discs used
Clutch No. Number of Number of discs

plates
FL clutch 11 10
R clutch 11 10
FH clutch 11 10
1st clutch 13 12
3rd clutch 10 9
2nd clutch 10 9
Combinations of clutches at respective gear

speeds and reduction ratio
Gear speed Operated clutches Reduction ratio
Forward 1st FL x 1st 6.477
Forward 2nd FH x 1st 4.103
Forward 3rd FL x 2nd 2.717
Forward 4th FH x 2nd 1.721
Forward 5th FL x 3rd 1.130
Forward 6th FH x 3rd 0.716
Neutral — —
Reverse 1st R x 1st 5.789
Reverse 2nd R x 2nd 2.429
HM300-2R 17
Unit: mm

Clearance between bearing and size Shaft Hole clearance limit
1
case
+0.032 0 -0.047– Replace
70 —
+0.002 -0.015 -0.002
Clearance between 0 -0.049 -0.073 –

2 100 —
R idler gear and bearing -0.015 -0.073 -0.034
3. Torque converter intermediate oil pressure sensor

4. Transmission input shaft speed sensor
5. Transmission control valve
6. Main relief, torque converter relief valve
7. R idler gear (number of teeth: 33)
8. Strainer
9. Power train lubricating oil temperature sensor
10. Lubricating oil relief valve
A: To front brake
18 HM300-2R
1. R clutch 9. Lower shaft

2. Upper gear (number of teeth: 53) 10. 3rd clutch
3. 1st clutch 11. Upper shaft
4. 2nd clutch 12. FH clutch
5. Differential lock clutch 13. Input shaft
6. Rear output shaft 14. FL clutch
7. Rear coupling 15. Torque converter
8. Front output shaft
HM300-2R 19
20 HM300-2R
Unit: mm
Clearance between
size Shaft Hole clearance limit
1 FL, R clutch bearing and case
(front) -0.015 -0.010 -0.045 –
120 —
-0.015 -0.045 0.005
Clearance between
-0.015 -0.012 -0.052 –
2 FL, R clutch bearing and case 130 —
-0.018 -0.052 0.006
(rear)
Clearance between
-0.015 -0.012 -0.052 –
3 FH, 1st clutch bearing and case 130 —
-0.018 -0.052 0.006
(front)
Clearance between
-0.015 -0.012 -0.052 –
4 FH, 1st clutch bearing and case 130 —
-0.018 -0.052 0.006
(rear)
Clearance between
+0.054 -0.015 -0.069 –
5 FH, 1st clutch bearing and 60 —
+0.044 -0.015 -0.044
upper shaft (rear)
Clearance between
-0.015 -0.010 -0.045 –
6 2nd, 3rd clutch bearing and 120 —
-0.018 -0.045 0.008
case (front)
Clearance between
-0.015 -0.015 -0.045 –
7 2nd, 3rd clutch bearing and 120 —
-0.018 -0.045 0.003
case (rear)
Clearance between
-0.015 -0.014 -0.060 –
8 differential lock clutch bearing 230 —
-0.030 -0.060 0.016
and case (front)
Replace
Clearance between
-0.015 +0.013 -0.033 –
9 differential lock clutch bearing 210 —
-0.030 -0.033 0.017
and case (rear)
Width of input shaft
10 +0.18
seal ring groove 2.5 2.7
+0.10
Width of input shaft +0.076
11 3.2 3.5
seal ring groove +0.076
+0.050
contact surface of input and 60 60.1
+0.076
12 upper shafts (rear)
Width of input and upper shafts +0.076
3.2 3.5
seal ring grooves (rear) +0.076
+0.050
contact surface of lower shaft 50 50.1
+0.076
13 (rear)
Width of lower shaft +0.076
3.2 3.5
seal ring groove (rear) +0.076
+0.030
contact surface of front output 80 80.1
+0.076
14 shaft
Width of front output shaft +0.076
3.2 3.5
seal ring groove +0.076
Outside diameter of oil seal -0.087
15 95 94.8
contact surface of rear coupling -0.087
HM300-2R 21
FL, R clutch
A: R clutch oil port C: Lubrication oil port

B: FL clutch oil port D: Lockup clutch oil port
1. Input shaft 5. FL, R cylinder (number of teeth: 78)

2. Input gear (number of teeth: 41) 6. R clutch
3. FL clutch gear (number of teeth: 34) 7. R clutch gear (number of teeth: 28)
4. FL clutch
Unit: mm

Clearance between size Shaft Hole clearance limit
8
FL, R shaft and bearing (front)
+0.033 -0.015 -0.048 – —
65
+0.022 -0.015 -0.022
Clearance between +0.033 -0.015 -0.048 – —
9 60
FL, R shaft and bearing (rear) +0.022 -0.015 -0.022
10 Clutch plate Thickness 1.7 ±0.05 1.5
Strain — 0.05 0.15 Replace
Thickness 2.2 ±0.08 1.75

11 Clutch disc
Strain — 0.10 0.25
Wave spring load 1,010 N ±101 N 859 N
12 {87.6 kg}
[Test height: 2.2 mm] {103 kg} {±10.3 kg}
Thickness of thrust washer 2.7
13 3 ±0.1
(FL clutch)
14 3 ±0.1
(R clutch)
22 HM300-2R
FH, 1st clutch
A: 1st clutch oil port C: Lubrication oil port

B: FH clutch oil port
1. FH clutch gear (number of teeth: 55) 4. 1st clutch

2. FH clutch 5. 1st clutch gear (number of teeth: 29)
3. FH, 1st cylinder (number of teeth: 72) 6. Upper shaft
Unit: mm

7
FH, 1st shaft and bearing (front)
+0.033 -0.015 -0.048 – —
60
+0.022 -0.015 -0.022
Strain — 0.05 0.15
Clutch disc Thickness 2.2 ±0.08 1.75

9 Replace
(FH clutch) Strain — 0.10 0.25

10
(1st clutch) Strain — 0.10 0.25
Wave spring load 1,010 N ±101 N 859 N
11
[Test height: 2.2 mm] {103 kg} {±10.3 kg} {87.6 kg}
Thickness of thrust washer ±0.1 2.7
12 3
(FH clutch)
13 3 ±0.1
(1st clutch)
HM300-2R 23
2nd, 3rd clutch
A: 3rd clutch oil port C: Lubrication oil port

B: 2nd clutch oil port
1. 3rd clutch gear (number of teeth: 26) 4. 2nd clutch

2. 3rd clutch 5. 2nd clutch gear (number of teeth: 46)
3. 2nd, 3rd cylinder (number of teeth: 60, 46) 6. Lower shaft
24 HM300-2R
Unit: mm

Clearance between size clearance limit
Shaft Hole
7 2nd, 3rd shaft and bearing
(front) +0.035 0 -0.050 – —
55
+0.020 -0.015 -0.020
Clearance between
+0.035 0 -0.050 – —
8 2nd, 3rd shaft and bearing 55
+0.020 -0.015 -0.020
(rear)
Clutch plate 1.5
9 Thickness 1.7 ±0.05
(3rd clutch)
Strain — 0.05 0.15
Clutch plate Thickness 2.0 ±0.05 1.8

10
(2nd clutch) Strain — 0.05 0.15
Clutch disc Thickness 2.2 ±0.08 1.75 Replace

11
(3rd clutch) Strain — 0.10 0.25

12
(2nd clutch) Strain — 0.10 0.25
Wave spring load 859 N
1,010 N ±101 N
13 (3rd clutch) {87.6 kg}
{103 kg} {±10.3 kg}
[Test height: 2.2 mm]
Wave spring load ±115 N 1,090 N
1,270 N
14 (2nd clutch) {±11.7 kg} {111 kg}
{130 kg}
[Test height: 3.8 mm]
Thickness of thrust washer ±0.1 2.7
15 3
(3rd clutch)
16 4 ±0.1
(2nd clutch)
HM300-2R 25
Differential lock clutch
A: Lubrication oil port

B: Differential lock clutch oil port
1. Front output shaft 7. Planetary gear (number of teeth: 22)

2. Front housing 8. Ring gear (number of teeth: 88)
3. Clutch hub 9. Sun gear (number of teeth: 44)
4. Differential lock clutch 10. Rear housing
5. Output gear (number of teeth: 68) 11. Rear output shaft
6. Carrier
26 HM300-2R
Unit: mm

12
front housing and bearing
+0.065 -0.015 -0.090 – —
170
+0.040 -0.025 -0.040
Clearance between +0.080 -0.015 -0.105 – —
13 150
rear housing and bearing +0.055 -0.025 -0.055
Clearance between -0.015 -0.020 -0.045 – —
14 140
front housing and bearing -0.018 -0.045 -0.002
Clearance between
+0.030 -0.015 -0.045 – —
15 front output shaft and bearing 80
+0.011 -0.015 -0.011
(front)
Clearance between
-0.015 -0.035 -0.075 – —
16 rear housing and bearing 140
-0.020 -0.075 -0.015
(large)
Clearance between
+0.024 -0.015 -0.039 – —
17 rear output shaft and bearing 80
+0.011 -0.015 -0.011
(large)
Clearance between
-0.015 -0.035 -0.075 – Replace
18 rear housing and bearing 130 —
-0.020 -0.075 -0.015
(small)
Clearance between
+0.024 -0.015 -0.039 – —
19 rear output shaft and bearing 75
+0.011 -0.015 -0.011
(small)
Strain — 0.05 0.15
Thickness 3.2 ±0.10 2.75
21 Clutch disc
Strain — 0.20 0.25
Inside diameter of seal ring +0.035 90.1 0.25
90
contact surface of front housing +0.035
Width of front output shaft +0.15 3.3
3.0
22 seal ring groove +0.10
-0.01 2.7
Wear of front output Width 3.0
-0.03
shaft seal ring
Thickness 3.7 ±0.12 3.3
HM300-2R 27
Operation of the disc clutch
When clutch is “engaged“ (fixed) When clutch is “disengaged“ (Released)
• The oil sent from the ECMV flows through the oil • When the oil sent from the ECMV is shut off,
passage of shaft (1), is pressure-fed to the back pressure of the oil acting on the back face of pis-
side of piston (2), and pushes piston (2) to the ton (2) goes down.
right. • Piston (2) is pushed back to the left by the ten-
• Piston (2) compresses plates (3) and discs (4) sion of wave spring (7).
and the rotation of discs (4) is stopped by the • The friction force between plates (3) and discs
frictional force. (4) is eliminated and shaft (1) and clutch gear (5)
• As the internal teeth of disc (4) are meshed with are released.
clutch gear (5), shaft (1) and cluch gear (5) • When the clutch is released, the oil in the back
transfer the power as a unit. side of piston is drained by the centrifugal force
• The oil is drained from oil drain hole (6), but the through oil drain hole (6) to prevent the clutch
drain amount is less than the amount of oil sup- from being partially applied.
plied, so there is no influence on the actuation of
the clutch. a Oil drain hole (6) is configured only for the 2nd,
differential lock clutch.
28 HM300-2R
HM300-2R 29
Power transmitting route
Forward 1st speed
a The diagram above shows the situation when the differential lock is "off".
30 HM300-2R
FL clutch (4) and 1st clutch (12) are fixed hydraulically.
The power from the torque converter

O
Input shaft (1)
O
FL and R cylinders (2)
O
FL clutch (4)
O
FL clutch gear (6)
O
FL and 1st cylinders (9)
O
1st clutch (12)
O
1st clutch gear (13)
O
2nd and 3rd cylinders (15)
O
Output gear (20)
(The operation when differential lock is turned
"OFF" is explained below)
O
Carrier (21)
O
Planetary gear (25)
O
Sun gear (26) Ring gear (27)
O O
Front output shaft (28) Rear output shaft (29)
a If the differential lock is "on", see Forward 2nd speed.
HM300-2R 31
Forward 2nd speed
a The diagram above shows the situation when the differential lock is "on".
32 HM300-2R
FH clutch (11) and 1st clutch (12) are fixed hydraulically.

O
Input shaft (1)
O
Input gear (3)
O
FH clutch gear (10)
O
FH clutch (11)
O
FH and 1st cylinders (9)
O
1st clutch (12)
O
O
O
Output gear (20)
"ON" is explained below)
O
Carrier (21)
O
Front housing (22)
O
Differential lock clutch (23) Planetary gear (25)
O O
Clutch hub (24) Ring gear (27)
O O
a If the differential lock is "off", see Forward 1st speed.
HM300-2R 33
Forward 3rd speed
34 HM300-2R
FL clutch (4) and 2nd clutch (18) are fixed hydraulically.

O
Input shaft (1)
O
O
FL clutch (4)
O
FL clutch gear (6)
O
O
Idler gear (14)
O
2nd clutch gear (16)
O
2nd clutch (18)
O
O
Output gear (20)
O
Carrier (21)
O
Planetary gear (25)
O
O O
HM300-2R 35
Forward 4th speed
36 HM300-2R
FH clutch (11) and 2nd clutch (18) are fixed hydraulically.

O
Input shaft (1)
O
Input gear (3)
O
FH clutch gear (10)
O
FH clutch (11)
O
O
Idler gear (14)
O
2nd clutch gear (16)
O
2nd clutch (18)
O
O
Output gear (20)
O
Carrier (21)
O
Front housing (22)
O
O O
O O
HM300-2R 37
Forward 5th speed
38 HM300-2R
FL clutch (4) and 3rd clutch (19) are fixed hydraulically.

O
Input shaft (1)
O
O
FL clutch (4)
O
FL clutch gear (6)
O
O
3rd clutch gear (17)
O
3rd clutch (19)
O
O
Output gear (20)
O
Carrier (21)
O
Planetary gear (25)
O
O O
HM300-2R 39
Forward 6th speed
40 HM300-2R
FH clutch (11) and 3rd clutch (19) are fixed hydraulically.

O
Input shaft (1)
O
Input gear (3)
O
FH clutch gear (10)
O
FH clutch (11)
O
O
3rd clutch gear (17)
O
3rd clutch (19)
O
O
Output gear (20)
O
Carrier (21)
O
Front housing (22)
O
O O
O O
HM300-2R 41
Reverse 1st speed
42 HM300-2R
R clutch (5) and 1st clutch (12) are fixed hydraulically.

O
Input shaft (1)
O
O
R clutch (5)
O
R clutch gear (7)
O
R idler gear (8)
(Output rotation is reversed through R idler gear (8).)
O
Upper gear (14)
O
O
1st clutch (12)
O
O
O
Output gear (20)
O
Carrier (21)
O
Planetary gear (25)
O
O O
HM300-2R 43
Transmission control valve 1
A: Differential lock clutch oil pressure pick-up port Operation table of ECMV
B: FH clutch oil pressure pick-up port ECMV
C: 1st clutch oil pressure pick-up port Gear FL FH R 1st 2nd 3rd L/U D/L
D: FL clutch oil pressure pick-up port speed
E: R clutch oil pressure pick-up port F1 Q Q Q Q
F: 3rd clutch oil pressure pick-up port
F2 Q Q Q Q
G: 2nd clutch oil pressure pick-up port
H: Lockup clutch oil pressure pick-up port F3 Q Q Q Q
F4 Q Q Q
1. Differential lock clutch ECMV F5 Q Q Q
2. FH clutch ECMV F6 Q Q Q
3. 1st clutch ECMV R1 Q Q Q
4. FL clutch ECMV
R2 Q Q Q
5. R clutch ECMV
6. 3rd clutch ECMV N Q
7. 2nd clutch ECMV L/U: Lockup clutch ECMV
8. Lockup clutch ECMV D/L: Differential lock clutch ECMV
9. Seat
10. Last chance filter Outline
• Lockup clutch ECMV operates when traveling
forward at the speed higher than the set speed
of transmission controller.
• Differential lock clutch ECMV operates in the 3rd
or lower gear speeds.
44 HM300-2R
ECMV 1
a ECMV: Abbreviation for Electronic Control Modulation Valve
For FL, FH, R, 1st, 2nd, 3rd clutches

a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
A: To clutch *1:
P: From pump Operated clutches Stamp of the nameplates
T: Drain
Dr: Drain FL, FH, R, 1st L*******
P1: Clutch oil pressure pick-up port 2nd, 3rd A*******
1. Fill switch connector

2. Proportional solenoid connector
3. Pressure detection valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
7. Nameplate (*1)
HM300-2R 45
Outline of ECMV ECMV and proportional solenoid

• The ECMV consists of 1 pressure control valve • For each ECMV, 1 proportional solenoid is in-
and 1 fill switch. stalled.
• Pressure control valve The proportional solenoid generates thrust
This valve receives the current sent from the shown below according to the command current
transmission controller with a proportional sole- from the controller.
noid, and then converts it into oil pressure. The thrust generated by the proportional sole-
• Fill switch noid is applied to the pressure control valve
This switch detects that the clutch is filled with spool to generate oil pressure as shown in the
oil and has the following functions. figure below. Accordingly, the thrust is changed
1. Outputs a signal (a fill signal) to the controller to by controlling the command current to operate
notify that filling is completed when the clutch is the pressure control valve to control the flow
filled with oil. and pressure of the oil.
2. Keeps outputting signals (fill signals) to the con-
troller to notify whether oil pressure is applied or Current - propulsion force characteristics of
not while oil pressure is applied to the clutch. proportional solenoid
Propulsion force - Hydraulic pressure character-

istics of proportional solenoid
Range A: Before shifting gear (When draining)

Range B: During filling
Range C: Pressure regulation
Range D: During filling (During triggering) ECMV and fill switch
Point E: Start of filling • For each ECMV, 1 fill switch is installed.
Point F: Finish of filling If the clutch is filled with oil, the fill switch is
a The logic is so made that the controller will not turned “on“ by the pressure of the clutch. The oil
recognize completion of filling even if the fill pressure is built up according to this signal.
switch is turned “on“ during triggering (Range
D).
46 HM300-2R
Operation of ECMV Before shifting gear (when draining) (Range A in

• ECMV is controlled with the command current chart)
sent from the controller to the proportional sole-
noid and the fill switch output signal.
The relationship between the proportional sole-
noid command current of ECMV, clutch input
pressure, and fill switch output signal is shown
below.
• Under the condition where any current is not

sent to proportional solenoid (1), pressure con-
trol valve (3) drains the oil from clutch port (A)
through drain port (T).
Also at this time, fill switch (5) is turned “off“
because oil pressure is not applied to pressure
Range A: Before shifting gear (When draining) detection valve (4).
Range B: During filling
Range C: Pressure regulation
Range D: During filling (During triggering)
Point E: Start of filling
Point F: Finish of filling
a The logic is so made that the controller will not

recognize completion of filling even if the fill
switch is turned “on“ during triggering (Range
D).
HM300-2R 47
During filling (Range B in chart) Pressure regulation (Range C in chart)
• If current is applied to proportional solenoid (1) • If current flows in proportional solenoid (1), the
with no oil in the clutch, the oil pressure force solenoid generates thrust in proportion to the
balanced with the solenoid force is applied to current. This thrust of the solenoid is balanced
chamber (B) and pushes pressure control valve with the sum of the thrust generated by the oil
(3) to the left. This opens pump port (P) and pressure in clutch port and the tension of pres-
clutch port (A) to feed oil in the clutch. When the sure control valve spring (2), and then the pres-
clutch is filled with oil, pressure detection valve sure is settled.
(4) actuates to turn “on“ fill switch (5).
48 HM300-2R
For lockup, differential lock clutch

a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
A: To clutch *1:
P: From pump Operated clutches Stamp of the nameplates
T: Drain Lockup,
Dr: Drain K*******
differential lock
P1: Clutch oil pressure pick-up port
1. Proportional solenoid connector

2. Sleeve
3. Proportional solenoid
4. Pressure control valve
5. Nameplate (*1)
HM300-2R 49
Outline
ECMV for lockup clutch ECMV for differential lock clutch
• This valve acts to set the lockup clutch oil pres- • For each ECMV, 1 proportional solenoid is in-
sure to the set pressure, and also to switch the stalled.
lockup clutch. The proportional solenoid generates thrust
It forms a modulation wave pattern, so the shown below according to the command current
lockup clutch is engaged smoothly to reduce from the controller.
the shock when shifting gear. In addition, it pre- The thrust generated by the proportional sole-
vents generation of peak torque in the power noid is applied to the pressure control valve
train. As a result, it provides a comfortable ride spool to generate oil pressure as shown in the
for the operator and greatly increases the dura- figure below. Accordingly, the thrust is changed
bility of the power train. by controlling the command current to operate
the pressure control valve to control the flow
Torque converter travel o direct travel and pressure of the oil.
Current - propulsion force characteristics of

proportional solenoid
When shifting gear (direct travel)
Propulsion force - hydraulic pressure character-

istics of proportional solenoid
50 HM300-2R
Operation
When clutch is “disengaged“ (Released) When clutch is “engaged“ (fixed)
• Under the condition where any current is not • If current is applied to proportional solenoid (1),
sent to proportional solenoid (1), pressure con- the oil pressure force balanced with the solenoid
trol valve (3) drains the oil from clutch port (A) force is applied to chamber (B) and pushes pres-
through drain port (T). sure control valve (3) to the left. As a result, the
circuit between pump port (P) and clutch port (A)
opens, and oil starts to fill the clutch.
• When the clutch is filled with oil, the propulsion
force of the solenoid, the propulsion force gener-
ated by the oil pressure in the clutch port, and
the tension of pressure control valve spring (2)
come into balance, and the pressure is adjusted.
HM300-2R 51
Main relief, torque converter relief valve 1
Unit: mm

Clearance between main size Shaft Hole clearance limit
1
relief valve and the valve body -0.035 +0.013 0.035 –
28 0.078
-0.045 +0.013 0.058
Clearance between torque
-0.035 +0.013 0.035 –
2 converter relief valve and valve 22 0.078
-0.045 +0.013 0.058
body
Standard size Repair limit
Replace
Installed Installed Installed
Main relief valve spring Free length Free length
3 length load load
(outside)
275 N 261 N
108 79.5 104.8
{28.0 kg} {26.6 kg}
Main relief valve spring 326 N 309 N
4 108 79.5 104.8
(inside) {33.2 kg} {31.5 kg}
Torque converter relief valve 173 N 164 N
5 50 41 48.5
spring {17.6 kg} {16.7 kg}
6. Body A: Drain (Torque converter relief)

7. Piston B: Drain
8. Torque converter relief valve C: From pump
9. Piston D: Drain
10. Main relief valve E: To torque converter
P1: Main relief oil pressure pick-up port
P2: Torque converter relief oil pressure pick-up port
52 HM300-2R
Outline Operation of main relief valve
Torque converter relief valve

The torque converter relief valve maintains the oil
pressure in the torque converter inlet circuit always
below the set pressure in order to protect the torque
converter from abnormally high pressure.
Set pressure: 0.91 MPa {9.31 kg/cm2}
(Cracking pressure)
Main relief valve

The main relief valve is keeping each oil pressure of
the transmission and the brake below the set pres-
sure.
Set pressure: 2.55 MPa {26.0 kg/cm2}
• The oil from the hydraulic pump flows through
(Engine at rated rotation)
the filter, port (C) of the relief valve, and orifice
(a) of main relief valve (1) to chamber (F).
Operation
Operation of torque converter relief valve
• When the oil pressure in the circuit exceeds the

set pressure, the oil in chamber (F) pushes pis-
ton (2), the reaction force of which moves spool
• The oil from the main relief valve flows through (1) to the left to open port (C) and port(E).
port (E) to the torque converter, and at the same Then the oil from the pump flows through port
time, also flows through orifice (b) of torque con- (E) into the torque converter.
verter relief valve (3) to chamber (G).
• When the oil pressure on the torque converter
exceeds the set pressure, the oil in chamber (G)
pushes piston (4), the reaction force of which
moves torque converter relief valve (3) to the
right to open port (E) and port (A).
Then the oil in port (E) is drained from port (A)
to the oil tank.
HM300-2R 53

© 2007 KOMATSU
All Rights Reserved
54 HM300-2R
SEN02666-00
HM300-2R


Power train, Part 2
Drive shaft....................................................................................................................................................... 2
Axle ................................................................................................................................................................. 3
Differential ....................................................................................................................................................... 6
Limited slip differential .................................................................................................................................. 12
Final drive ..................................................................................................................................................... 16
HM300-2R 1
Drive shaft 1
1. Drive shaft (right) Outline

2. Front drive shaft • The power from the engine goes from the output
3. Drive shaft (left) shaft through front drive shaft (2), the transmis-
4. Center drive shaft sion, and the differential, and is transmitted to fi-
5. Rear drive shaft (front) nal drive by right and left drive shafts (1) and (3).
6. Rear drive shaft (rear) The rest of the power passes through center
drive shaft (4) and the oscillation hitch, and is
transmitted by rear drive shafts (5) and (6) to
the center and rear axles.
• The drive shaft does not only transmit the power
but also has the following function.
When the machine articulates or receives
impacts from the ground and other things during
travel and operation, the positions of the
engine, transmission, and each axle change.
The drive shaft has the universal joints and slid-
ing joints to absorb the change of angles and
lengths and transmit the power without damag-
ing the parts even when the positions of the
components change and impacts are given to
the machine.
2 HM300-2R
Axle 1
Front
1. Drive shaft
2. Front differential
3. Brake
4. Final drive
HM300-2R 3
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
4 HM300-2R
Rear
1. Drain plug
2. Oil filler port used as oil level plug
3. Rear axle housing
4. Rear differential
5. Final drive
HM300-2R 5
Differential 1
Front
1. Bevel gear (No. of teeth: 41) 6. Shaft

2. Bevel pinion (No. of teeth: 13) 7. Drive shaft
3. Limited slip differential 8. Disc
4. Side gear (No. of teeth: 24) 9. Plate
5. Pinion gear (No. of teeth: 12)
6 HM300-2R
Unit: mm

Wear of coupling oil seal con-
10 -0.087
tact surface 95 94.9 Repair or
-0.087
replace
Wear of coupling oil seal con- -0.087
11 90 89.9
tact surface -0.087
Backlash between bevel gear
12 0.36 – 0.55 (in circumferential direction at outside diameter) Adjust
and pinion
HM300-2R 7
Center
1. Bevel pinion (No. of teeth: 13) 8. Shaft

2. Disc 9. Gear (No. of teeth: 27)
3. Plate 10. Shaft
4. Pinion gear (No. of teeth: 12) 11. Coupling
5. Limited slip differential 12. Shaft
6. Bevel gear (No. of teeth: 41) 13. Gear (No. of teeth: 27)
7. Side gear (No. of teeth: 24)
8 HM300-2R
Unit: mm

Wear of coupling oil seal con- Repair or
14 -0.087
tact surface 95 94.9 replace
-0.087
Wear of coupling oil seal -0.087 Repair or
15 90 89.9
contact surface -0.087 replace
and pinion
HM300-2R 9
Rear
1. Bevel pinion (No. of teeth: 13)

2. Plate
3. Disc
4. Bevel gear (No. of teeth: 41)
5. Shaft
6. Limited slip differential
7. Pinion gear (No. of teeth: 12)
8. Side gear (No. of teeth: 24)
10 HM300-2R
Unit: mm

Wear of coupling oil seal con- Repair or
9 -0.087
tact surface 90 89.9 replace
-0.087
and pinion
HM300-2R 11
Limited slip differential 1
1. Washer
2. Plate
3. Disc
4. Pressure ring
5. Bevel gear
6. Side gear
7. Pinion gear
8. Shaft
9. Case
10. Cover
11. Shaft
12 HM300-2R
Unit: mm

1 Plate thickness 3.1
± 0.02 2.3
3.2
2 Disc thickness 3.2 ± 0.07 3.1
Clearance between disc and
3 0.2 – 0.75
plate (Total on both sides)
4 Replace
4 Washer thickness ± 0.05 3.8
4.1
End play of side gear in axial
5 0.15 – 0.35
direction (Each side)
Backlash between case and
6 0.4 – 0.7
plate
Backlash between side gear
7 0.13 – 0.36
and disc
HM300-2R 13
Operation of limited slip differential When travelling in a straight line

The power transmitted from the transmission goes 1. When there is no imbalance between drive
from bevel gear (5) to case (9), pressure ring (4), force of left and right wheels.
shaft (8), pinion gear (7), side gear (6), and is then (The road surface condition (friction coeffident)
divided and sent to left and right shafts (11). A brake for the left and right wheels and the load on the
mechanism consisting of disc (2) and plate (3) is as- wheels are uniform.)
sembled at the rear face of side gear (6), and the The power from the transmission is divided uni-
brake torque is generated in proportion to the torque formly to the left and right by the side gear. Un-
transmitted from pressure ring (4) to shaft (8). der these conditions, the limit for wheel slip for
In order for this brake torque to act to suppress the the left and right wheels is the same, so even if
rotation in relation to side gear (6) and case (9), it is the power from the transmission exceeds the
made difficult for left and right side gears (6) to rotate wheel slip limit, the wheels on both sides slip
mutually, and the action of the differential is sup- and the differential is not actuated.
pressed. No load is applied to the brake at the rear sur-
face of the side gear.
Mechanism for generation of brake torque of left
and right side gears (6)
Shaft (8) is supported by the cam surface cut into the
mating surfaces of left and right pressure rings (4).
The power (= torque) transmitted from pressure ring
(4) to shaft (8) is transmitted by the cam surface, but
force (Fa) to separate left and right pressure rings (4)
is generated in proportion to the torque transmitted
by the angle of this cam surface.
This separation load (Fa) acts as a brake on the rear
face of left and right side gears (6) and generates
brake torque.
14 HM300-2R
2. When there is imbalance between drive force

of left and right wheels
(The road surface condition (friction coefficient)
for the left and right wheels and the load on the
wheels are not uniform and the wheel on one
side tends to slip more than the wheel on the
other side.)
Example:
When wheel on one side is on soft ground sur-
face.
The power from the transmission is divided uni-

formly to the left and right by the side gear.
However, if the divided drive force exceeds the
wheel slip limit on the side where the wheel is
slipping, a drive force equal to the excess is sent
through the brake at the rear face of the side
gear and the case to the brake on the opposite
side (side where wheel is locked), and is sup-
plied to the wheel on the side which is locked.
If this excess drive force becomes greater than
the braking force, the differential starts to be ac-
tuated.
Difference in wheel drive force for each type of differ-

ential when wheel on one side is slipping
Wheel drive force

(taken as 1 for wheel that is slipping)
Slipping Locked Total

wheel wheel (proportional)
Limited slip
1 2.64 3.64 (1.82)
differential
Normal
1 1 2 (1)
differential
On road surfaces where the wheel on one side is

likely to slip, the limited slip differential increases the
drive force 1.82 times that of the normal differential
supplied as standard.
<When turning>
The side gear built into the limited slip differential is
the same as the gear used on the normal differential,
so the difference in rotation of the inside and outside
wheels generated when turning can be generated
smoothly.
HM300-2R 15
Final drive 1
Front
1. Shaft
2. Ring gear (No. of teeth: 66)
3. Planetary gear (No. of teeth: 23)
4. Planetary carrier
5. Sun gear (No. of teeth: 18)
6. Drain plug
7. Brake
16 HM300-2R
Unit: mm
Backlash between planetary

8 0.17 – 0.41
gear and sun gear
Replace
9 0.20 – 0.55
gear and ring gear
10 Curvature of shaft Repair limit: 0.7TIR Repair or replace
11 Thickness of spacer Replace
14 ± 0.1 13.5
Wear of outside diameter of
+0.040
12 portion of ring gear hub 170 170
+0.015
inserted into bearing
Repair
-0.030
13 portion of axle tube inserted 140 139.83
-0.055
into bearing

Clearance between shaft (out- size Shaft Hole clearance limit
14 Replace
side diameter) and bushing
-0.013 +0.337 0.251 –
65 0.4
-0.013 +0.251 0.350
HM300-2R 17
Center
1. Shaft 5. Sun gear (No. of teeth: 18)

2. Ring gear (No. of teeth: 66) 6. Drain plug
3. Planetary gear (No. of teeth: 23) 7. Brake
4. Planetary carrier
Unit: mm

8 0.17 – 0.41
gear and sun gear
Replace
9 0.20 – 0.55
gear and ring gear
28 ± 0.1 27.5
+0.040
+0.015
Repair
-0.030
-0.055
into bearing
18 HM300-2R
Rear
1. Shaft 4. Planetary carrier

2. Ring gear (No. of teeth: 66) 5. Sun gear (No. of teeth: 18)
3. Planetary gear (No. of teeth: 23) 6. Drain plug
Unit: mm

7 0.17 – 0.41
gear and sun gear
Replace
8 0.20 – 0.55
gear and ring gear
28 ± 0.1 27.5
+0.040
+0.015
Repair
-0.030
-0.055
into bearing
HM300-2R 19
Function
• The final drive uses a planetary gear mechanism
to reduce the speed in order to give a large drive
force, and transmits this drive force to the tires.
Operation
• The power from the differential passing through
shaft (1) is transmitted to sun gear (5) and then
goes to planetary gear (3).
The planetary gear rotates on the inside of fixed
ring gear (2) and transmits the reduced speed
to planetary carrier (4). This power is then
transmitted to the wheels that are installed to
the planetary carrier.
20 HM300-2R
HM300-2R 21

© 2007 KOMATSU
All Rights Reserved
22 HM300-2R
SEN02667-00
HM300-2R


Steering system
Steering column .............................................................................................................................................. 2
HM300-2R 1
Steering column 1
1. Steering shaft
2. Steering column
3. Lock lever
4. Yoke
5. Joint shaft
6. Steering valve
2 HM300-2R
HM300-2R 3

© 2007 KOMATSU
All Rights Reserved
4 HM300-2R
SEN02668-00
HM300-2R


Brake system
Brake piping .................................................................................................................................................... 2
Brake valve ..................................................................................................................................................... 4
Accumulator charge valve............................................................................................................................... 7
Accumulator ...................................................................................................................................................11
Slack adjuster ............................................................................................................................................... 12
Brake............................................................................................................................................................. 14
Proportional reducing valve .......................................................................................................................... 19
Brake system tank ........................................................................................................................................ 20
Parking brake................................................................................................................................................ 22
Parking brake solenoid ................................................................................................................................. 26
HM300-2R 1
Brake piping 1
2 HM300-2R
1. Slack adjuster (Front)

2. Shuttle valve
3. Slack adjuster (center)
4. Proportional reducing valve
5. Accumulator (for center)
6. Accumulator (for front)
7. Parking brake solenoid valve
8. Brake system tank
9. Accumulator charge valve
10. Brake valve
11. Brake filter
HM300-2R 3
Brake valve 1
1. Pilot piston A: To center brake

2. Rod B: To front brake
3. Lower cylinder T: To brake system tank
4. Spool PA: From center accumulator
5. Upper cylinder PB: From front accumulator
6. Spool
4 HM300-2R
Operation Applying brake when upper valve fails

• Even if there is leakage of oil in the upper piping,
Upper portion spool (5) is moved down mechanically when
• When brake pedal (1) is depressed, the operat- pedal (1) is depressed, and the lower portion is
ing force is transmitted to spool (3) through rod actuated normally.
(2) and spring (4). When spool (3) goes down, The upper portion of center brake is not actu-
drain port (a) is closed, and the oil from the pump ated.
and accumulator flows from port (PA) to port (A)
and actuates the center brake cylinders. Applying brake when lower valve fails
• Even if there is leakage of oil in the lower piping,
Lower portion the upper portion of brake is actuated normally.
• When brake pedal (1) is depressed, the operat-
ing force is transmitted to spool (3) through rod
(2) and spring (4). When spool (3) goes down,
spool (5) is also pushed down by plunger (6).
When this happens, drain port (b) is closed, and
the oil from the pump and accumulator flows
from port (PB) to port (B) and actuates the front
brake cylinders.
When actuation is balanced

Upper portion
• When oil fills the center brake cylinders and the
pressure between port (PA) and port (A) be-
comes high, the oil entering port (H) from orifice
(e) of spool (3) pushes against spring (4). It
pushes up spool (3) and shuts off the circuit be-
tween port (PA) and port (A). When this hap-
pens, drain port (a) stays closed, so the oil
entering the brake cylinder is held and the brake
remains applied.
HM300-2R 5
Lower portion Brake released

• When spool (3) in the upper portion moves up
and the circuit between port (PA) and port (A) is Upper portion
shut off, oil also fills the front brake cylinder at • When pedal (1) is released and the operating
the same time, so the pressure in the circuit be- force is removed from the top of the spool, the
tween port (PB) and port (B) rises. The oil enter- back pressure from the brake cylinder and the
ing port (J) from orifice (f) of spool (5) pushes up force of the spool return spring move spool (3)
spool (5) by the same amount that spool (3) up. Drain port (a) is opened and the oil from the
moves, and shuts off port (PB) and port (B). brake cylinder flows to the brake system tank re-
Drain port (b) is closed, so the oil entering the turn circuit to release the center brake.
brake cylinder is held, and the brake is applied.
• The pressure in the space in the upper portion is
balanced with the operating force of the pedal, Lower portion
and the pressure in the space in the lower por- • When the pedal is released, spool (3) in the up-
tion is balanced with the pressure in the space in per portion moves up. At the same time, the
the upper portion. When spools (3) and (5) move back pressure from the brake cylinder and the
to the end of their stroke, the circuits between force of the spool return spring move spool (5)
ports (PA) and (A) and between ports (PB) and up. Drain port (b) is opened and the oil from the
(B) are fully opened, so the pressure in the brake cylinder flows to the brake system tank re-
space in the upper and lower portions and the turn circuit to release the front brake.
pressure in the left and right brake cylinders is
the same as the pressure from the pump.
Therefore, up to the point where the piston
moves to the end of its stroke, the effect of the
brake can be adjusted by the amount that the
pedal is depressed.
6 HM300-2R
Accumulator charge valve 1
ACC. To accumulator Function

P. From hydraulic pump • The accumulator charge valve is actuated to
PP. To accumulator maintain the oil pressure from the pump at the
T. To brake system tank specified pressure and to store it in the accumu-
lator.
• When the oil pressure reaches the specified
pressure, the oil from the pump is connected to
the drain circuit to reduce the load of the pump.
HM300-2R 7
1. Main relief valve (R3) 4. Relief valve (H1)

2. Valve body 5. Filter
3. Relief valve (R1) 6. Filter
8 HM300-2R
Operation 2. When oil supplied to accumulator

1) Cut-in condition
1. When no oil is being supplied to accumulator • When the pressure at port B is lower than the set
(cut-out condition) pressure of relief valve (R1), piston (8) is pushed
• The pressure at port (B) is higher than the set back down by spring (5).
pressure of relief valve (R1), so piston (8) is forc- Valve seat (7) and poppet (6) are brought into
ibly pushed up by the oil pressure at port (B). tight contact, and port (C) and port (T) are shut
Poppet (6) is opened, so port (C) and port (T) are off.
short circuited. • The spring chamber at the right end of spool (15)
• The spring chamber at the right end of spool (15) is also shut off from port (T), so the pressure ris-
is connected to port (C) of relief valve (R1), so es, and the pressure at port (P) also rises in the
the pressure becomes the oil tank pressure. The same way.
oil from the pump enters port (P), pushes spool • When the pressure at port (P) goes below the
(15) to the right at a low pressure equivalent to pressure at port (B) (accumulator pressure), the
the load on spring (14). supply of oil to the accumulator starts immedi-
It also passes through orifices (17), (18) and ately. In this case, it is decided by the size (area)
(16), and flows to the oil tank. of orifice (17) and the pressure difference
(equivalent to the load on spring (14)) generated
on both sides of the orifice. A fixed amount is
supplied regardless of the engine speed.
HM300-2R 9
2) When cut-out pressure is reached 3. Main relief valve (R3)

• When the pressure at port (B) (accumulator • When the pressure at port (P) (pump pressure)
pressure) reaches the set pressure of relief increases above the set pressure of the relief
valve (R1), poppet (6) separates from valve seat valve, the oil from the pump pushes up ball (11)
(7), so an oil flow is generated and the circuit is against spring (3) and flows in the tank circuit.
relieved. As a result, the maximum pressure in the brake
• When the circuit is relieved, a pressure differ- circuit is regulated and the circuit is protected.
ence is generated above and below piston (8),
so piston (8) moves up, poppet (6) is forcibly
opened, and port (C) and port (T) are short cir-
cuited.
• The spring chamber at the right end of spool (15)
is connected to port (C) of relief valve (R1), so
the pressure becomes the brake oil tank pres-
sure.
• The pressure at port (P) drops in the same way
to a pressure equivalent to the load on spring
(14), so the supply of oil to port (B) is stopped.
10 HM300-2R
Accumulator 1
1. Valve
2. Top cover
3. Cylinder
4. Piston
Function
• The accumulator is installed between the accu-
mulator charge valve and the brake valve. It is
charged with nitrogen gas between cylinder (3)
and free piston (4), and uses the compressibility
of the gas to absorb the pulse of the hydraulic
pump or to maintain the braking force and to
make it possible to operate the machine if the
engine stops.
Specifications
Gas used: Nitrogen gas
Gas capacity: 4,000 cc
Charging pressure: 4.4 ± 0.15 MPa
{45 ± 1.5 kg/cm2} (at 20 ± 5 °C)
HM300-2R 11
Slack adjuster 1
1. Breather
2. Cylinder
3. Check valve
4. Spring
5. Piston
A: Inlet port
B: Outlet port
Unit: mm

Clearance Front
6 between body and -0.030 +0.074 0.030 –
55 -0.076 +0.074 0.150 0.25
piston
-0.030 +0.074 0.030 –
Center 55 -0.076 +0.074 0.150 0.25
Standard size Repair limit Replace

Free Installed Installed Free Installed
Front length length load length load
7 Slack adjuster
spring 39.8 N
198 58 {4.1 kg} – –
Center 198 60 39.2 N – –

{4.0 kg}
12 HM300-2R
Specifications • If the brake pedal is depressed further, and the

Piston actuation oil pressure: oil pressure discharged from the brake valve
0.01 +0.01 +0.1 2
+0.01 MPa {0.1 +0.01 kg/cm } goes above to the set pressure, check valve (3)
Check valve cracking pressure: opens and the pressure is applied to port (C) to
1.74 ± 0.05 MPa {7.8 ± 0.5 kg/cm2} act as the braking force.
Check valve closing pressure: Therefore, when the brake is applied, the time
1.09 ± 0.05 MPa {1.11 ± 0.5 kg/cm2} lag is a fixed value.
Function
• The slack adjuster is installed in the brake oil line
from the brake valve to the brake piston. It acts
to keep a constant time lag when the brake is
operated.
Operation
1. When brake pedal is depressed

• Before the brake is depressed, piston (4) is re-
turned by the distance of stroke (S) (full stroke).
When the brake pedal is depressed, the oil dis-
charged from the brake valve flows from port (P) 2. When brake pedal is released
of the slack adjuster and is divided to left and • When the brake is released, piston (4) returns
right cylinders (2), where it moves piston (4) by because of the brake cooling oil pressure by an
stroke (S) to the left and right. amount equivalent to the oil for stroke (S), and
the brake is released again.
In other words, return stroke (T) of brake piston
(7) is determined by the amount of oil for stroke
(S) of the slack adjuster. The time lag of the
brake is always kept constant regardless of the
wear of the brake disc.
• As a result, brake piston (7) moves by an

amount equal to stroke (S). When this happens,
the relationship between the brake piston and
disc is simply that the clearance becomes 0. No
braking force is generated.
HM300-2R 13
Brake 1
Front
1. Stud bolt
2. Cylinder
3. Brake piston
4. Disc
5. Plate
6. Outer gear (No. of teeth: 148)
7. Hub gear (No. of teeth: 96)
14 HM300-2R
Unit: mm
Backlash between outer gear Standard backlash Repair limit
1
and plate 0.22 – 0.56 1.1
Backlash between hub gear
2 0.17 – 0.52 1.1
and disc
3 Thickness of plate
2.4 2.15
4 Thickness of disc 5.2 4.7
5 Thickness of damper 6.9 5.1 Replace
6 Thickness of damper 3.45 2.55
Distortion of disc friction sur- Standard distortion Repair limit
7
face Max 0.45 0.7
Distortion of plate and damper
8 Max 0.50 0.7
friction surface
Assemble thickness of plate Standard size Repair limit
9
and disc 61.2 56.7
HM300-2R 15
Center
1. Bolt
2. Cylinder
3. Brake piston
4. Disc
5. Plate
6. Outer gear (No. of teeth: 148)
7. Hub gear (No. of teeth: 96)
16 HM300-2R
Unit: mm
Backlash between outer gear Standard backlash Repair limit
1
and plate 0.22 – 0.56 1.1
Backlash between hub gear
2 0.17 – 0.52 1.1
and plate
3 Thickness of plate
2.4 2.15
4 Thickness of disc 5.2 4.7
5 Thickness of damper 6.9 5.1 Replace
6 Thickness of damper 3.45 2.55
Distortion of disc friction sur- Standard distortion Repair limit
7
face Max 0.45 0.7
Distortion of plate and damper
8 Max 0.50 0.7
friction surface
Assemble thickness of plate Standard size Repair limit
9
and disc 76.4 70.9
HM300-2R 17
Function
• There are wet-type multiple disc brakes installed
to the front and center axles.
Operation
• When the brake pedal is depressed, pressure oil
from the brake valve moves brake piston (3) to
the right in the direction of the arrow. This press-
es disc (7) and plate (6) together and generates
friction between the disc and plate. The wheel is
rotating together with the disc, so this friction re-
duces the travel speed and stops the machine.
• When the brake pedal is released, the pressure

at the back face of brake piston (3) is released,
so the piston is moved to the left in the direction
of the arrow by the internal pressure, and this re-
leases the brake.
18 HM300-2R
Proportional reducing valve 1
1. Filter Function
2. Connector • The proportional reducing valve is a valve used
3. Solenoid assembly for retarder control. It is installed between the
brake valve and the system tank in the brake cir-
A: To brake valve cuit.
P: From accumulator It varies the discharge pressure of the pressure
T: To brake system tank oil in accordance with the turning angle of the
retarder control lever, so the retarder control
can be carried out as desired.
HM300-2R 19
Brake system tank 1
1. Plug
2. Inlet tube
3. Outlet tube
4. Oil gauge
5. Valve
A: From accumulator charge valve, brake valve

B: To transmission
C: To hydraulic pump
20 HM300-2R
HM300-2R 21
Parking brake 1
1. Spring cylinder Function

2. Parking brake disc • The parking brake is the disc type and installed
3. Parking brake caliper to the rear of the oscillation hitch.
• It is actuated mechanically by the force of the
spring inside the spring cylinder and is released
by hydraulic pressure.
• The parking brake calipers are fixed to the oscil-
lation hitch.
The disc is installed to the oscillation hitch shaft
output coupling and rotates together with the
coupling.
22 HM300-2R
Unit: mm
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 ± 0.4 1.5
brake assembly
+0.4
23
-0.1
HM300-2R 23
Parking brake caliper
1. Adjuster Outline
2. Piston • A piston guide is installed to caliper (5). Piston
3. Piston shaft (2) and piston shaft (3) are inserted, and the ro-
4. Pad tation of piston shaft (3) moves piston (2) in the
5. Caliper axial direction to bring pad (4) into tight contact.
• Adjuster (1) is joined by a spline to the spline
side of piston shaft (3).
Pad (4) is inserted together with caliper (5) into
the caliper mounting plate and is held in posi-
tion.
24 HM300-2R
Spring cylinder
1. Outer spring Outline

2. Inner spring • The oil pressure from the parking brake solenoid
3. Piston valve pushes the spring and releases the park-
4. Cylinder ing brake.
5. Boot When the engine is stopped, the parking brake
6. Rod is applied by springs (1) and (2), so the machine
is prevented from moving.
HM300-2R 25
Parking brake solenoid 1
1. Solenoid valve assembly Function

2. Relief valve • The parking brake solenoid valve is installed on
3. Block the rear of right fender. When the parking brake
switch is turned ON, the solenoid valve is ener-
A: Outlet port gized. This sends the brake oil to the parking
P: Inlet port brake spring cylinder and sets the parking brake
T: Drain port to the TRAVEL position. When the parking
brake is turned OFF, the solenoid valve is de-en-
ergized, and the brake oil pressure is removed
from the parking brake spring cylinder to set the
machine to the PARKING condition.
• Parking brake solenoid energized: TRAVEL
de-energized : PARKING
26 HM300-2R
HM300-2R 27

© 2007 KOMATSU
All Rights Reserved
28 HM300-2R
SEN02669-00
HM300-2R


Undercarriage and frame
Suspension ..................................................................................................................................................... 2
Suspension cylinder........................................................................................................................................ 8
Oscillation hitch............................................................................................................................................. 10
HM300-2R 1
Suspension 1
Front
2 HM300-2R
1. Front suspension cylinder

2. Arm
3. Lateral rod
4. Dust cover
Unit: mm

Clearance between pin and size Shaft Hole clearance limit
5
bushing
45 -0.025 +0.039 0.025 – 0.3 Replace
-0.064 +0.039 0.103
Clearance between pin and -0.025 +0.039 0.025 –
6 bushing 45 -0.064 +0.039 0.103 0.3
HM300-2R 3
Rear
4 HM300-2R
1. Arm
2. Equalizer bar
3. Lateral rod (center)
4. Spring
5. Rear suspension cylinder
6. Lateral rod (rear)
HM300-2R 5
Unit: mm

Clearance between pin and size Shaft Hole clearance limit
7
bushing
60 -0.030 +0.046 0.030 – 0.3
-0.076 +0.046 0.122 Replace
Clearance between pin and -0.030 +0.046 0.030 –
8 bushing 60 -0.076 +0.046 0.122 0.3
9 Clearance between pin and 60 -0.030 +0.046 0.030 – 0.3

bushing -0.076 +0.046 0.122
Outline 2. Center, rear suspension

• The suspension supports the weight of the ma- The center axle and rear axle are both fixed to arms.
chine. It also reduces any impact caused by un- The center axle is joined to the equalizer bar through
evenness in the road surface and provides a a spring, and the rear axle is joined to the equalizer
comfortable ride for the operator. By ensuring bar through the rear suspension cylinder. The arm
that all the tires are always in contact with the and equalizer bar oscillate in accordance with the
road surface, it maintains the stability of the ma- condition of the road surface to keep the wheels in
chine, and also fulfills the operating perfor- contact with the road surface.
mance by ensuring that the machine can carry The main frame and arm are connected by a lateral
out acceleration, braking, and turning. rod and receive the lateral load.
• The suspension cylinders reducing the impact
from the road surface are a hydropneumatic
type. The inside of the suspension cylinder is
charged (sealed) with oil and nitrogen gas. In
this way, the compression and expansion of the
nitrogen gas and oil act as a spring and shock
absorber, and is used to absorb the load from
the road surface.
Function
1. Front suspension
The front suspension cylinder has the function of a
shock absorber and spring. It is joined to the arm
and main frame by a spherical bearing, and the arm
oscillates according to the extension and retraction
of the front suspension cylinder.
The main frame and arm are connected by a lateral
rod and receive the lateral load.
6 HM300-2R
HM300-2R 7
Suspension cylinder 1
a This diagram shows front suspension cylinder.
1. Oil level valve

2. Feed valve
3. Flange
4. Rod
5. Cylinder
6. Piston
8 HM300-2R
Unit: mm

Clearance between piston rod size Shaft Hole clearance limit
7
and bushing
110 -0.036 +0.235 0.096 – 0.4 Replace
-0.090 +0.060 0.325
Clearance between cylinder -0.21 +0.100
8 and wear ring 150 -0.21 +0.100 0 – 0.31 0.8
Structure and operation

The suspension cylinder has the function of both a
shock absorber and spring.
When a fixed amount of oil is sent from oil chamber
(1) through orifices (4) and (5) to cavity (3), the oil is
throttled by the orifices and a shock-absorbing effect
is obtained.
1. Retracting action
When the machine is traveling and it hits a
bump or object on the road, the wheels are
pushed up, and the cylinder rod is pushed
inside the cylinder.
When this happens, the nitrogen gas inside
chamber (2) is compressed, the oil in chamber
(1) is sent through both orifices (4) and (5) to
cavity (3), and cavity (3) is filled more quickly
than when extending.
2. Extending action
When the machine has passed any bump or
object on the road surface, the cylinder rod is
pushed up by the weight of the wheels and axle
and the pressure of the nitrogen inside chamber
(2).
As a result, the amount of oil in cavity (3) is
reduced, and pressure is applied to the oil
remaining in cavity (3).
This pressurized oil closes orifice (4) with check a This diagram shows rear suspension cylinder.
ball (6), and is sent to chamber (1) through only
orifice (5), so the flow of oil passing through the 1. Oil chamber
orifice is controlled so that it is less than during 2. Nitrogen gas chamber
retraction. 3. Cavity
In this way, the amount of oil returning to cham- 4. Orifice
ber (1) is restricted to provide a shock absorb- 5. Orifice
ing effect. 6. Check ball
HM300-2R 9
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 HM300-2R
HM300-2R 11
12 HM300-2R
Unit: mm
12 Standard shim thickness 2

1
13 Standard shim thickness Standard Tolerance Standard Clearance
Clearance between bushing -0.036 +0.054 0.036 –

14 110 -0.090 +0.054 0.144 –
and front frame
Clearance between shaft and -0.030 +0.046 0.030 –
15 bushing 80 -0.049 +0.046 0.095 0.5
16 Clearance between shaft and 80 -0.030 -0.015 0.015 – 0.5

bearing -0.049 -0.015 0.049
17 Clearance between shaft and 80 -0.030 +0.046 0.030 – 0.5

bushing -0.049 +0.046 0.095
Clearance between front frame -0.030 +0.046 0.030 –
18 and shaft 80 -0.049 +0.046 0.095 –
20 Clearance between bushing 80 -0.030 +0.046 0.030 – 0.5

and pin -0.049 +0.046 0.095
Clearance between pin and -0.030 -0.015 0.015 – Replace
21 bearing 80 -0.049 -0.015 0.049 0.5
Clearance between front frame +0.089 +0.054 -0.089 –

22 and bushing 95 +0.054 +0.054 0 –
23 Clearance between hitch frame 120 -0.015 -0.035 -0.035 – –

and bearing -0.015 -0.035 0.015
Clearance between hitch frame -0.052 -0.035 -0.035 –
24 and bearing 300 -0.052 -0.035 0.052 –
Clearance between rear frame -0.045 -0.017 -0.080 –

25 and bearing 420 -0.045 -0.080 0.028 –
26 Clearance between rear frame 400 -0.018 +0.057 0.018 – –

and retainer -0.075 +0.057 0.122
Clearance between rear frame -0.040 -0.016 -0.073 –
27 and bearing 380 -0.040 -0.073 0.024 –
Clearance between bearing -0.056 -0.035 0.021 –

28 and hitch frame 280 -0.108 -0.035 0.108 –
Clearance between hitch frame -0.018 -0.012 -0.052 –

29 and bearing 150 -0.052 0.006 –
-0.018
Outline
• The front frame and the rear frame are connect- • In addition, the output from the transmission is
ed by the oscillation hitch. transmitted from center drive shaft (3) to cou-
• Front frame (2) is connected with bearings and pling (10). It is then transmitted from coupling
pins (5) and (11); rear frame (4) is connected (8) through the rear drive shaft to the rear axle.
with a spacer, retainer, and bearing. This makes
it possible for the front and rear frames to articu-
late and oscillate.
HM300-2R 13

© 2007 KOMATSU
All Rights Reserved
14 HM300-2R
SEN02670-00
HM300-2R


Hydraulic system
Steering, hoist oil pressure piping diagram ..................................................................................................... 2
Dump body control.......................................................................................................................................... 3
Hydraulic tank and filter .................................................................................................................................. 4
Flow amp valve ............................................................................................................................................... 5
Steering valve ................................................................................................................................................. 8
Steering cylinder ........................................................................................................................................... 12
Hoist valve .................................................................................................................................................... 14
EPC valve ..................................................................................................................................................... 20
Hoist cylinder ................................................................................................................................................ 21
Hydraulic pump ............................................................................................................................................. 22
HM300-2R 1
Steering, hoist oil pressure piping diagram 1
1. Steering, hoist control pump

(SDR(30)100+(20)25+SB(1)6)
2. Steering cylinder
3. Hydraulic tank
4. Flow amp valve
5. Steering valve
6. Hoist valve
7. Hoist cylinder
2 HM300-2R
Dump body control 1
1. Dump control lever Function

2. Hoist valve • This control is carried out by the body position
3. EPC valve sensor. The body position sensor senses the po-
4. Steering, hoist control pump sition of the dump body and the retarder control-
(SDR(30)100+(20)25+SB(1)6) ler controls it.
5. Hoist cylinder • The signal from the dump control lever is con-
6. Body position sensor trolled by the retarder controller, and actuates
the EPC valve. The pilot pressure generated by
the EPC valve moves the spool of the hoist valve
and controls the hoist cylinder.
HM300-2R 3
Hydraulic tank and filter 1
1. Hydraulic oil filter

2. Breather
3. Oil level gauge
4. Drain plug
5. Bypass valve
6. Element
7. Strainer
4 HM300-2R
Flow amp valve 1
1. Valve CL: To steering cylinder Outline

2. Relief valve L: To steering valve • The flow amp valve consists of the directional
3. Orifice P: To steering valve valve, amplifying stage, priority valve, relief
4. Spring PP: From steering valve valve, pressure control valve, and suction valve.
5. Pin HP: From hydraulic pump • It amplifies the oil flow sent from ports (L) and
6. Valve LS: From steering valve (R) of the steering unit by the specified ratio.
7. Valve HT: From hoist valve The amplified oil then goes from ports (CL) and
8. Plug T: To steering valve (CR) of the flow amp valve and flows to the
9. Valve EF: To hoist valve steering cylinder.
10. Spool R: From steering valve The amplified oil flow is proportional to the
11. Valve body CR:To steering cylinder amount the steering wheel is turned.
12. Stopper
HM300-2R 5
Operation
1. At neutral
• Port (P) of steering unit (7) is closed and the flow • For priority valve (2) also, the oil is drained from
amp valve is closed at chamber (M) of pressure relief valve (1).
control valve (3). Before starting, priority valve (2) is pushed
• Ports (L), (R), and (T) of steering unit (7) are strongly to the left by the spring, so in reality,
connected to each other, so the oil passes port (EF) of the flow amp valve is almost closed.
through port (T) of the flow amp valve and is • At the same time as the engine starts, oil flows
drained to the hydraulic tank. to port (HP) of the flow amp valve and then flows
By connecting in this way, directional valve (6) to port (P) of steering unit (7). At the same time,
is always held at the neutral position by the the pilot pressure that is connected to port (PP)
springs on both sides. For this reason, at the suddenly rises. As a result of balancing with
neutral position, the reaction or impact from the the spring and moving to the right, port (EF)
steering cylinder is not transmitted to steering opens and the oil flows to the hoist piping.
unit (7).
6 HM300-2R
2. When turning
• When steering unit (7) is actuated, the oil sent • The oil at the steering cylinder head end goes
from port (P) of priority valve (2) passes through out from suction valve (5). It then goes from port
ports (P) and (L) of steering unit (7) and enters (CR) of directional valve (6) through check valve
port (L) of directional valve (6). (4) and is drained to the hydraulic tank from port
At the same time, oil from priority valve (2) also (HT) of the flow amp valve.
enters chamber (M) of pressure control valve • If there are rocks on the road or the the road sur-
(3). face is uneven, and any abnormal external force
• When the oil entering directional valve (6) rises is applied to the tires and steering cylinder, relief
to a pressure greater than the force of the valves (8) and (9) of suction valve (5) open at a
spring, it pushes the spool to the right, and en- pressure of 29.1 ± 1.0 MPa {285.5 ± 10 kg/cm2},
ters chamber (C) of pressure control valve (3). so the oil passes through directional valve (6)
When it rises to a pressure greater than the and is drained to the hydraulic tank.
force of the spring in chamber (C) also, it push-
es the spool to the left.
• The oil that is already in chamber (M) of pres-
sure control valve (3) enters chamber (N) when
the spool is pushed to the left by the action of
steering unit (7). It then flows from port (P), goes
out from port (CL) of directional valve (6), and
flows from suction valve (5) to the bottom end of
the steering cylinder.
HM300-2R 7
Steering valve 1
1. Cover L: To flow amp valve

2. Drive shaft LS: To flow amp valve
3. Valve body P: From flow amp valve
4. Center pin R: To flow amp valve
5. Bearing T: To flow amp valve
6. Spool
7. Centering spring
8. Sleeve
9. Stator
10. Rotor
11. Lower cover
8 HM300-2R
Outline Structure
• The steering valve is connected directly to the • Spool (9) is connected to the drive shaft of the
steering wheel shaft. If the steering wheel is op- steering wheel, and is connected to sleeve (8)
erated, the steering valve operates the steering by center pin (7) (this is not touching the spool
valve by using the oil from the PPC pump as the when the steering wheel is at the neutral posi-
pilot pressure. Then, the oil from the steering tion) and centering spring (2).
pump is sent to the right or left steering cylinder • Drive shaft (3) is meshed at the top with center
through the steering valve to change the travel pin (7) and forms one unit with sleeve (8). The
direction of the machine. bottom is meshed with the spline of rotor (5) of
• The steering valve, broadly speaking, consists the Gerotor set.
of the following components: rotary type spool • Valve body (4) has five ports. These are con-
(9) and sleeve (8), which have the function of se- nected to the pump circuit, tank circuit, steering
lecting the direction, and the Girotor set (a com- cylinder head end, bottom end, and flow amp
bination of rotor (5) and stator (10)), which acts valve pilot end. In addition, the port at the pump
as hydraulic motor during normal steering oper- end and the port at the tank end are connected
ations, and as a hand pump (in fact, the operat- by the check valve inside the body. If there is
ing force of the steering wheel is too high, so it any failure in the pump or engine, this check
cannot be operated) when the steering pump or valve acts to suck in oil directly from the tank.
engine have failed and the supply of oil is
stopped.
HM300-2R 9
Connection between hand pump and sleeve
• The diagrams above show the connections with

the sleeve ports used to connect the suction and Suctiion /
discharge port
discharged ports of the Girotor.
• If the steering wheel has been turned to the
right, ports (a), (c), (e), (g), (i) and (k) are con-
nected by the vertical grooves in the spool to the
pump side. At the same time, ports (b), (d), (f),
(h), (j) and (l) are connected to the head end of
the left steering cylinder in the same way.
In the condition in diagram above left, ports (1),
(2) and (3) are the discharge ports of the Girotor
set. SBW00727
They are connected to ports (l), (b) and (d) so
the oil is sent to the cylinder.
Ports (5), (6) and (7) are connected and the oil • In this way, the ports of the Girotor acting as dis-
flows in from the pump. charge ports are connected to ports which are
If the steering wheel is turned 90°, the condition connected to the end of the steering cylinder.
changes to the condition shown in diagram The ports acting as suction ports are connected
above right. In this case, ports (1), (2) and (3) to the pump circuit.
are the suction ports, and are connected to • Adjusting delivery in accordance with angle of
ports (i), (k) and (c). Ports (5), (6) and (7) are steering wheel:
discharge ports, and are connected to ports (d), For every 1/7 turn of the steering wheel, the
(f) and (h). inner teeth of the Girotor gear advance one
position so the oil flow from the pump is
adjusted by this movement. In this way, the oil
delivered from the pump is directly proportional
to the amount the steering wheel is turned.
10 HM300-2R
Function of center spring

• 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.
HM300-2R 11
Steering cylinder 1
Unit: mm

Clearance between piston rod size Shaft Hole clearance limit
1
and bushing
-0.030 +0.271 0.105 –
70 0.675
-0.104 +0.075 0.375
Clearance between piston rod -0.030 +0.174 0.130 –
2 65 1.0
support shaft and bushing -0.076 +0.100 0.250
Replace
Clearance between cylinder
-0.030 +0.174 0.130 –
3 bottom support shaft and 65 1.0
-0.076 +0.100 0.250
bushing
4 Cylinder bore +0.15
110 –
+0.05
12 HM300-2R
HM300-2R 13
Hoist valve 1
14 HM300-2R
T: To tank
P: From flow amp
A1: To hoist cylinder bottom
B1: To hoist cylinder head
PA: From EPC valve (Pressurized side for lowering and floating operation)
PB: From EPC valve (Pressurized side for raising operation)
T2: To tank (through pilot check valve)
1. Body
2. Spool
3. Retainer
4. Spring (RAISE)
5. Relief valve
6. Spring (FLOAT)
7. Spring (LOWER)
8. Retainer
9. Retainer
10. Retainer
11. Check valve
Unit: mm

Free length Installed Installed Free Installed
12 Relief valve poppet spring x O.D. length load length load
259 N 233 N
49.4 x 12.8 4.2 –
(26.4 kg) {23.8 kg}
44 N 40 N Replace spring
13 Check valve spring 32.7 x 10.9 24.5 –
{4.5 kg} {4.1 kg} if damaged or
deformed
156 N 140 N
14 Spool return spring 51.3 x 34.5 50 –
{15.9 kg} {14.3 kg}
124 N 112 N
{12.7 kg} {11.4 kg}
1005 N 905 N
{102.6 kg} {92.3 kg}
HM300-2R 15
Operation
1. Hoist valve at HOLD position
• The oil from the flow amp enters chamber (C). • The ports to the hoist cylinder are blocked at
The passage to the hoist cylinder is blocked by both the bottom end and head end, so the hoist
hoist spool (2), so the oil is drained from cham- cylinder is held in position.
ber (D) to the tank.
16 HM300-2R
2. Hoist valve at RAISE position
• When the hoist lever inside the cab is operated • At the same time, the return oil from the head
to the RAISE position, hoist spool (2) is moved end flows from chamber (B) to chamber (D), and
to the left by the solenoid valve. flows to the tank circuit.
• As a result, the oil flows from chamber (C),
opens check valve (11), and enters chamber
(A).
• From chamber (A), the oil enters the bottom end
of the hoist cylinder, extends the hoist cylinder,
and raises the dump body.
HM300-2R 17
3. Hoist valve at FLOAT position
• When the hoist lever inside the cab is operated • The bottom end and head end of the hoist cylin-
to the FLOAT position, hoist spool (2) is moved der are connected inside the hoist valve, so the
to the right by the solenoid valve. As a result, hoist cylinder is placed in the free condition.
chamber (C) and chamber (D), and chamber (B)
and chamber (H) and chamber (D) are connect-
ed.
• The oil from the flow amp passes from chamber
(C) through chamber (B) and flows to the hoist
cylinder. Oil also flows from chamber (C) to
chamber (D), and then flows to the brake oil
cooler circuit.
18 HM300-2R
4. Hoist valve at LOWER position
• When the hoist lever inside the cab is operated • At the same time, the return oil from the head
from the FLOAT position to the LOWER position, end of the hoist cylinder flows from chamber (A)
hoist spool (2) is moved further to the right from to chamber (H).
the FLOAT position by the solenoid valve. As a • When the dump body is lowered, the output
result, the oil flows from chamber (C), pushes pressure of the solenoid valve rises and be-
open check valve (11), and enters chamber (B). comes greater than the cracking pressure of the
• The oil from chamber (B) enters the head end of pilot check valve. As a result, the return oil from
the hoist cylinder, retracts the cylinder, and low- chamber (H) returns to the tank through two
ers the dump body. lines: one from chamber (D) to the tank, and the
other from chamber (E) to the tank.
HM300-2R 19
EPC valve 1
1. Manual operation button Function

2. Solenoid assembly • With the EPC valve, the oil from the hydraulic
3. Relief valve pump is controlled by the retarder controller. It
4. Solenoid assembly (EPC) is then sent to the spool of the hoist valve, and
switches the pilot pressure to control the hoist
A: To hoist valve valve.
B: From hoist valve
P1: From hydraulic pump
T1: To hydraulic tank
T2: To hydraulic tank
20 HM300-2R
Hoist cylinder 1
Unit: mm

Clearance between cylinder size Shaft Hole clearance limit
1
and bushing
120 -0.036 +0.277 0.098 – 0.700
-0.123 +0.062 0.400
Clearance between piston rod -0.030 +0.271 0.091 – Replace
2 and bushing 80 -0.104 +0.061 0.375 0.675
Clearance between piston rod -0.030 +0.004 0.011 –

3 support pin and bushing 60 -0.076 -0.019 0.080 1.0
4 Clearance between cylinder 60 -0.030 +0.004 0.011 – 1.0

support pin and bushing -0.076 -0.019 0.080
HM300-2R 21
Hydraulic pump 1
Steering , hoist and pilot pump
SDR(30)100+(20)25+SB(1)6
Unit: mm
SDR(30)-100
1 Side clearance 0.16 – 0.20 0.24
SDR(20)-25
SB(1)-6 0.10 – 0.15 0.19
Clearance between inside SDR(30)-100 0.06 – 0.131
diameter of plain bearing and SDR(20)-25 0.06 – 0.132
2 0.20
outside of diameter of gear Replace
shaft SBR(1)-6 0.06 – 0.119
-0.5
SDR(30)-100 10
–
SDR(20)-25
9.1 ±0.3
SBR(1)-6
Discharge
pressure
Model speed delivery limit
{MPa
Delivery (rpm) 2 (l/min) (l/min) –
(kg/cm )}
– Oil: EO10-CD
Oil temperature: 45–55°C SDR(30)-100 230.9 213.4
20.6
SDR(20)-25 2,500 55.4 51.7
{210}
SBR(1)-6 13.8 12.6
22 HM300-2R
Emergency steering pump

SBL(1)26
Unit: mm
Standard clearance Clearance limit

1 Side clearance
0.10 – 0.15 0.19
Clearance between inside
2 diameter of plain bearing and 0.060 – 0.119 0.20
Replace
outside diameter of gear shaft
10 –
-0.5
Discharge
pressure
Delivery speed delivery limit
{MPa –
– Oil: EO10-CD (rpm) (l/min) (l/min)
(kg/cm2)}
Oil temperature: 45–55°C
20.6
3,500 67.6 62.4
{210}
HM300-2R 23

© 2007 KOMATSU
All Rights Reserved
24 HM300-2R
SEN02671-00
HM300-2R


Cab and its attachments
ROPS cab ....................................................................................................................................................... 2
Cab tilt............................................................................................................................................................. 3
Air conditioner ................................................................................................................................................. 4
Rear view monitor ......................................................................................................................................... 12
Controller related .......................................................................................................................................... 15
HM300-2R 1
ROPS cab 1
1. Front glass
2. Front wiper
3. Washer tank
4. Front working lamp
5. Door (left)
6. Radio antenna
7. KOMTRAX GPS antenna (if equipped)
8. Rear glass
9. Rear wiper
10. Air conditioner fresh air filter
11. Door (right)
2 HM300-2R
Cab tilt 1
1. Tilt stopper bar

2. Tilt cylinder (if equipped)
3. Breather
4. Adapter
5. Pin
HM300-2R 3
Air conditioner 1
1. Air conditioner unit Function

2. FRESH filter • The air conditioner makes a pleasant operating
3. Control panel environment for the operator and acts to reduce
4. Compressor fatigue.
5. Receiver dryer
6. Condenser Specifications
7. RECIRC filter Refrigerant used HFC134a (R134a)
Refrigerant refilling level (g) 1,200 ± 50
4 HM300-2R
Refrigerant flow system
Table of tightening torque for refrigerant piping adapter

• Condenser refrigerant outlet side

• Connecting part to cab 12 – 15 Nm {1.2 – 1.5 kgm}
A
(Between receiver drier and air conditioner (Screw size: M16 x 1.5)
unit)
20 – 25 Nm {2.0 – 2.5 kgm}
B • Condenser refrigerant inlet side
(Screw size: M22 x 1.5)
• Connecting part to cab 30 – 35 Nm {3.0 – 3.5 kgm}
C Retighten
(Between air conditioner unit and compressor) (Screw size: M24 x 1.5)
8 – 12 Nm {0.8 – 1.2 kgm}
D • Receiver refrigerant piping lock bolt
(Screw size: M6 bolt of receiver)
20 – 25 Nm {2.0 – 2.5 kgm}
E • Compressor refrigerant piping lock bolt
(Screw size: M8 bolt of compressor)
8 – 12 Nm {0.8 – 1.2 kgm}
F • Air conditioner unit refrigerant piping lock bolt
(Screw size: M6 bolt of air conditioner unit)
HM300-2R 5
Air conditioner unit
1. Face outlet port Outline

2. Face outlet port q The vertical air conditioner unit on which evap-
3. Ambient air inlet port orator and heater core is synchronized with the
4. Hot and cool box duct connecting port blower and intake unit to generate cool and hot
5. Internal air inlet port air.
6. Foot outlet port q The temperature adjusting switch on the air
7. Defroster output port conditioner panel controls air mix dampers and
to adjust the spurting out temperature.
A: Refrigerant gas inlet side
B: Refrigerant gas outlet side Cooler
C: Hot water outlet port q The cooler circulates refrigerant through evap-
D: Hot water inlet port orator to cause heat exchange (dehumidifica-
E: Drain port tion and cooling).
q Air taken in by the blower and intake unit is
cooled with evaporator and then blown out from
the grille through the duct.
Heater
q The heater circulates engine coolant in heater
core to cause heat exchange (heating).
q Air taken in by the blower and intake unit is
heated with heater core and then blown out
from the grille through the duct.
6 HM300-2R
Receiver dryer
1. Pressure switch Function

2. Label q It is used to store liquefied high-pressure, high-
temperature misty refrigerant from the con-
A: Refrigerant gas inlet port denser. It is capable of completely liquefying
B: Refrigerant gas outlet port the refrigerant even when bubbles are con-
tained in refrigerant due to the condenser con-
dition in heat dissipation.
q It eliminates foreign substances in the circula-
tion circuit and water content in the refrigerant
by use of the built-in filter and desiccating
agent.
q Sight glass allows inspecting flow of the refrig-
erant.
Specifications
Effective cubic capacity (cm3) 578
Mass of desiccating agent (g) 300
HM300-2R 7
Condenser
1. Fin Function
2. Tube q The condenser cools and liquefies the high-
pressure and high-temperature refrigerant gas
A: Refrigerant gas inlet port compressed by the compressor.
B: Refrigerant gas outlet port
a If the fin crushes or is clogged with dusts, heat
exchange efficiency is degraded and complete
liquefaction of refrigerant becomes unavailable.
As the result, pressure in the refrigerant circula-
tion circuit will be increased, applying extra
load to the engine or degrading the cooling
effect. Thus, care must be used in its handling
and daily inspection.
Specifications
Fin pitch (mm) 1.5
Total heat dissipation surface (m )
2 6.55
Max. pressure used (MPa {kg/cm }) 2 3.6 {3.6}
8 HM300-2R
Compressor
1. Diode Function
2. Pulley q Other than circulating the refrigerant, it com-
3. Label presses the refrigerant gas from the evaporator
to high-pressure, high-temperature gas so that
it may be easily regenerated (liguefied) at nor-
mal temperature.
q Its built-in magnet clutch turns on or off
depending on the evaporator temperature and
refrigerant pressure.
Specifications
Number of cylinder – Bore x Stroke (mm) 7 – 29.3 x 27.4
Piston capacity (cc/rev) 129.2
Allowable maximum speed (rpm) 4,000
HM300-2R 9
Air conditioner panel
Display section
Display
No. Display type Display item Display range Display method Remarks
color
Outlet air All segments of current level and below
1 See above figure
temperature light up (Display in 8 levels).
Gauges
All segments of current level and below
2 Air flow rate See above figure
light up (Display in 4 levels).
RECIRC or FRESH is displayed accord-
RECIRC and RECIRC or
3 ing to RECIRC/FRESH selector switch
FRESH air FRESH air
position.
Turning "ON" of Black LCD
Air condi- When air conditioner switch is turned
4 air conditioner
tioner "ON", lamp lights up.
Pilot switch
Turning "ON" of When DEF switch is turned "ON", lamp
5 DEF air flow
DEF switch lights up.
FACE, FAC/ FACE, FACE/FOOT or FOOT air outlet is
6 Mode FOOT of FOOT displayed according to mode selector
mode switch position.
10 HM300-2R
Switch section
No. Name Function Operation
RECIRC
Switch to select RECIRC or FRESH air
7 RECIRC/FRESH switch I O
(Pilot display on display section changes according to setting)
FRESH
8 Air conditioner switch Switch to turn ON and OFF air-conditioning function. OFF io ON
Switch to turn ON and OFF main power supply for air conditioner
9 ON/OFF switch ON: Setting in "OFF" state is displayed on display section. OFF io ON
OFF: Display section is turned OFF and fan is stopped.
Switch to control air flow from fan
10 Fan switch
(Control in 4 levels [LO, M1, M2, HI]) LO io HI
Low temperature
Switch to control outlet air temperature
11 Temperature control switch I O
(Control in 8 levels)
High temperature
12 DEF switch Switch to turn ON and OFF defroster OFF io ON
FACE
Switch to change air outlet position O
13 Mode selector switch (3 modes [FACE, FACE/FOOT, FOOT]) FACE/FOOT
If pressed in DEF mode, setting before DEF mode is selected. O
FOOT
Outline
q CPU (central processing unit) installed on the
panel processes input signals from respective
sensors and operation signals of the panel
switches to display and output them.
q The self-diagnosis function of CPU makes the
troubleshooting easier.
Input and output signals
JAE IL-AG5-14P JAE IL-AG5-22P

Pin Signal name Input/output Pin Signal name Input/output
No. signals No. signals
1 GND — 1 NC —
2 Sensor ground — 2 NC —
3 Internal/external air changeover damper ac-
3 Blower motor relay Input
Input
tuator limiter
4 Internal/external
air changeover damper
Output
4 NC — actuator output 1
5 Evaporator temperature sensor Input
5 Internal/external
air changeover damper
actuator output 2 Output
6 NC —
7 Starting switch (ON) Input 6 Mode selector actuator output 2 Output
8 Night lamp signal Input 7 Mode selector actuator output 1 Output
9 NC — 8 Air mix damper actuator output 2 Output
10 NC — 9 Air mix damper actuator output 1 Output
11 NC — 10 Actuator potentiometer power supply (5V) —
12 NC — 11 NC —
13 NC — 12 NC —
14 NC — 13 NC —
14 NC —
15 Magnet clutch Input
16 Air mix damper actuator limiter Input
17 Mode selector actuator limiter Input
18 Air mix damper actuator potentiometer Input
19 Mode selector actuator potentiometer Input
20 Blower gate Input
21 Blower feedback Input
22 Actuator potentiometer ground —
HM300-2R 11
Rear view monitor 1

(If equipped)
1. Monitor
2. Camera
3. Cable
12 HM300-2R
Monitor
1. Auto switch Specifications

2. Manual switch TV signal method:
3. Zoom/Iris switch As per Japanese standard TV method
(Reverse light compensation switch) Scanning method: 2:1 Interlace method
4. Bright/Dim light selector switch CRT: 4.5 inch, black and white, 90-deg. deflection
5. Mark switch Resolution:
Horizontal 400 lines and vertical 300 lines
6. Contrast adjustment knob
Power supply voltage: DC 24/12 V
7. Brightness adjustment knob
HM300-2R 13
Camera
1. Camera Specifications
2. Connector TV signal method:
As per Japanese standard TV method
Scanning method: 2:1 Interlace method
Image sensor:
1/4 inch color CCD with 250,000 pixels
Lens: 1.7 mm, 1:2.8
Angle of view: Horizontal; Approx. 118 deg.,
Vertical; Approx. 97.6 deg.
Electronic zoom: Approx. 1.4 power
Using luminance range:
Min. luminance of object; 3 lux
Power supply voltage:
DC 5.5 V – 99.5 V for main unit
(supplied by monitor)
Power consumption: Max. 120 mA
14 HM300-2R
Controller related 1
Controller layout
1. Engine controller
2. Transmission controller
3. Retarder controller
4. KOMTRAX controller (if equipped)
HM300-2R 15

© 2007 KOMATSU
All Rights Reserved
16 HM300-2R
SEN02672-00
ARTICULATED DUMP TRUCK

HM300-2R


maintenance standard
Electrical system, Part 1
Machine monitor system ................................................................................................................................. 2
HM300-2R 1
Machine monitor system
Network data
1. From machine monitor to each controller
• Switch sensor data
• Option setting data
• Model selection data
2. From each controller to machine monitor
• Display data related to each controller
• Service mode data
• Troubleshooting data
2 HM300-2R
Outline
• In the machine monitor system, each controller • To make it easier to carry out troubleshooting of
on the network monitors and controls the ma- the controllers on the network (including the
chine condition with the sensors installed to var- monitor panel itself), a service mode function is
ious parts of the machine, and then sends the provided. Its main content is as follows.
result as the network information to the machine 1. Displaying failure history data for electrical
monitor, which displays the information to notify equipment system
the operator of the machine condition. • Displays electrical equipment system
failure occurrence data from each con-
• There are two types of display on the machine troller that is saved in machine monitor
monitor: the normal mode and the service mode. • Deletes data from memory
2. Displaying failure history data for machine
• The items that are always displayed for the op- Displays machine failure occurrence data
erator are the normal mode items. Their main from each controller that is saved in machine
content is as follows. monitor.
1. Normal display items 3. Real-time monitor
• Meters (speedometer, tachometer) Takes input, output signal, and calculation
• Gauges (engine coolant temperature, values recognized by each controller on
torque converter oil temperature, retard- network and displays them in real time
er oil temperature, fuel gauge) 4. Reduced cylinder mode
• Pilot display This function is used to stop the supply of
• Service meter, odometer (character dis- fuel sprayed from the fuel injector to each of
play) the cylinders. This function is used for the
2. Items displayed when there is abnormality purpose of, for example, determining the
Caution, action code display (while an cylinder where there is defective combus-
action code is being displayed, press tion.
machine monitor mode selector switch (>). 5. No injection cranking
A failure code (6-digit) is then displayed.) This function is used to lubricate an engine
3. Maintenance monitor function without starting the engine to drive a
When the filter, oil replacement interval is machine after a long-term storage.
reached, the item needing replacement is 6. Adjusting function
displayed in the character display. This function is used to correct installation
4. Others errors of sensors, solenoid valves, and
In combination with the character display compensate production tolerances of parts
and the machine monitor mode selector and components. This function is also used
switch, which is used to operate the charac- to change control characteristic data in
ter display, the following items can be dis- response to user's request.
played, set, and adjusted. 7. Maintenance monitor
1) Dozing counter (if equipped) This function is used to change filter and oil
2) Display reverse travel distance mea- replacement interval and stop the function.
surement value 8. Operation information display function
3) Reset filter and oil replacement interval This function is used to display fuel con-
4) Input telephone number sumption amount per operation hour.
5) Select language 9. Option selection function
This function is used to select controller
information and optional equipment to be
operated.
10. Model selection function
Input model information to be mounted.
11. Initialize
This function is used to set the machine
monitor when the machine is shipped from
the factory.
HM300-2R 3
Machine monitor
1. Speedometer 20. Steering oil temperature caution lamp

2. Engine tachometer 21. Engine oil pressure caution lamp
3. Retarder oil temperature gauge 22. Brake oil pressure caution lamp
4. Torque converter oil temperature gauge 23. Machine monitor, option system caution lamp
5. Engine coolant temperature gauge 24. Engine system caution lamp
6. Fuel gauge 25. Transmission system caution lamp
7. Character display 26. Retarder system caution lamp
8. Turn signal pilot lamp (R.H.) 27. Tilt caution lamp
9. Turn signal pilot lamp (L.H.) 28. Seat belt caution lamp
10. Front lamp high beam pilot lamp 29. Parking brake pilot lamp
11. Gear shift lever position pilot lamp 30. Retarder pilot lamp
12. Shift indicator 31. Inter-axle differential lock pilot lamp
13. Lockup pilot lamp 32. Dump body pilot lamp
14. Shift hold pilot lamp 33. Emergency steering pilot lamp
15. Power mode pilot lamp (power mode) 34. Preheating pilot lamp
16. Power mode pilot lamp (economy mode) 35. Retarder oil temperature caution lamp
17. Central warning lamp 36. Torque converter oil temperature caution lamp
18. Maintenance caution lamp 37. Engine coolant temperature caution lamp
19. Battery charge circuit caution lamp 38. Fuel level caution lamp
4 HM300-2R
39. Rotary switch [SW1] a Do not change the setting of the rotary switches
40. Rotary switch [SW2] and dipswitches on the back side of the machine
41. Rotary switch [SW3] monitor.
42. Dipswitch [SW5-4]
45. SI Spec. Non-SI Spec. selection switch [SW5-1]
HM300-2R 5
Machine monitor normal display functions
Q : Lights up E: Sounds intermittently

A: Q shows that all lamps light up for approx. 2 seconds after starting o all off for 1 second
Related actuation A
Immediately
No. Display Display Device Color Display range/ Method of Central after Remarks
item category conditions display warning Alarm starting
buzzer switch is
lamp
turned ON
0 - 80 km/h or
Scale: 0 - 50 mph
Meter White
Movement Background (MPH display is only Analog — — —
when non-SI spec. is display
Travel color: Black
1 speed used)
When small lamps Lights up

Backlight LED Amber light up when — — Q
actuated
Scale:
0 - 3400 rpm (red Analog * When engine speed is 2,350
Meter White, red zone: More than 2500
Movement Background display Q E — rpm or higher, buzzer and
rpm) (*) central warning lamp operate.
Engine color: Black
2
speed
actuated
Scale: 50 - 150°C
White, red Analog
Gauge Movement Background (red zone: More than display — — —
color: Black 120°C)
Brake
3 cooling oil When temperature is Lights up
36 Caution LED Red when Q E Q
temperature more than 120°C abnormal

Backlight LED Amber when — — Q
light up actuated
Scale:
50 - 135°C
White, red (red zone: Analog
Gauge Movement More than — — —
Background 120°C) display
color: Black
Torque
4 converter Lights up
37 oil Caution LED Red When temperature is when Q E Q
more than 120°C
temperature abnormal

actuated
Scale:
50 - 135°C
White, red (red zone: Analog
Gauge Movement More than — — —
Background display
102°C)
color: Black
Engine
5 coolant When temperature is Lights up
38 Caution LED Red when Q E Q
temperature more than 102°C abnormal
Lights up
Backlight LED Amber When small lamps when — — Q
light up actuated
Scale:
White Analog
Gauge Movement Background EMPTY-FULL display — — —
color: Black
6 Fuel gauge When below specified Lights up

level (amount of fuel
39 Caution LED Red remaining in tank is when — — Q
less than 75 l) actuated
Lights up
Backlight LED Amber When small lamps when — — Q
light up actuated
Actuated
Service 0 - 65535.0h when
meter Service * Displayed on top engine is When time exceeds 65535.0h,
(normal Display running — —
display meter letters: line of character Ratio of stops at 65535.0h
Black display
7 items) LED movement
Background to time 1:1
color:
Odometer Green 0 - 999999.9km
(normal * Displayed on bottom Actuated When distance exceeds
display Odometer line of character when — — 999999.9km, stops at
items) display traveling 999999.9km
6 HM300-2R
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 When abnormality

failure occurs on or failure occurs on Note: Top line displays
machine machine, top line "KOMATSU", bottom
Action code Action code * Displayed on top and shows action code; — — 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; — — 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 — — Q
light up when small lamps
light up
When operated:
Right turn Lights up
8 signal LED Green When operated When not — — Q
operated: Goes
out
When operated:
Lights up
9 Left turn signal LED Green When operated When not — — Q
operated: Goes
out
When operated:
Lights up
10 High beam LED Blue When operated When not — — Q
operated: Goes
out
11 Gear shift lever LED Green When gear shift lever is Lights up (*) — — Q * Flashes when neutral
(R2) position R2 at R2 safety is actuated
(R1) position R1 at R1 safety is actuated
11 Gear shift lever LED Orange When gear shift lever is Lights up — — Q
(N) position N at N
(D) position D Pilot at D safety is actuated
(5) position 5 at 5 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 — — All light up
12 Gray * When alarm is controller
actuated when making
emergency escape, "E-"
and "N" are displayed in
turn
Night lighting LED Amber
HM300-2R 7

Display Display Display range/ Method of after
No Device Color Central Alarm starting Remarks
item category conditions display warning buzzer switch is
lamp turned ON
When
When torque operated:
converter lockup is Lights up
13 Lockup LED Green actuated and When not — — Q
transmission is set to operated:
direct drive Goes out
When
operated:
When shift hold Lights up
14 Shift hold LED Green switch is operated When not — — Q
operated:
Goes out
Pilot
High power
Output mode:
mode Lights up
15 (high power LED Green High power mode When not — — Q
mode) actuated:
Goes out
Economy
Output mode:
16 mode LED Green Economy mode Lights up — — Q
(economy When not
mode) actuated:
Goes out
Central Lights up
When there is
17 warning LED Red when Q E Q
lamp abnormality in system abnormal
Note 1: Lamp lights up and at

When warning is
issued for same time action code E01 and
location for warning is displayed
18 Maintenance LED Red maintenance system, Lights up or — — Q on character display
caution or when filter, oil flashes
Note 2: See Operation and
replacement interval Maintenance Manual for details
has passed
of applicable item
Battery
charge When there is Lights up
19 circuit LED Red abnormality in charge when Q E Q
circuit abnormal
caution
Steering oil When steering oil Lights up
20 temperature LED Red when Q E Q
caution temperature rises abnormal
Engine oil Lights up
21 pressure LED Red When engine oil when Q E Q
caution pressure drops abnormal
Brake oil When brake oil Lights up Note: Actuated only when
22 pressure LED Red pressure drops when Q(Note) E(Note) Q alternator R terminal = ON
caution abnormal
Machine When there is
monitor or Caution abnormality in Lights up
Actually only used when failure
23 option LED Red machine monitor or when E E Q occurs in machine monitor
system option controller abnormal
caution system
Engine When there is Lights up
24 system LED Red abnormality in engine when E E Q
caution control system abnormal
When there is
Transmission abnormality in Lights up
25 system LED Red transmission control when E E Q
caution abnormal
system
Retarder When there is Lights up

26 system LED Red abnormality in when E E Q
caution retarder control abnormal
system
When dump body is Lights up
27 Tilt caution LED Red raised and there is when Q E Q
excessive tilt to left or abnormal
right
When
actuated:
28 Seat belt LED Red When seat belt is not Lights up — — Q
caution fastened When not
actuated:
Goes out
8 HM300-2R

Display Display Display range/ Method of after
No Device Color Central Alarm starting Remarks
item category conditions display warning buzzer switch is
lamp turned ON
Parking When parking brake Lights up Note: Actuated when parking
29 brake pilot Red when Q(Note) E(Note) Q brake is applied and gear shift
lamp is applied
applied lever is at position other than N
Retarder When retarder brake Lights up

30 Orange when — — Q
pilot lamp is applied
applied
When
Inter-axle operated:
differential Lights up when inter- Lights up
31 lock pilot LED Orange axle differential lock is When not — — Q
lamp operated operated:
Goes out
When
For details, see operated:
Body pilot Operation and Lights up Note: Actuated when gear shift
32 Pilot LED Red Q(Note) E(Note) Q
lamp Maintenance Manual When not lever is at position other than N
operated:
Goes out
When
operated:
Emergency Lights up when Lights up
33 steering LED Red emergency steering is When not — — Q
pilot lamp actuated operated:
Goes out
When
operated:
Lights up when Lights up
Preheating electric heater for Q
34 pilot lamp LED Red engine preheating is
When not — —
operated:
actuated Goes out
HM300-2R 9
Table of signals for each monitor connector
HM series monitor panel

No. Specification
CN PIN I/O A/D
1 CN1 1 — — —
2 CN1 2 — — —
3 CN1 3 — — —
4 CN1 4 — — NSW power supply (+24V)
5 CN1 5 — — NSW power supply (+24V)
6 CN1 6 — — SW power supply (+24V)
7 CN1 7 — — SW power supply (+24V)
8 CN1 8 — — —
9 CN1 9 — — GND
10 CN1 10 — — GND
11 CN1 11 O D D_OUT_3, (Sync 200mA)
15 CN1 15 — — Sensor power output (+24 V, 100 mA)
16 CN1 16 — — Sensor power output (+5 V, 100 mA)
17 CN1 17 — — GND
18 CN1 18 — — GND
19 CN1 19 — — GND
20 CN1 20 — — GND
21 CN2A 1 I D D_IN_0 (+24 V, 5mA, PULL DOWN)
27 *1 CN2A 7 I D D_IN_12 (NSW+24 V, 5mA, PULL DOWN)
*1: NSW +24V input port is active even if the setting is made to KEY OFF when power is supplied directly from
battery.
10 HM300-2R
Signal and model

Model name Remarks
Signal name
HM300 HM350 HM400
— — — —
— — — —
— — — —
BAT DIRECT +24V Q Q Q Directly from battery
BAT DIRECT +24V Q Q Q Directly from battery
POWER SUPPLY +24V Q Q Q In-cab power supply
POWER SUPPLY +24V Q Q Q In-cab power supply
— — — — (–): NON CONNECT
POWER SUPPLY GND Q Q Q
POWER SUPPLY GND Q Q Q
— — — —
— — — —
BUZZER Q Q Q Alarm buzzer
HEAD LIGHT H/L CHANGE Q Q Q Head lamp Hi/Low change
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
HI BEAM Q Q Q
AISS SW Q Q Q
— — — —
PASSING SW Q Q Q
CONNECTOR CHECK Q Q Q Used to detect improper connector connection
PANEL MODE SW2-1 Q Q Q Mode SW2 upper side
RIGHT TURN Q Q Q
PANEL MODE SW1-1 Q Q Q Mode SW1 upper side
HM300-2R 11

No. Specification
CN PIN I/O A/D
29 CN2A 9 — — GND
38 CN2A 18 I A A_IN_0 (0 – 30 V)
39 *2 CN2B 1 I D D_IN_16 (GND, 5mA, PULL UP)
43 CN2B 5 I D D_IN_24 (+24 V, 5mA, PULL DOWN)
44 CN2B 6 — — GND
49 CN2B 11 I D D_IN_25 (+24 V, 5mA, PULL DOWN)
50 CN2B 12 I A A_IN_1 (0 – 30 V)
*1: NSW +24V input port is active even if the setting is made to KEY OFF when power is supplied directly from
battery.
*2: Setting is made to PULL UP.
12 HM300-2R
Signal and model

Model name Remarks
Signal name
HM300 HM350 HM400
GND Q Q Q
— — — — Accelerator linked retarder switch upper side
— — — —
FR DIFF LOCK SW Q Q Q Front and rear differential lock switch
ENGINE MODE SW Q Q Q
PANEL MODE SW1-2 Q Q Q Mode SW 1 lower side
PANEL MODE SW2-2 Q Q Q Mode SW 2 upper side
LEFT TURN Q Q Q
— — — —
— — — —
— — — —
AIR CLEANER Q Q Q Air cleaner clogging
HYD OIL LEVEL Q Q Q Hydraulic oil level
COOLANT LEVEL Q Q Q Coolant level
REOSTAT +24 V Q Q Q Night lighting dimmer switch ON/OFF recognition
SENSOR GND Q Q Q
RETARD COOLING FILTER Q Q Q Retarder cooling filter clogging (option)
— — — —
— — — —
— — — —
SEAT BELT Q Q Q
REOSTAT Q Q Q Night lighting luminance adjustment
LR DIFF LOCK FOOT SW Q Q Q Left and right differential lock foot switch
LR DIFF LOCK SW1 Q Q Q Left and right differential lock 3 position switch
LR DIFF LOCK SW2 Q Q Q Left and right differential lock 3 position switch
HM300-2R 13

No. Specification
CN PIN I/O A/D
54 *2 CN3A 4 I D D_IN_32 (GND, 5mA, PULL UP)


58 CN3A 8 I P P_IN_0 (0.5Vp-p)

59 CN3A 9 — — GND
62 CN3A 12 I D NC
67 CN3A 17 I P P_IN_1 (0.5Vp-p)

68 CN3A 18 — — NC
69 CN3B 1 I A A_IN_2 (Low resistance input)
70 CN3B 2 I A A_IN_4 (High resistance input)
71 CN3B 3 I A A_IN_6 (Low resistance input)
72 CN3B 4 I A A_IN_8 (0 – 5 V)
73 CN3B 5 I A A_IN_10 (0 – 5 V)
74 CN3B 6 — — SGND
75 CN3B 7 I A A_IN_3 (High temperature input)
76 CN3B 8 I A A_IN_5 (High temperature input)
77 CN3B 9 I A A_IN_7 (0 – 5 V)
78 CN3B 10 I A A_IN_9 (0 – 5 V)
79 CN3B 11 — — GND
80 CN3B 12 — — NC
81 CN4 1 — — S_NET (+)
82 CN4 2 — — S_NET (+)

83 CN4 3 — — CAN (+)
*2: Setting is made to PULL UP.
14 HM300-2R
Signal and model

Model name Remarks
Signal name
HM300 HM350 HM400
— — — —
CONNECTOR CHECK 2 Q Q Q NON CONNECT, Used to detect improper connector

connection
— — — —
— — — —
— — — —
GND Q Q Q GND
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
OP7 Q Q Q for service
— — — —
— — — —
— — — —
RETARD OIL TEMP Q Q Q Retarder oil temperature sensor (center)

(MIDDLE)
FUEL LEVEL Q Q Q Fuel level sensor
— — — —
— — — —
ANALOG GND Q Q Q
RETARD OIL TEMP Q Q Q Retarder oil temperature sensor (front)

(FRONT)
RETARD OIL TEMP — — Q Retarder oil temperature sensor (rear)
(REAR)
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
CAN (+) Q Q Q
HM300-2R 15

No. Specification
CN PIN I/O A/D
84 CN4 4 — — S_NET (+)

85 CN4 5 — — S_NET (+)
86 CN4 6 — — GND
87 CN4 7 — — GND
88 CN4 8 — — CAN (–)

89 CN4 9 — — NC
90 CN4 10 — — NC
91 CN4 11 — — NC
92 CN4 12 — — NC
93 CN5 1 — — NC
94 CN5 2 — — RS232C_1_RTS
95 CN5 3 — — RS232C_1_RD
96 CN5 4 — — RS232C_2_RD
97 CN5 5 — — RS232C_2_RTS
98 CN5 6 — — NC
99 CN5 7 — — NC
100 CN5 8 — — RS232C_1_CTS
101 CN5 9 — — RS232C_1_TX
102 CN5 10 — — RS232C_1_SG
103 CN5 11 — — RS232C_2_SG
104 CN5 12 — — RS232C_2_TX

105 CN5 13 — — RS232C_2_CTS
106 CN5 14 — — NC
107 CN6 1 — — —
108 CN6 2 — — —
109 CN6 3 — — —
110 CN6 4 — — —
111 CN6 5 — — —
112 CN6 6 — — —
113 CN6 7 — — —
114 CN6 8 — — —
16 HM300-2R
Signal and model

Model name Remarks
Signal name
HM300 HM350 HM400
— — — —
— — — —
— — — —
— (CAN SHIELD GND) — — —

CAN (–) Q Q Q
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
HM300-2R 17
a Switch input on monitor panel board
No. SW Position I/O A/D Specification
1 SW1 0 I D
2 SW1 1 I D
3 SW1 2 I D
4 SW1 3 I D
5 SW1 4 I D
6 SW1 5 I D
7 SW1 6 I D
8 SW1 7 I D
Rotary switch (16 positions)
9 SW1 8 I D
10 SW1 9 I D
11 SW1 A I D
12 SW1 B I D
13 SW1 C I D
14 SW1 D I D
15 SW1 E I D
16 SW1 F I D
17 SW2 0 I D
18 SW2 1 I D
19 SW2 2 I D
20 SW2 3 I D
21 SW2 4 I D
22 SW2 5 I D
23 SW2 6 I D
24 SW2 7 I D
25 SW2 8 I D
26 SW2 9 I D
27 SW2 A I D
28 SW2 B I D
29 SW2 C I D
30 SW2 D I D
31 SW2 E I D
32 SW2 F I D
18 HM300-2R
Model name
Signal name Remarks
HM300 HM350 HM400
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
Reserved
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
Reserved
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
HM300-2R 19
No. SW Position I/O A/D Specification
33 SW3 0 I D
34 SW3 1 I D
35 SW3 2 I D
36 SW3 3 I D
37 SW3 4 I D
38 SW3 5 I D
39 SW3 6 I D
40 SW3 7 I D
41 SW3 8 I D
42 SW3 9 I D
43 SW3 A I D
44 SW3 B I D
45 SW3 C I D
46 SW3 D I D
47 SW3 E I D
48 SW3 F I D
49 SW5 1 I D
Dip switch (2 positions)
50 SW5 2 I D
51 SW5 3 I D
52 SW5 4 I D
53 SW6 1 I D Dip switch (2 positions)
54 SW6 2 I D
55 SW6 3 I D
56 SW6 4 I D
20 HM300-2R
Model name
Signal name Remarks
HM300 HM350 HM400
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
Reserved
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
ON: SI specification Q Q Q
Do not the switch setting.
OFF: Non-SI specification
— — — —
— — — —
— — — —
— — — — Reserved
— — — —
— — — —
— — — —
HM300-2R 21
© 2007 KOMATSU
All Rights Reserved
22 HM300-2R
SEN02673-00

HM300-2R


Automatic shift control system ........................................................................................................................ 2
Retarder control system................................................................................................................................ 34
Auto emergency steering system.................................................................................................................. 46
Dump control lever........................................................................................................................................ 47
HM300-2R 1
Automatic shift control system

(Transmission control system with all-range electronic modulation)
* For details of the network communication, see the next page.
2 HM300-2R
Outline RTCDB2 (Machine monitor, retarder controller, and

• The transmission controller receives the shift po- others) (Updated every 100 msec.)
sition signal for the gear shift lever, the acceler- No. Item
ator position signal for the accelerator pedal, the 1 Gear speed
speed signal for the transmission, and the other 2 Shift lever position
signals from the switches and sensors. It then 3 Torque converter oil temperature
automatically controls the transmission and
4 Emergency escape state
shifts it to the optimum speed range.
5 Overrun alarm command
• In addition to the shift control, the transmission
6 Neutral safety alarm command
controller also controls the torque converter
7 Lockup operation state
lock-up solenoid and operates the brake, the in-
ter-axle differential lock, the hoist, and the others Transmission controller option setting abnormality
8
state
to prevent overrun.
Transmission controller model setting abnormality
Each clutch pack of the each transmission 9
state
clutch and torque converter lock-up clutch is
10 KEY SW C terminal state
equipped with an electronically controlled mod-
ulation valve, and each clutch pack is indepen- 11 Alternator R terminal state
dently controlled. 12 Emergency steering operation state
By this operation, the initial pressure, build-up 13 Accumulator oil pressure drop state (front, rear)
ratio and torque-off time of each clutch are con- 14 Engine speed
trolled according to the machine condition to 15 Engine coolant temperature
reduce the gear shift shock, prevent gear shift 16 Float caution command
hunting and improve the durability of the clutch. 17 Body seating state
• The hoist EPC valve (proportional solenoid 18 Parking brake operation state
valve) and hoist selector valve (ON/OFF valve) 19 Retarder brake operation state
are controlled to operate the body according to 20 RCM controller option setting abnormality state
the dump control lever position. 21 RCM controller model setting abnormality state
• The transmission shift controller uses the sig- 22 Shift hold state
nals from the switches and sensors to operate 23 Rear tipping alarm command
the machine monitor displays and caution and 24 Inter-axle differential lock operation state
pilot lamps, and transmits these data to the net- 25 Right and left differential lock operation command
work. 26 Engine preheat
27 Body positioner voltage
28 Momentary fuel consumption
Data items transmitted from transmission con-
29 Input shaft speed
troller to network.
30 Output shaft speed
RTCDB1 (Machine monitor, retarder controller, and 31 L/U clutch command
others) (Updated every 10 msec.) 32 HL clutch engagement command
33 HL clutch release command
No. Item 34 SP clutch engagement command
1 Transmission output shaft speed 35 SP clutch release command
2 Brake command value (front wheel)
3 Brake command value (rear wheel) RTCDB2 (special to engine controller) (Updated
every 100 msec.)
RTCDB1 (special to +83) (Updated every 10 msec.) No. Item
No. Item 1 Automatic warm cancel flag
1 Throttle correction value
2 Throttle lower limit
3 Throttle upper limit
4 2nd method throttle
5 HSI line / brake point speed
6 Torque curve select
7 ABS reference type
8 Droop switch
9 ABS droop trim
HM300-2R 3
Data items sent from network to transmission RPC-k (irregularly updated)

controller
No. Item
1 Model selection information
RTCDB1 (Updated every 10 msec.)
2 Option selection information
No. Item [Option item]
1 Engine speed a. Maximum gear speed setting
2 Accelerator position b. Maximum gear speed setting for the Body-up state
c. Accelerator linked retarder provided/not provided
3 Retarder switch (front) state
d. Maintenance sensor provided/not provided
4 Retarder switch (rear) state e. Parking brake interlock provided/not provided
f. Economy output change function E1/E2
RTCDB2 (Updated every 100 msec.)
No. Item
1 Service meter
2 Engine mode switch
3 Parking brake state
4 Retarder brake state
5 Brake pedal (service brake) state
6 AISS inhibit switch
7 Engine coolant temperature
8 RCM controller option setting abnormality state
9 RCM controller model setting abnormality state
10 Accumulator oil pressure drop state (front, rear)
11 Inter-axle differential lock switch
12 Accelerator linked retarder switch 1
13 Accelerator linked retarder switch 2
14 Accelerator pedal abnormality flag
15 Right and left differential lock switch 1 (pressed up)
Right and left differential lock switch 2
16
(pressed down)
17 Right and left differential lock foot switch
18 Retarder oil temperature (front)
19 Retarder oil temperature (mid)
20 Retarder oil temperature (rear) * HM 400-2 only
4 HM300-2R
Transmission controller
Outline
• The transmission controller controls the trans- 8. It receives the model selection data (what
mission system. model it is mounted on) through the net-
It has the following features and functions. work.
1. The gear shifting patter is set in the power 9. The self-diagnostic function is installed for
mode or economy mode. each of the input and output systems.
2. In the braking mode, the brake is used and 10. The self-diagnostic function is displayed on
the gear shifting point is heightened to in- the monitor.
crease the brake cooling pump speed. Ac- 11. If a trouble is detected, its contents are sent
cordingly, the retarder cooling effect is to the network.
increased and the engine is used as a brake 12. It uses the machine monitor to display if the
efficiently. failure is still existing.
3. It controls the brake through the retarder 13. It provides an escape function for use when
controller for the torque converter lockup so- there is a failure in the electrical system.
lenoid valve and overrun prevention.
4. It controls the inter-axle differential lock so-
lenoid valve.
5. To reduce the gear shift shocks, the throttle
correction command is output to the engine
controller to adjust the engine speed during
gear shifting operation.
6. Speed sensors are installed to 3 places of
the transmission input shaft, intermediate
shaft and output shaft to sense slip of the
transmission clutch and protect the trans-
mission when the hydraulic system has a
trouble.
7. It connects to the network and shares vari-
ous data with other controllers.
HM300-2R 5

DEUTSCH-24P [ATC1]
Pin Input/output Pin Input/output
Signal name Signal name
No. signal No. signal
1 Hoist lever potentiometer 2 Input 13 Machine inclination angle Input
2 Body position Input 14 Steering oil temperature Input
3 T/M oil temperature Input 15 Alternator (R) terminal Input
4 — 16 Sensor power supply Output
5 Input 17 Input
6 Shift lever position N Input 18 Emergency steering operation 1 Input
7 Shift lever position 1 Input 19 Torque converter oil pressure Input
8 Input 20 Input
9 Torque converter oil temperature Input 21 GND (for sensor) —
10 — 22 Sensor power supply (5V) Output
11 Input 23 Memory clear (hoist) Input
12 Shift hold Input 24 Start Input
DEUTSCH-40P(1) [ATC2]
1 Output 21 Input/output
2 Input 22 Network Low Input/output
3 Engine oil filter condition (if equipped) Input 23 Input/output
4 Input 24 Input
5 Shift lever position 5 Input 25 Shift lever position R1 Input
6 Shift lever position 1 Input 26 Shift lever position 3 Input
7 Emergency escape Input 27 Input
8 Output 28 Input
9 Output 29 GND (for output shaft speed input, differential gear speed) —
10 T/M output rotation sensor Input 30 T/M output shaft speed Input
11 Output 31 —
12 — 32 Network High Input/output
13 Engine oil level Input 33 Input/output
14 Output 34 —
15 Shift lever position D Input 35 Shift lever position R2 Input
16 Shift lever position 2 Input 36 Shift lever position 4 Input
17 Input 37 T/M oil filter condition Input
18 Output 38 Input
19 Output 39 GND (for input shaft speed input, intermediate shaft speed input) —
20 T/M intermediate shaft speed Input 40 T/M input shaft speed Input
DEUTSCH-40P(2) [ATC3]
1 Power supply 24V Input 21 GND Input
2 Proportional solenoid power supply 24V Input 22 Proportional solenoid power voltage 24V Input
3 ECM output Low, 2nd, Hoist, Epc, Kichou (-) Input 23 ECM Rev, 3 rd, lockup, Inter-axle differential lock (-) Input
4 Output 24 Key SW ACC Input
5 ECMV 2nd (+) Output 25 ECMV Rev (+) Output
6 ECMV lockup (+) Output 26 ECMV High (+) Output
7 Output 27 Output
8 Torque converter oil pressure sensor power supply (24V) Output 28 Hoist EPC valve Output
9 Fill switch 2nd Input 29 Fill switch Rev Input
10 Input 30 Fill switch High Input
11 Power supply 24V Input 31 GND Input
12 Proportional solenoid power supply 24V Input 32 GND Input
13 ECMV output High, 1st, Hoist, Change (-) Input 33 GND Input
14 Key SW ACC Input 34 —
15 ECMV 3rd (+) Output 35 ECMV inter-axle differential lock (+) Output
16 ECMV Low (+) Output 36 ECMV 1st (+) Output
17 Hoist selector valve Output 37 Output
18 Output 38 Kick-out solenoid (hoist) Output
19 Fill switch 3rd Input 39 Input
20 Fill switch Low Input 40 Fill switch 1st Input
6 HM300-2R
Gear shift lever position and automatic gearshifting range

• The relationship between each gearshift position and the automatic gearshifting range is as shown in the
table below.
Gearshifting characteristics Braking mode:

• Shifting the transmission up and down is carried The shift-down point and the shift-up point are both
out according to the shift map saved in the con- raised, the engine speed is maintained at a higher
troller memory. level, and the amount of cooling oil for the retarder is
There are four types of shift map, depending on ensured to provide greater effect when the engine is
the condition of the input signals. used as a brake.
The settings for each mode are as shown in the
table below. Coasting mode:
The difference between the shift-down point and the
Mode Set conditions shift-up point is increased to reduce the number of
Braking mode Brake signal ON
unnecessary gear shifting operations.
When the following conditions are fulfilled Power mode:

Coasting
1. Brake signal OFF
mode
2. Accelerator idle The power mode uses the power of the machine to
the maximum to provide the maximum payload.
When the following conditions are fulfilled
1. Brake signal OFF
However, when the machine is unloaded or has only
Power mode a light load (high acceleration), an acceleration sen-
2. Accelerator pedal depressed
3. Power mode selector switch is at power sitive type variable shifting point is used. This de-
When the following conditions are fulfilled tects the acceleration of the machine and shifts the
Economy 1. Brake signal OFF transmission up sooner to provide better accelera-
mode 2. Accelerator pedal depressed tion and to reduce the fuel consumption, noise, and
3. Power mode selector switch is at economy
transmission shock.
Economy mode:
When the machine is being used under light load,
such as when traveling unloaded or on flat ground,
the shift-up point and shift-down point are both low-
ered, the engine speed is maintained at a lower level,
and the fuel consumption, noise, and transmission
shock are reduce. In this mode, the maximum en-
gine output is limited.
HM300-2R 7
Automatic gearshifting graph

• The shift-up/shift-down points, the torque converter lock-up ON/OFF points, and the automatic braking (for
overrun prevention) ON/OFF points of each mode are as shown in the figure below.
Note: • If the travel speed lowers below 1 km/h or the

1. Power mode foot brake is not applied or the lockup is kept
• The optimum shift-up point is selected between turned on for a long period, the lockup is turned
2,100 and 1,750 rpm according to the accelerat- off and a gear speed proper for the travel speed
ing condition of the machine and gear speed. is selected.
• The optimum shift-down point is selected be- 4. Lockup
tween 1,080 and 1,320 rpm according to the ac- • The optimum lock-up ON point is selected be-
celerator pedal position and gear speed. tween 1,050 and 1,350 rpm according to the
2. Economy mode torque converter inlet speed (engine speed) and
• The optimum shift-up point is selected between outlet speed (transmission input shaft speed).
1,950 and 1,750rpm according to the accelerat- • The lockup OFF point when traveling in R1 or R2
ing condition of the machine and gear speed. is 1,200 rpm. The lockup OFF point when trav-
• The optimum shift-down point is selected be- eling F1 or F2 is selected between 1,200 and
tween 1,080 and 1,180 rpm according to the ac- 1,000 rpm according to the accelerator position.
celerator pedal position and gear speed. The lockup OFF point when traveling in F3 to F6
3. Braking mode (foot brake) with the foot brake or retarder brake applied is
• If the travel speed lowers below 10 km/h on the 950 rpm, with the foot brake or retarder brake
3rd speed or 7 km/h on the 2nd speed while the not applied, it is 850 rpm.
foot brake is applied, the gear speed at that time • When the machine moves off downhill with the
(F3, F2) is held. accelerator pedal released, the lockup is not en-
Accordingly, if the machine travels downhill with gaged until the accelerator pedal is depressed
the foot brake applied and the engine speed or the foot brake is applied.
kept low by the lockup, the brake cooling oil flow 5. The auto brake ON point when traveling in F6 is
becomes insufficient and the engine overheats 2,400 rpm.
easily.
8 HM300-2R
Gear shift lever positions and method of shifting 4) Gear shift lever position N
1) Gear shift lever position D At the neutral position, none of the transmission
• When shifting up (in power mode) clutches are actuated.
I) When the gear shift lever is set at position D,
the transmission is set to F2 torque converter Shift hold function
range. • If the hold switch on the gear shift lever is
II) When the accelerator pedal is depressed, the pushed once, the current gear speed is held. If
engine speed rises and accelerates. When the the hold switch is pressed once again or the
transmission input shaft speed reaches 1050 - gear shift lever is operated, the gear speed can
1,350 rpm, the lockup clutch is engaged, so the be changed. If the travel speed lowers exces-
torque converter is directly engaged and the sively while the gear speed is held, the gear is
transmission is set to direct travel. shifted down. When the travel speed rises
III) As the engine speed rises further and reaches again, however, the original gear speed is held.
1,780-2,080 rpm, the transmission shifts up to
F3. Time when gear cannot be shifted
While the transmission is shifting up, the engine No-shift time
speed is also lowered (a command is output to • In the automatic shift range, no-shift time is se-
the engine controller) in order to reduce the cured during each gear shifting operation to pre-
shock when shifting gear. vent a malfunction caused by transient change
IV) Immediately after shifting up, the engine speed of the speed at the gear shifting operation. The
momentarily goes down, but as the machine gear is not shifted in this no-shift time.
accelerates, it rises again and the transmission • The no-shift time is controlled finely for each
shifts up to F4 to F6 in the same way as in III) gear shift pattern by the all-range electronic
above. modulation system.
• When shifting down (in power mode) The no-shift time for each gear shift pattern is
I) When the load increases and the engine speed roughly shown below.
drops to 1,080 - 1,320 rpm, the transmission
shifts down one speed.
(For example, when traveling in F6, the trans-
mission shifts down to F5.)
While the transmission is shifting down, the
engine speed is also raised (a command is out-
put to the engine controller) in order to reduce
the shock when shifting gear.
II) As the engine speed goes down further and the
transmission shifts down to F2, the torque con-
verter lockup clutch is disengaged and the
transmission enters the torque converter drive.
a The set speed and operating condition in the

above explanation are subject to change, de-
pending on the travel condition. For details, see
the automatic gear shifting graph.
2) Gear shift lever positions 5, 4, 3, 2, 1

The method of shifting automatically from F1 to
F5 (F4, F3, F2) is the same as for "gear shift
lever position D" above.
3) Gear shift lever positions R1, R2
These gear shift lever positions are for reverse
travel.
The safety functions related to travel in reverse
are the directional inhibitor and reverse safety.
If the operation is not correct, gearshifting is
restricted.
HM300-2R 9
Parking brake interlock function (if equipped) When traveling forward at a speed of more than
Functional outline 2.0 km/h, even if the gear shift lever is operated
When the parking brake is applied, the transmission to positions R1 or R2, the transmission will not
is set in neutral, regardless of the gear shift lever be shifted immediately to travel in reverse. The
position. speed range is shifted to N and the engine
This function works only when options are set. speed is lowered to reduce the travel speed.
When the travel speed goes below 2.0 km/h,
Actuation condition: the transmission is shifted to REVERSE.
Parking brake = ON
When traveling in reverse at a speed of more
Release condition: than 7.6 km/h with the gear shift lever at posi-
1. Parking brake = OFF and the shift lever position = N tion R2, even if the gear shift lever is operated
2. Parking brake = ON, the engine speed is more from R2 to R1, the transmission does not shift
than 500 rpm, and the gear shift lever is operat- to R1. When the travel speed goes below 2.0
ed N o D o N o D o N o D o N within five sec- km/h, the transmission is shifted to R1.
onds After the travel speed goes below 2.0 km/h, if
the gear shift lever is operated again from R2 to
a When the transmission needs to be set in a gear R1, the transmission shifts to R1.
speed other than "N" with the parking brake ap-
plied for inspection, the parking brake interlock After the machine is stopped on a slope with the
must be released under release condition 2. gear shift lever at the N position, if it starts and
travels forward or in reverse at a speed of more
Safety functions than 4.0 km/h with the gear shift lever kept at
1) Down-shift inhibitor function the N position, the transmission is kept at N
If gear shift lever is operated D o 5 - 1, 5 o 4 - even if the gear shift lever is set to any position
1, 4 o 3 - 1, 3 o 2 -1, 2 o 1 from the N position.
For example, when traveling in D (F6), even if When the travel speed goes below 4.0 km/h, it
the gear shift lever is operated to 4, the trans- is permitted to move the machine off.
mission does not shift directly F6 o F4. It shifts (To prevent overload on power train, to improve
down F6 o F5 o F4 according to the travel durability and reliability)
speed. 4) Power train overrun prevention rear brake func-
(Even if the operator makes a mistake in operation
tion of the gear shift lever, the transmission If the engine speed rises to more than 2,400
does not skip a gear speed. This is to prevent rpm (more than 2,350 rpm in F6), the central
overrunning of the engine.) warning lamp flashes and the alarm buzzer
2) Neutral safety function sounds.
This circuit prevents the engine from starting if If the engine speed rises to more than 2,450
the gear shift lever is not at the N position, even rpm (more than 2,400 rpm in F6), the retarder
if the starting switch is turned to the START brake is automatically actuated.
position. (To prevent overrun of engine, torque converter,
(This is a safety circuit to prevent the machine and transmission, to improve durability and reli-
from moving unexpectedly when the engine is ability)
started.)
3) Directional inhibit function
When traveling in reverse at a speed of more
than 4.0 km/h, even if the gear shift lever is
operated to D or positions 5 to 1, the transmis-
sion will not be shifted immediately to travel for-
ward. The engine speed is lowered to reduce
the travel speed, and when the travel speed
goes below 4.0 km/h, the transmission is shifted
to FORWARD.
(To prevent overload on power train, to improve
durability and reliability)
10 HM300-2R
5) REVERSE safety
When the dump control lever is at the "RAISE"
position and "the body is seated" or when the
dump control lever is not in the "FLOAT OUT-
PUT" position and the body is not seated, the
machine does not travel in reverse.
(Turnover prevention function)
However, if the gear shift lever is at the R1 posi-
tion and the shift hold switch is pressed, it is
possible to travel in reverse while the switch
being pressed, even if the dump body is not
fully lowered.
6) Speed range limit function when dump body is
raised
After dumping the load, if the body is not com-
pletely lowered, shifting up is limited.
If the gear shift lever is at D, the machine starts
in F2. If the former is at positions 5 to 1, the lat-
ter starts in F1. The gear is not shifted up until
the body is completely lowered.
Self-diagnostic function
• The controller carries out self-diagnosis of the
system and displays abnormalities.
• The details of the self-diagnosis are displayed
on a monitor.
• If any abnormality is detected by the self-diagno-
sis function, the abnormality data is transmitted
to the network and is displayed as an action
code on the machine monitor. The transmission
system caution, warning lamp, or alarm buzzer
may also be actuated.
Overload prevention traction force limit function

• To prevent overload on power train, there is pro-
vided a function to restrict the upper limit of the
throttle for each speed ranges "F1" and "R1".
The details are shown in the diagram blow.
HM300-2R 11
Transmission controller list of real-time monitoring display contents

The input and output signal states of the transmission controller can be checked with the real-time monitoring
function of the machine monitor.
Real-time monitoring display items related to transmission controller and contents displayed in normal state
are as follows.
No. Item ID number Displayed spec. Data contents
1 Software part number 20201 VERSION Mass production software part number is output
2 Application version 20223 VERSION (APP) Software version No. is output

(Soft logic part version No.)
3 Data version 20224 VERSION (DATA) Software version No. is output

(Soft data part version No.)
4 Transmission input shaft 31200 T/M SPEED:IN Input shaft speed is output
speed
5 Transmission intermediate 31300 T/M SPEED:MID Intermediate shaft speed is output

shaft speed
6 Transmission output 31400 T/M SPEED:OUT Output shaft speed is output

shaft speed
7 Transmission differential 31402 T/M DIFF OUT Differential shaft speed is output
shaft speed
8 Alternator R 04301 ALTERNATOR R Alternator R terminal input state (A_IN_0) is output
9 Torque converter oil 30100 T/C OIL TEMP Torque converter oil temperature (A_IN_1) is output
temperature
10 Torque converter oil 30101 T/C OIL TEMP Torque converter oil temperature (A_IN_1) voltage is
temperature output
11 Transmission oil 32500 T/M OIL TEMP Transmission oil temperature is output
temperature
12 HM300-2R
Data range Remarks
Depending upon software part number
Depending upon software version No.
x1 [min-1] (0 – 32767 [min-1])

---- [Other than above]
x1 [min-1] (0 – 32767 [min-1])

x1 [min-1] (0 – 32767 [min-1])

x1 [min-1] (0 – 32767 [min-1])

0: OFF
1: ON
x1 [°C] (0 – 150 [°C])

x1 [mV] (0.00 – 5.00 [V])

4.72 V = 0°C
4.33 V = 30°C
3.55 V = 60°C
2.20V = 100°C
1.61 V = 120°C
x1 [°C] (0 – 150 [°C])

HM300-2R 13
12 Transmission oil 32501 T/M OIL TEMP Transmission oil temperature voltage is output
temperature
13 Steering oil temperature 32701 STRG OIL TEMP Steering oil temperature (A_IN_4) is output
14 Steering oil temperature 32702 STRG OIL TEMP Steering oil temperature (A_IN_4) voltage is output
15 Torque converter oil 32600 T/C OIL PRESS Torque converter oil pressure (A_IN_3) conversion value
pressure is output
16 Torque converter oil 32605 T/C OIL PRESS Torque converter oil pressure (A_IN_3) of input voltage
pressure is output
17 Clutch FILL SW 38921 FILL HLR123 Every each clutch of FILL SW recognition condition of
each clutch is output
18 Solenoid output (H) 31600 ECMV H DIR ECMV output command current to HIGH clutch is output
14 HM300-2R
Data range Remarks
x1 [mV] (0.00 – 5.00 [V])

---- [Other than above ]
4.72 V = 0°C
4.33 V = 30°C
3.55 V = 60°C
2.20 V = 100°C
1.61 V = 120°C
x1 [°C] (0 – 150 [°C])

---- [Other than above ]
x1 [mV] (0.00 – 5.00 [V])

4.72 V = 0°C
4.33 V = 30°C
3.55 V = 60°C
2.20 V = 100°C
1.61 V = 120°C
x1 [MPa] (0.00 – 5.00 [MPa])
x1 [mV] (0.00 – 5.00 [V])
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 – 1000 [mA])

HM300-2R 15
19 Solenoid output (L) 31601 ECMV L DIR ECMV output command current to LOW clutch is output
20 Solenoid output (1st) 31602 ECMV 1 DIR ECMV output command current to 1st clutch is output
21 Solenoid output (2nd) 31603 ECMV 2 DIR ECMV output command current to 2nd clutch is output
22 Solenoid output (3rd) 31604 ECMV 3 DIR ECMV output command current to 3rd clutch is output
23 Solenoid output (R) 31606 ECMV R DIR ECMV output command current to REV clutch is output
24 Solenoid output (L/U) 31609 ECMV LU DIR ECMV output command current to L/U clutch is output
25 Solenoid output (DIFF) 31607 ECMV D DIR ECMV output command current to differential is output
26 Angle sensor 32900 ANGLE SENSOR Angle sensor input (A_IN_8) angle conversion value is
output
27 Angle sensor 32902 ANGLE SENSOR Angle sensor input (A_IN_8) voltage is output
28 Brake output (front 33807 BK OUTP DIR F
wheel) command value
29 Brake output (Rear 33808 BK OUTP DIR R
wheel) command value
30 Throttle modified value 36000 THROTTLE MOD Throttle modified value to be sent to engine controller is
output
31 Body positioner 34603 BODY POSITION A_IN_6
16 HM300-2R
Data range Remarks
x1 [mA] (0 – 1000 [mA])

x1 [mA] (0 – 1000 [mA])
x1 [mA] (0 – 1000 [mA])
x1 [mA] (0 – 1000 [mA])

x1 [mA] (0 – 1000 [mA])
x1 [mA] (0 – 1000 [mA])

x1 [mA] (0 – 1000 [mA])

x1 [° ] (-25.0 – +25.0 [° ])
x1 [mV] (0.00 – 5.00 [V])
x1 [%] (0 – +100.0 [%])
x1 [%] (0 – +100.0 [%])
x1 [%] (-100.0 – +100.0 [%])

x1 [mV] (0.00 – 5.00 [V])
Seating condition: 0.32 V – 0.64 V

(When shipped from factory 0.52 V)
HM300-2R 17
32 Dump lever (hoist lever) 34506 DUMP LEVER 1 A_IN9

potentiometer 1
33 Dump lever (hoist lever) 34507 DUMP LEVER 2 A_IN10

potentiometer 2
34 Body seating 34600 BODY SEATING Body seating condition is output
35 Seating control command 45100 S CNT DIR H
(Hi)
36 Seating control command 45101 S CNT DIR L
(Lo)
37 Seating condition 45200 S CAL A
calibration value ( )
38 Cylinder stopper 45300 S CAL B
calibration value ( )
39 Seating control time (Hi) 45400 S CNT TIME H
40 Hoist EPC output 45601 HOIST EPC DIR SOL_OUT4
41 Seating control time (Lo) 45401 S CNT TIME L
18 HM300-2R
Data range Remarks
x1 [mV] (0.00 – 5.00 [V])

Lower: 0.3 V – 1.57 V
Float: 1.47 V – 2.01 V

Adjustment mode: 1.91 V – 2.30 V
Hold: 2.29 V – 3.30 V

Raise: 2.60 V – 3.50 V
Raise END: 3.40 V – 4.70 V
x1 [mV] (0.00 – 5.00 [V])

Lower: 4.7 V – 3.43 V
Float: 3.53 V – 2.99 V
Adjustment mode: 3.09 V – 2.70 V
Hold: 2.71 V – 1.70 V
Raise: 2.40 V – 1.50 V
Raise END: 1.60 V – 0.30 V
0: Other than seating
1: Seating
x1 [mA] (0 – 1000 [mA])
x1 [mA] (0 – 1000 [mA])
x1 [mV] (0.00 – 5.00 [V])

x1 [mV] (0.00 – 5.00 [V])

x1 [s] (0.0 – 10.00 [s])

x1 [mA] (0 – 1000 [mA])

x1 [s] (0.0 – 10.00 [s])

HM300-2R 19
42 Low clutch trigger 38900 TRIGGER MOD L Low clutch trigger modification value is output (all oil
modification value temperature mode)
43 High clutch trigger 38901 TRIGGER MOD H High clutch trigger modification value is output (all oil
20 HM300-2R
Data range Remarks
Hexadecimal numbers show below

Display of 8 characters
AABBCCDD
AA: Low temperature correction value [x10 msec]
BB: Medium temperature correction value [x10 msec]

CC: Normal temperature correction value [x10 msec]
DD: High temperature correction value [x10 msec]
00000000 – FFFFFFFF [00000000 – FFFFFFFF]

(Each range: -1.28 (80) – +1.27 (7F) [sec])
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
AABBCCDD


(Each range: -1.28 (80) – +1.27 (7F) [sec])
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
HM300-2R 21
44 1st clutch trigger 38902 TRIGGER MOD 1 1st clutch trigger modification value is output (all oil
45 2nd clutch trigger 38903 TRIGGER MOD 2 2nd clutch trigger modification value (all oil temperature
modification value mode)
22 HM300-2R
Data range Remarks

AABBCCDD


(Each range: -1.28 (80) – +1.27 (7F) [sec])
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
AABBCCDD


(Each range: -1.28 (80) – +1.27 (7F) [sec])
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
HM300-2R 23
46 3rd clutch trigger 38904 TRIGGER MOD 3 3rd clutch trigger modification value (all oil
47 Reverse clutch trigger 38906 TRIGGER MOD R Reverse clutch trigger modification value (all oil
24 HM300-2R
Data range Remarks

AABBCCDD


(Each range: -1.28 (80) – +1.27 (7F) [sec])
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
AABBCCDD


(Each range: -1.28 (80) – +1.27 (7F) [sec])
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
HM300-2R 25
48 Trigger initial learning flag 38922 TRIG HLR123 Trigger time initial learning flag state for each clutch is
output
[H, L, R, 1, 2, 3]
8 characters are displayed in following order
[HLR123]
H: H flag [1:ON, 0:OFF]
L: L flag [1:ON, 0:OFF]
R: R flag [1:ON, 0:OFF]
1: One flag [1:ON, 0:OFF]
2: Two flag [1:ON, 0:OFF]
3: Three flag [1:ON, 0:OFF]
49 Fill time (L) 41800 FILL TIME L Low clutch fill time is output
(Last gear shifting condition)
x10 [msec] (0 – 2.55 [sec], No fill :0)
50 Fill time (H) 41801 FILL TIME H HIGH clutch fill time is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
51 Fill time (1) 41802 FILL TIME 1 1st clutch fill time is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
52 Fill time (2) 41803 FILL TIME 2 2nd clutch fill time is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
53 Fill time (3) 41804 FILL TIME 3 3rd clutch fill time is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
54 Fill time (R) 41806 FILL TIME R REV clutch fill time is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
55 Throttle lower limit 44201 THROT LIMIT LO Throttle lower limit to be sent to engine controller is output
output x0.1 [%] (0 – +100.0 [%])
56 Throttle higher limit 44200 THROT LIMIT HI Throttle upper limit to be sent to engine controller is output
output x0.1 [%] (0 – +100.0 [%])
26 HM300-2R
Data range Remarks
Corresponding clutch learning flag ON/OFF state is

displayed by [1 or 0] just below HLR123.
HLR123
1111111 (All clutches have been learned)
HLR123
0000000 (No clutch has been learned)
x10 [msec] (0 – 2550 [msec])

x10 [msec] (0 – 2550 [msec])

x10 [msec] (0 – 2550 [msec])

x10 [msec] (0 – 2550 [msec])

x10 [msec] (0 – 2550 [msec])

x10 [msec] (0 – 2550 [msec])

x0.1 [%] (0 – +100.0 [%])

x0.1 [%] (0 – +100.0 [%])

HM300-2R 27
57 Input signal D_IN_0-7 40905 D-IN--0------7 Input signal condition is output
58 Input signal D_IN_8-15 40906 D-IN--8-----15 Input signal condition is output
59 Input signal D_IN_16-23 40907 D-IN-16-----23 Input signal condition is output
28 HM300-2R
Data range Remarks
**0*****: Emergency steering not operated (HM400) D_IN_2: Emergency steering relay 2 (HM400 only)
Always0 (HM300, HM350) D_IN_4: C terminal signal
**1*****: Emergency steering operated (HM400) D_IN_5: Emergency steering relay 1
****1***: Cranking D_IN_6: Shift hold SW
*****0**: Emergency steering not operated D_IN_7: Shift lever N
*****1**: Emergency steering operated

******0*: Shift hold SW=OFF
******1*: Shift hold SW=ON
*******1: Shift lever N
*1******: L fill D_IN_9: Fill signal L
**1*****: H fill D_IN_10: Fill signal H
***1****: 1ST fill D_IN_11: Fill signal 1st
****1***: 2nd fill D_IN_12: Fill signal 2nd
*****1**: 3rd fill D_IN_13: Fill signal 3rd
******1*: R fill D_IN_14: Fill signal R
Example
01010000: When in F1
00001010: When in R2
00000000: When in N
00100100: When in F6
10000000: Shift lever R2 D_IN_16: Shift range R2
01000000: Shift lever R1 D_IN_17: Shift range R1

00100000: Shift lever D D_IN_18: Shift range D
00010000: Shift lever 5 D_IN_19: Shift range 5


HM300-2R 29
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.
When power supply output is set, 0 is displayed.
30 HM300-2R
Data range Remarks
0*******: TM oil filter clogging D_IN_24: TM filter SW
****0***: Dropped engine oil level D_IN_27: Emergency escape SW
*****0**: Engine oil filter clogging D_IN_28: Engine oil level

D_IN_29: Engine oil filter SW
* Not used
*1**0*00: Hoist selector valve ON D_OUT_1: Hoist selector valve
****0100: Hoist lever kick-out ON D_OUT_5: Hoist lever kick-out solenoid
* Not used
* Not used
HM300-2R 31
Hoist control function

Hoist control system diagram
1. Hoist control function If the engine is not started, even if the hoist
When the engine is running, the EPC valve lever is operated, the condition remains at
(solenoid proportional valve) and selector valve HOLD.
are controlled according to the operation of the Starting switch at OFF:
dump control lever and operate the dump body. The hoist valve is closed and the dump body is
held in position regardless of the position of the
2. Lever positioner function
lever.
The dump control lever has four positions:
Engine started:
RAISE, HOLD, FLOAT, and LOWER.
Immediately after the engine is started, the out-
If the dump control lever is operated to the
put is set to HOLD, regardless of the position of
RAISE position, the dump body is raised, and
the lever. After the lever is moved to the HOLD
when the top of the dump body reaches the set
position, it becomes possible to carry out nor-
position of the body position sensor, the lever is
mal operations.
returned to the HOLD position.
5. Float caution function
3. Body seating speed control In the case of "NOT FLOAT OUTPUT" or "NOT
When the dump body is lowered and reaches SEATED", the float caution lamp on the monitor
the position just before it is seated, the area of panel lights up.
opening of the EPC valve is throttled to control "FLOAT OUTPUT" and "SEATED" o Float cau-
the lowering speed of the dump body and tion OFF
reduce the shock when the dump body comes "NO FLOAT OUTPUT" or "NOT SEATED" o
into contact with the chassis. Float caution ON
4. Control when starting switch is turned to ON,
OFF, or START
Starting switch at ON:
The output is set to HOLD, regardless of the
position of the lever.
32 HM300-2R
6. Reverse inhibit function

Information on permission and prohibition of
reverse travel is judged.
"NOT RAISE" and "SEATED" or "FLOAT OUT-
PUT" and "NOT SEATED" o Reverse travel is
permitted.
"RAISE" and "SEATED" or "NOT FLOAT OUT-
PUT" and "NOT SEATED" o Reverse travel is
prohibited.
Or "RAISE" and "SEATED"
7. Calibration function
To absorb any inherent error in the dump body
potentiometer, calibration is carried out to rec-
ognize the dump body seating and the body cyl-
inder stopper condition.
After adjusting the installation of the body

potentiometer or after replacing the transmis-
sion controller, carry out calibration in the fol-
lowing order.
Order of dump control calibration (hydraulic oil
temperature: 80 - 90°C)
(1) Lower the dump body completely and run
the engine. Change the lever from HOLD
to FLOAT and check the float caution lamp
goes off.
(2) Operate the lever to the RAISE position and
raise the dump body until it contacts the
stopper. Keep the lever at the RAISE posi-
tion with the cylinder at the stopper position
for at least 5 seconds.
(3) Lower the dump body completely and keep
the lever at HOLD for at least 5 seconds.
(4) Run the engine at low idle and operate
RAISE o FLOAT with the dump body
raised to the maximum height, then lower
the dump body completely. Repeat this
operation 10 times.
(5) Run the engine at high idle and operate
RAISE o FLOAT with the dump body
raised to the maximum height, then lower
the dump body completely. Repeat this
operation 10 times.
HM300-2R 33
Retarder control system
34 HM300-2R
HM300-2R 35
Retarder controller
Outline
The retarder controller has the following functions. 5. Transmission of network data
1. Retarder control 1) Retarder actuation, parking brake actuation,
The solenoid proportional valve for the front and accumulator oil pressure drop warning, and
rear wheels is controlled according to the oper- other data are transmitted to the monitor
ating angle of the retarder control lever and panel.
actuates the retarder brake. 2) The overrun prevention, retarder command
when there is abuse, and other data sent
2. Overrun prevention, retarder control when there from the transmission controller are re-
is transmission abuse ceived.
The solenoid proportional valve for the front and
rear wheels is controlled based on the com-
mand (Analog command) from the transmission
controller and actuates the retarder brake by a
fixed amount.
3. Left and right differential lock control

The left and right differential lock is actuated
when the low speed range (F1, F2, F3, R1, R2)
is selected based on the setting of the left and
right differential lock selector switch, and the dif-
ferential lock foot switch is ON.
4. BCV (brake cooling valve) control

The BCV control transmits a command to the
BCV valve to lower the cooling flow and reduce
horse power loss when service brake and
retarder brake are not actuated.
36 HM300-2R

DEUTSCH-24P [BRC1]
1 Accumulator oil pressure (rear) Input 13 Input
2 Input 14 Retarder lever Input
3 Input 15 Alternator (R) terminal Input
4 GND(SIG) — 16 SENS PWR Output
5 Retarder switch (rear) Input 17 Service brake oil pressure switch Input
6 Input 18 Validation switch 2 Input
7 Accumulator oil pressure (front) Input 19 Input
8 Input 20 Input
9 Input 21 GND (Analog) —
10 GND(SIG) — 22 POT PWR Output
11 Retarder switch (front) Input 23 Input
12 Input 24 Validation switch 1 Input
DEUTSCH-40P(1) [BRC2]
1 Output 21 S-NET Input/output
2 Input 22 CAN0_L Input/output
3 Input 23 CAN1_L Input/output
4 232C R x D Input 24 FWE switch Input
5 Input 25 Input
6 Input 26 Input
7 Input 27 Input
8 Output 28 Input
9 Output 29 GND (pulse) —
10 Input 30 Input
11 Output 31 GND (S_NET GND) —
12 CAN_SH — 32 CAN0_H Input/output
13 Input 33 CAN1_H Input/output
14 232C T x D Output 34 GND (232C GND) —
15 Input 35 Key switch C (engine start) Input
16 Input 36 Input
17 Memory clear switch Input 37 Input
18 Output 38 Input
19 Output 39 GND (pulse) —
20 Input 40 Input
DEUTSCH-40P(2) [BRC3]
1 VB (controller PWR) Input 21 GND (controller GND) Input
2 VIS (solenoid PWR) Input 22 VIS (solenoid PWR) Input
3 SOL_COM (solenoid common GND) Input 23 SOL_COM (solenoid common GND) Input
4 Output 24 Key SIG Input
5 Output 25 Output
6 Retarder valve (front) Output 26 Output
7 Differential solenoid (front) Output 27 Brake cooling valve (front) Output
8 Output 28 Output
9 Parking brake pressure switch Input 29 Input
10 Differential pressure switch (front) Input 30 Input
11 VB (controller PWR) Input 31 GND (controller GND) Input
12 VIS (solenoid PWR) Input 32 GND (controller GND) Input
13 SOL_COM (solenoid common GND) Input 33 GND (controller GND) Input
14 Key SIG Input 34 Reservoir —
15 Output 35 Output
16 Retarder valve (rear) Output 36 Output
17 Differential solenoid (rear) Output 37 Brake cooling valve (center) Output
18 Output 38 Output
19 Input 39 Input
20 Differential pressure switch (rear) Input 40 Input
HM300-2R 37
Retarder controller list of real-time monitoring display contens

The input and output signal states of the retarder controller can be checked with the real-time monitoring func-
tion of the machine monitor.
Real-time monitoring display items related to retarder controller and contents displayed in normal state are as
follows.
1 Part No. of software 20214 VERSION Mass production software part number is output
2 Application version 20231 VERSION (APP) Software version No. is output

(soft logic part version No.)
3 Data version 20232 VERSION (DATA) Software version No. is output

(soft data part version No.)
4 Alternator R 4302 ALTERNATOR R Alternator R terminal input state (A_IN_0) is output
5 Accumulator oil pressure 35500 ACC OIL PRE F Front accumulator oil pressure (A_IN_9) conversion
(front) value is output
6 Accumulator oil pressure 35506 ACC OIL PRE F Front accumulator oil pressure (A_IN_9) voltage is
(front) output
7 Accumulator oil pressure 35501 ACC OIL PRE R Rear accumulator oil pressure (A_IN_9) conversion
(rear) value is output
8 Accumulator oil pressure 35507 ACC OIL PRE R Rear accumulator oil pressure (A_IN_9) voltage is
(rear) output
9 Brake output 33807 BK OUTP DIR F SOL_OUT6

(front wheel)
10 Brake output 33806 BK OUTP DIR R SOL_OUT7

(rear wheel)
11 Retard lever 33900 RETARD LEVER A_IN_4
38 HM300-2R
Data range Remarks
Depending upon software part number.
ON [1: Operate]
OFF [0]
x1 [MPa] (0.00 – 50.0 [MPa])

x10 [mV] (0.00 – 5.00 [V])

0.00 – 99.99
x10 [mV] (0.00 – 5.00 [V])

x1 [mA] (0 – 1000 [mA])

x1 [mA] (0 – 1000 [mA])

x10 [mV] (0.00 – 5.00 [V])

HM300-2R 39
12 Input signal D_IN_0--7 40932 D-IN--0------7 Input signal state of D_IN_0 – D_IN_7 are output as they
are.
13 Input signal D_IN_8--15 40933 D-IN--8-----15 Input signal state of D_IN_8 – D_IN_15 are output as
they are.
14 Input signal D_IN_16-23 40934 D-IN-16-----23 Input signal state of D_IN_16 – D_IN_23 are output as
they are.
15 Input signal D_IN_24-31 40935 D-IN-24-----31 Input signal state of D_IN_24 – D_IN_31 are output as
they are.
16 Input signal D_IN_32 40943 D-IN-32-----39 Input signal state of D_IN_32 – D_IN_39 are output as
they are.
17 Output signal 40955 D-OUT--0------7 D_OUT_0 – 7 refer to SOL_OUT_0 – 7 of CR710.

D_OUT_0-7
18 Output signal 40956 D-OUT--8-----15 D_OUT_8 – 15 refer to SOL_OUT_8, 9, 10A, 10B, 11A,
D_OUT_8-15 11B, SIG_OUT_0 and SIG_OUT_1 of CR710.
19 Output signal D_OUT_23 40957 D-OUT-16-----23 D_OUT_16 – 23 refer to SIG_OUT_2, 3, HSW_OUT_0,

1 and BATTRY_OUT of CR710. D_OUT_21, 22 and 23
are not used.
40 HM300-2R
Data range Remarks
01010101 [1.0 is displayed under corresponding display See signal table

(number)] Input signal ON [1], Input signal OFF [0],
0 is displayed on unused part



0 or 1 [1.0 is displayed under corresponding display See signal table




HM300-2R 41
Retarder control function

Retarder control system diagram
Retarder lever control

• The operating angle of the retarder lever is de-
tected by the potentiometer and a current corre-
sponding to this is output to the solenoid
proportional reducing valve for the front and rear
wheels to actuate the retarder.
• Overrun prevention, retarder control when there

is transmission abuse
• The solenoid proportional reducing valve for the
front and rear wheels is controlled based on the
command (Analog command) from the trans-
mission controller and actuates the retarder by a
fixed amount.
42 HM300-2R
Relationship between retarder lever potentiometer and output to solenoid proportional reducing valve
(1) To improve the initial response of the solenoid

proportional reducing valve, the output (trigger
output) is set to a high value.
(2) To make the actuation of the hydraulic pressure
smooth in the low pressure range, the output is
set to a high value.
(3) In the range where the retarder is normally
used, the output is proportional to the angle of
the lever.
(4) To make the opening of the hydraulic pressure
smooth in the low pressure range, the output is
set to a low value.
HM300-2R 43
Inter-axle differential lock output

• Left and right differential lock output
• The left and right differential lock command is
transmitted as ON/OFF signal from the retarder
controller to actuate the left and right differential
lock solenoid (front wheel, rear wheel).
Retarder control lever

• The manual retarder potentiometer and lever
validation switches 1 and 2 are built into the le-
ver.
• The manual retarder potentiometer output is a
voltage signal matching the position of the lever
and is sent to the retarder controller.
• The lever validation switches output the ON/
OFF data for the lever position to the retarder
controller.
Dump control lever

• The dump control lever potentiometer and lever
kick-out solenoid are built into the dump control
lever.
• The dump control lever potentiometer output is
a voltage signal matching the position of the le-
ver and is sent to the retarder controller.
• The lever kick-out solenoid fixes the lever at the
RAISE position when it receives the ON signal
from the retarder controller and returns the lever
to the HOLD position when it receives the OFF
signal.
44 HM300-2R
Differential lock control function

Differential lock control system diagram
1. Inter-axle differential lock control sion output shaft speed exceeds the set
The inter-axle differential lock is actuated auto- value.
matically, or manually by turning the inter-axle a The inter-axle differential lock is actuat-
differential lock switch ON/OFF. ed when electric current is output to the
solenoid proportional valve.
• Manual differential lock:
In the low speed ranges (F1, F2, F3, R1, 2. Left and right differential lock control (controlled
R2) or N, the inter-axle command is output by the retarder controller)
when the differential lock switch is ON. Depending on the setting of the left and right dif-
ferential lock selector switch, one of the follow-
• Emergency braking control (automatic): ing is selected:
The inter-axle differential lock command is (1) rear wheel left and right differential lock ON;
output when the travel speed is more than (2) front and rear wheel left and right differential
35 km/h and the brake is ON. lock ON; or
(3) front and rear wheel left and right differential
• Brake ON control (automatic): lock OFF.
The inter-axle differential lock command is If (1) or (2) is selected, the differential lock foot
output according to the difference in speed switch is pressed, and the speed range is low
between the front and rear axles when the (F1, F2, F3, R1, R2), the differential lock com-
brake is ON. mand is output.
• Control (automatic) when there is variation

in transmission output shaft speed:
The inter-axle differential lock command is
output when the variation in the transmis-
HM300-2R 45
Auto emergency steering system
1. Steering oil pressure sensor Outline

2. Hydraulic tank • If the engine stops or an abnormality occurs in
3. Flow amp valve the hydraulic pump when the machine is travel-
4. Emergency steering pump ing, and the oil in the steering circuit goes below
5. Emergency steering motor the specified oil pressure, the auto emergency
steering system automatically actuates the
emergency steering pump to ensure the steer-
ing oil pressure and to make it possible to oper-
ate the steering. It is also possible to operate it
manually.
46 HM300-2R
Dump control lever
HM300-2R 47
1. Lever
2. Rod
3. Spring
4. Spring
5. Retainer
6. Body
7. Body
8. Bushing
9. Solenoid
10. Nut
11. Rod
12. Detent spring
13. Retainer
14. Ball
15. Seat
16. Potentiometer
17. Lever
18. Rod
19. Rod
20. Detent spring
48 HM300-2R
Function
• When lever (1) is operated, rod (18) moves up or
down according to the amount the lever is oper-
ated, and rotates potentiometer (16).
• The amount the control lever is operated (trav-
els) is detected by the potentiometer, and this is
sent as a signal voltage to the controller.
• One potentiometer is installed and outputs two
related signal voltages as shown in the "Output
voltage characteristics" graph.
Operation
1. Dump control lever operated to FLOAT
• When LOWER rod (2) is pushed by lever (1) and
moves down, ball (14) contacts protrusion (a) of
rod (11) during the stroke. (Before start of actu-
ation of mechanical detent)
• When rods (2) and (11) are pushed in further,
ball (14) is being held by detent spring (12).
While pushing retainer (13) up, it escapes to the
outside, and rod (11) passes over protrusion (a).
• When this happens, rod (18) on the opposite
side is pushed up by spring (4). Ball (14) is
moved to the small diameter side of protrusion
(b) of rod (19) by retainer (13) that is being held
by detent spring (20).
• Even if the lever is released, rod (18) is held in
position by the pushing force of the ball and pro-
trusion (b) of rod (19), so the lever is held at the
FLOAT position.
HM300-2R 49
2. Dump control lever FLOAT canceled 4. Dump control lever operated to RAISE
• When lever (1) is returned from the FLOAT posi- • When RAISE rod (18) is pushed by lever (1) and
tion, it is pushed down by a force greater than moves down, ball (14) contacts protrusion (a) of
the holding force of rod (19), detent spring (20), rod (19) during the stroke. (Before start of actu-
retainer (13), and ball (14). ation of electrical detent)
• When rods (18) and (19) are pushed in further,
3. Dump control lever operated to LOWER ball (14) pushes up retainer (13) which is held by
• When lever (1) is operated further from the detent spring (20) and it escapes to the outside,
FLOAT position, it moves to the LOWER posi- and rod (19) passes over protrusion (a).
tion. • When this happens, rod (2) on the opposite side
• Rod (18) is pushed up by the spring (4) in accor- is pushed up by spring (4).
dance with the amount lever (1) is operated. • When an electric current is flowing to solenoid
• Lever (17) and rod (19), which are installed to (9), if rod (2) is pushed up, nut (10) is held in con-
the rotating shaft of potentiometer (16), are inter- tact with bushing (8).
connected, so a voltage matching the up or • As a result, rod (2) is held at the pushed up po-
down movement of the rod is output from poten- sition, so even if the lever is released, it is held
tiometer (16). at the RAISE position.
50 HM300-2R
5. Dump control lever RAISE canceled

• When lever (1) is returned from the RAISE posi-
tion, it is pushed down by a force greater than
the attraction force of the solenoid.
Or, when the solenoid power source is turned
OFF, the RAISE position is canceled and the
lever returns to the flating position.
HM300-2R 51
© 2007 KOMATSU
All Rights Reserved
52 HM300-2R
SEN04842-00

HM300-2R


Payload meter (Card type).............................................................................................................................. 2
HM300-2R 1
Payload meter (Card type)

Structure of system
1. Shift lever neutral detection switch (relay)

2. Body sensor
3. Inclinometer
4. Pressure sensor (for front left)
5. Pressure sensor (for front right)
6. Pressure sensor (for rear left)
7. Pressure sensor (for rear right)
8. Suspension cylinder
9. Payload meter
10. Lamp drive relay
11. External display lamp
12. Battery
13. Fuse (for external display lamp)
14. Fuse (for controller)
15. Memory card
16. Travel signal sensor
17. RS232C output (PC cable communication) socket
18. Battery charge signal (alternator terminal R)
19. Articulate angle sensor
2 HM300-2R
Principle of calculation
1. Outline
The articulate dump truck is suspended by 6 wheels, front, central and rear pair of wheels. The front & rear
wheels are suspended by hydro-pneumatic suspension cylinder. The force Fr, which the rear wheel sus-
pends is equal as the force Fc, which the central wheel suspends because the central and rear wheels are
suspended by the equalizer bar.
The suspended force F = Ff + Fc + Fr = Ff + 2 × Fr
The force Ff = Af × Pf (Af: Suspension cylinder cross section, Pf: Suspension gas pressure)
2. Measurement of weight when empty 4. Correction on slope

(calibration) If the dump truck is loaded on a slope, the mea-
Drive the empty truck in the second gear at full sured weight is different from the weight mea-
throttle for 30 seconds. The payload meter measured on a level ground. To solve this problem,
sures the average of supported load F (empty the longitudinal inclination of the dump track is
truck) and uses it as the weight when empty. measured and measured weight is corrected ac-
The reason why the weight is measured while cording to the inclination angle. Correction
the truck is traveling is that the frictional resis- range of inclination angle: ± 5°
tance of the suspension cylinders must be aver-
aged by driving the truck and extracting and
retracting the cylinders. The weight measured
when empty is saved as a calibration data in the
memory in the controller.
3. Measurement of weight when full

Payload is measured by subtracting the sus-
pended force F (empty) when empty from the
suspended force F (loaded) when loaded.
The payload meter has 3 measurement meth-
ods in which the timing to measure the payload
is different.
1) Loading (during loading)
2) Traveling (during traveling)
3) Dumping (just before dumping)
These 3 methods are executed for each cycle.
The result of the one method can be recorded
for the cycle data. The method to be recorded
can be selected by the switch operation (service
check mode). Which method to be selected has
to be considered the site conditions and the cus-
tomer's needs.
Basically the accuracy of traveling method (de-
fault setting) is the best for normal conditions.
HM300-2R 3
Method of using accurately 4. Dumping method (same as payload meter II

for rigid dump truck)
1. Suspension cylinder length When the dumping method is selected,
The payload meter calculate the payload by the 1) The ground in the dumping area has to be
signal of the suspension cylinder pressure sen- well maintained.
sors. Please maintained the length of the sus- 2) The incline of the loading spot has to be
pension cylinder to be within nominal length. within ± 5°. If the incline exceeds ± 5°, the
accuracy is getting worse.
2. Calibration run 3) Do not hit the dump truck to the wheel stop-
Calibration run has to be carried out when per too much. If the dump truck is hit to the
1) The dump truck is shipped to the site wheel stopper too much, the calculated
2) The dump body is modified (the weight of payload might be much higher than the
the dump truck is changed) actual payload.
3) The gas of the suspension cylinder is main- 4) When the dump truck is stopped, please
tained activate the parking brake and release the
4) Periodically (each season) service brake or retarder brake.
A flat, level and straight 100 m course is neces- 5) Please wait for raising the body until the
sary for calibration travel. If the course is not flat, pitching of the dump truck by braking is sus-
level or straight, the calibration accuracy travel pended. Normally wait for dumping for 3 to
lowers. This affects the accuracy of payload cal- 5 seconds to get accuracy after the parking
culation. brake is activated and the service brake or
retarder brake is released.
3. Traveling method
When the traveling method is selected to be
stored,
1) The accuracy of traveling method depends
on the road condition. The more flat the
road is, the more accurate. Please main-
tained the road conditions to get the higher
accuracy.
2) The accuracy of traveling method depends
on the distance of traveling. The longer the
distance is, the more accurate. It needs
100m measurement at shortest to get accu-
racy. The traveling measurement is carried
o ut only when the dump tr uck speed
exceeds 8 km/h and the incline of the road
is within ± 5°. The haul road has to contain
more than 100 m which meets the condition
above for Traveling method.
3) Rapid acceleration, braking and steering
cause that the accuracy might be worre.
4 HM300-2R
5. Loading method
To keep the accuracy of loading method (including external display lamps)
1) The better maintained the ground of loading spot is, the more accurate.
2) The incline of the loading spot has to be within ± 5°. If the incline exceeds ± 5°, the accuracy is getting
worse.
3) Stop the dump truck gently. Do not change the shift to neural position until the dump truck is stopped
completely.
4) When the dump truck is stopped, please activate the parking brake and release the service brake or
retarder brake. Please stop the dump truck gently.
5) Do not load the material before the dump truck is stopped completely.
6) The controller recognize the loading is finished when the dump truck travels more than 5m after the
loading is stared.
7) The equalizer bar hit the stopper
• If the equalizer bar hit the stopper, the accuracy would become very bad.
• The payload meter detect this hit when the empty dump truck stops at the loading spot. The payload
meter detects the equalizer bar to be hit the stopper, then the error code 'F-FL' is displayed in the
payload meter display, and all the external display lamps are flashed.
• Do not load when all the external display lamps are flashed.
• If the error code 'F-FL' comes out, please move the dump truck forward a little bit and stop until the
'F-FL' disappears.
• When move the dump truck forward, please shift the transmission to drive range. When stop the
dump truck, please shift the transmission to neutral range after the dump track is completely
stopped.
6. Download
1) The payload meter stores the cycle data for 2,900 cycles (normally more than 1 month operation). If
the number of cycles exceeds 2,900, the newest data is overwritten on the oldest data. Please down-
load the data periodically and clear the all data before overwriting.
HM300-2R 5
General locations of payload meter
1. Display
2. Communication "receiving" lamp
(Rx busy)
3. Communication "transmitting" lamp
(Tx busy)
4. Memory card access lamp
(CARD busy) (not used)
5. Mode switch
6. Calibration/clear switch (CAL/CLR)
7. Total/shift switch (TOTAL/SFT)
8. Light/increment switch (LIGHT/INC)
9. Memory card (not used)
10. Cover
a Communication "transmitting" lamp (3) also

lights up when the communication cable is not
connected to a PC or when there is defective
connection.
a When not inserting or removing memory card
(9), keep cover (10) closed.
6 HM300-2R
Left face
a The switches are adjusted before the machine is shipped.

Do not touch any other switch.
HM300-2R 7
Basic functions
1. Power ON
When the power is turned ON, all functions are checked and displayed.
Power ON
Display portion 8.8.:8.8. (3 seconds) External display lamps all ON

Buzzer sounds (green, yellow and red)
(30 sec)
Model selection code display (8 seconds)

C0 : 00 o HM400-2, HM400-2R, HM400-1
C0 : 02 o HM300-2, HM300-2R, HM300-1
Weight unit setting

US : - - o Metric tons
US : oo o Short tons (US tons)
Machine ID code (3 seconds)

d.xxx (xxx o 0 – 200 shows code for set input)
Opened ID code (3 seconds)

o.xxx (xxx o 0 – 200 shows code for set input)
Normal operation display
2. Measuring empty weight (calibration)

The weight of the dump truck when empty is measured and this is used as the calibration data.
These data are retained even when the power is turned OFF.
8 HM300-2R
3. Normal operation display
Display during normal operations

Gearshift lever Dump body Payload meter External display
Condition of the machine
position position display lamps
Stopped N Seated Time OFF
When empty
Traveling Except N Seated Time OFF
Payload display and
Stopped N Seated Payload [ton]
During display of estimate
loading Traveling
Traveling (*1) Except N Seated OFF
distance [m]
Stopped N Seated Payload [ton] Payload display
When loaded
Total payload
When dumping N Seated o Unseated OFF
(*2) [100 ton]
When
abnormality is — — — See "Error code table"
happened
*1. When load is less than 50% of correct weight, display shows 0 t.
*2. The aggregate weight display is shown in units of 100 t. (rounded to the nearest 100)
4. External display lamp drive The estimated display shows the estimation of
(estimated display) the total payload when one more load is added.
The chart on the below shows the payload dis- The applicable lamp flashes to prevent over-
play level for the external display lamps during load.
the normal operation display. If current payload is 20 ton and the last bucket
This threshold can be modified by the key oper- was 5 ton for example, the green lamp is turned
ation in the service check mode. on from the table. The estimated payload for
next bucket is 25 ton. Then the yellow lamp is
Color of lamp HM300-2, HM300-2R flashed.
1 Green 13.7 tons and up If the red lamp is flashed, one more bucket
reaches over the red threshold and it will be
2 Yellow 24.6 tons and up
overloaded.
3 Red 28.7 tons and up
HM300-2R 9
5. Content of memory
(for details, see Operation and Maintenance Manual)
1) Cycle data
• The period between one dumping operation and the next dumping operation is taken as one cycle and
the data are recorded.
• The cycle data are recorded when the dumping is finished.
• The maximum limit for cycle data in memory is 2,900 cycles.
• Cycle data is recorded for more than 2,600 cycles, the error message 'L:FUL' is coming out in the dis-
play.
Item Unit Range

Engine operation number Integer 1 – 65,535
Month Month 1 – 12
Day Day 1 – 31
Time hour Hour Displayed as 0 – 23
Time minute Minute 0 – 59 Displays value and set value
at time of dumping
Machine ID Integer 0 – 200
Open ID Integer 0 – 200
t (Metric ton) or
Payload 0 – 6,553.5
US ton (Short ton)
Warning items/cycle
2) Engine ON/OFF data

• Each time the engine was stopped and started is recorded.
• The maximum limit in memory for engine ON/OFF data is 115.
• If the data is over 105, the error message 'E:FUL' is coming out. In this case, please download the data
and clear the data.
Item Unit Range

Engine operation number Integer 1 – 65,535 Consecutive number for operation of engine
Year (last 2 digits) Year 0 – 99
Shows when engine was
Day Day 1 – 31
switched ON
Time minute Minute 0 – 59
Shows when engine was
Day Day 1 – 31
switched OFF
t (Metric ton) or
Aggregate payload 0 – 9,999,000 Total value between engine ON and
US ton (Short ton)
engine OFF
Total number of cycles Times 0 – 9,999
10 HM300-2R
3) Abnormality, warning data

a Each time a payload meter abnormality or warning is generated or cancelled is recorded.
The maximum limit in memory for abnormality or warning data is 230 generated/cancelled sets.
Item Unit Range

Engine operation number when
Integer 1 – 65,535
error code was generated
Frequency of generation
Times 1 – 255
after engine is switched ON
Day Day 1 – 31 Shows when error code was
generated
Time hour Hour (0 – 23) Displayed as 0 – 23
Engine operation number
Integer 0 – 65,535
when cancelled
Month Month 1 – 12 Shows when error code was
cancelled
Day Day 1 – 31
Time hour Hour (0 – 23) Displayed as 0 – 23
HM300-2R 11
6. Forced display of aggregate payload, total d) Forced initialization

number of cycles This forcibly deletes all the data in payload
By operating the [TOTAL/SFT] switch of payload meter. Payload meter becomes just same
meter, it is possible to carry out forcible display as the one when the controller is shipped
of these items. For details, see the Operation from the factory.
and Maintenance Manual. • Before carrying out this operation,
check the time and date. Always carry
7. Operator check mode out the operation with the machine un-
By operating the switch of payload meter, it is loaded. Do not carry out the operation
possible to carry out the following items. unless necessary.
For details, see the Operation and Maintenance • If this is carried out, the calibration data
Manual. as well as each setting are cleared. The
1) Data all clear inclinometer calibration and the calibra-
2) Machine ID setting tion run are necessary to be done again.
3) Open ID setting
4) Time, date correction
8. Dimming of display portion

It is possible to adjust the brightness of payload
meter display portion to 10 levels with the
[LIGHT/INC] switch
9. Downloading saved data

It is possible to download any data recorded in
payload meter to a PC through a cable (RS232C)
For details, see the PC software manual provid-
ed by Komatsu.
10. Service check mode

By operating the switches of payload meter, it is
possible to forcibly carry out display, setting, and
correction of the following items.
a) Detailed calibration data display
The display shows the date, suspension
pressure, etc. when the latest calibration
was carried
b) Data all clear (service area)
This forcibly deletes all the calibration data
and analog data, except for the latest cali-
bration data.
a Before clearing the data, always down-
load the data to a PC or carry out (a)
Card dump.
c) Input signal condition display
This displays some of the signal conditions
for the sensors input to payload meter and
the present recognition condition of the pay-
load meter.
12 HM300-2R
e) Parameter setting
This allows to modify the parameter setting.
Display Item Unit Default Min Max

1. 5 Loading completion travel distance m 5 5 999
2. 10 Loading start threshold % 10 5 25
3. 0.0 Payload offset ton 0.0 -5.0 5.0
4.100 Payload gain % 100 80 120
5. 0.0 Loading payload offset ton 0.0 -5.0 5.0
6. 05 Travel mode min. speed km/h 8 1 20
7. 05 Travel mode max incline deg 5 5 10
8. 50 Green lamp threshold (X1) % 50 50 X2
9.090 Orange lamp threshold (X2) % 90 X1 X3
A.105 Red lamp threshold (X3) % 105 X2 120
b. 2 Store mode — 2 1 3
C. 2.0 Stopper-hit threshold ton 2.0 2.0 5.0
d. 50 Dump completion threshold % 50 10 50
E. 1.0 Stable payload threshold ton 2.0 0.5 3.0
F. 0 External display lamps check mode — 0 0 3
H.000 Machine Code (0: HM400, 2: HM300) — 0 0 0
J.000 payload unit (0: ton,1: short ton) — 0 0 1
L.000 Area code (1: Australia, 0: other) — 0 0 1
P.100 C1 % 100 80 120
U.100 C2 % 100 80 120
G.100 C3 % 100 80 120
y.100 C4 % 100 80 120
1) Loading completion travel distance 2) Loading start threshold

If the truck moves this distance after load- If the calculated payload becomes over this
ing, payload meter recognize the loading is threshold, payload meter recognizes the
completed. After the recognize of loading loading is started. And the difference
completion, the estimate function of the between the current payload and the last
external display doesn't work. The default payload is over this threshold, payload
setting is 5 m. meter recognizes one more bucket is
loaded. The default is 10%. This default
setting is for 8-bucket load or less. If the
bucket of the loader or excavator is too
small for this truck, the count of buckets
might be less than actual. In this case, this
setting has to be modified less value (7 to
8%).
HM300-2R 13
3) Payload offset, payload gain 6) Travel mode max incline

If the calculated payload is different from Payload meter calculates the paylaod by
the payload measured with the scale, the averaging the data during the traveling in
former can be adjusted by this setting and the traveling mode. Normally when the
the following setting (Payload gain). How- slope is steep, the accuracy tends to be
ev er, onl y the download data can be worse. Payload meter averages the data
adjusted by this setting, and the payload only when the slope is less steep than this
displayed on the payload meter cannot be thireshold. The default setting is 5 degree.
adjusted. This setting is proper for almost all road
(The adjusted payload) = (Payload gain) × conditions. But if the major part of the haul
(Calculated payload) + (Payload off set) load has more than 5 degree slope and the
To modify these setting, do not set the value accuracy of traveling mode is not good
enough, this threshold can be modifed to
by few data because the data has deviation.
larger value (7 – 8 degree).
To do this, at least 5 cycles measuremet is
necessary.
7) Green/Yellow/Red lamp threshold
If the error is almost constant, regardless of As default, the green is set to 50%, yellow
the payload, "Payload offset" must be 90%, and red 105% similarly to a rigid
changed. For example, if the payload dump truck. If these are set severer, for
meter indicates 1 ton heavier than each of example, if the green is set to 80%, yellow
the actual loads of 19.1 ton (70%) and 27.3 95%, and red 105%, more accurate display
ton (100%), "Payload offset" must be set to is obtained. Do not set a threshold value
"-1.0". higher than 105% to the red, however.
If the error depends on the payload, both of
"Payload offset" and "Payload gain" must 8) Store mode
be changed. For example, if the payload Payload meter has 3 measurement meth-
meter indicates 1 ton heavier than the 70% ods as described before. But only 1 mea-
actual load and 2 ton heavier than the surement method is stored and can be
100% actual load, "Payload gain" must be downloaded. A mode of one type that
set to "89" (27.3 – 19.1)/(29.3 – 20.1%) and meets the jobsite condition and customer's
"Payload offset" must be set to "1.2" (27.3 – needs must be recommended to the cus-
0.89 x 29.3). tomer and must be set in the payload meter
controller.
4) Loading payload offset Guideline is
If the payload calculated at the loading time • Traveling mode is the most accurate. If
has an error but the saved payload is free not any special reason, choose travel-
ing mode.
of error, the display of the payload at the
• If the haul road is very rough or very
loading time can be adjusted by this setting.
short (less than 200 m) and the dumping
Normally the ground condition impacts to
area is well maintained, choose Dump-
the accuracy of the paylaod when loading. ing mode.
Please check the ground condition first. • If the customer wants to store the pay-
load displayed during loading, choose
5) Travel mode min. speed loading mode.
Payload meter calculates the paylaod by
averaging the data during the traveling in 9) Stopper-hit threshold
the traveling mode. Normally the ground If the equalizer bar hits to the stopper, the
condition is very rough when the vehicle accuracy of the payload when loading
speed is low. If the ground condition is very becomes very bad as described before.
rough, the accuracy tends to be worse. Payload meter recognize the hitting if the
Payload meter averages the data only calculated payload is over this threshold
when the vehicle speed is over this thresh- when the empty vehicle stops at the loading
old. The default setting is 8 km/h. This set- spot. The default setting is 2 ton. If payload
ting is proper for almost all road conditions. meter recognize the hitting, the error mes-
But if the truck speed is very slow for a long sage 'F-FL' is coming out. If this detection is
time and the accuracy of traveling mode is too sensitive, this threshold can be modifed
not good enough, this threshold can be to the higher value (3.0 ton). But this
modified to less value (5 – 6 km/h). causes the fail to detect the hitting. Please
take care when the setting is modified.
14 HM300-2R
10) Dump completion threshold 16) C1, C2, C3, C4

Payload meter recognize the dump comple- The formaulation to calculate the payload is
tion when the paylaod becomes under this described simply as below.
threshold during the dumping. There is no (Calculated paylaod) = C1 x (Sum of the
need to modify this parameter. front suspension cylinder pressure) + C2 x
(Sum of the rear suspension cylinder pres-
11) Stable payload threshold sure) + C3 x (incline) + C4 (offset)
The calculated payload changes dynami- This setting can modify these parameter.
cally when loading. Payload meter waits for These parameters are set for each ma-
the calculation until the calculated payload chine. If sufficient accuracy is not obtained
becomes stable. This threshold is the one by changing the parameters for 'payload
payload meter recognize the calculated offset' and 'payload gain', the above param-
payload to be stable. This setting (2 ton) is eters need to be changed. Do not change
proper for almost all conditions. This these settings without checking with the de-
impacts to the accuracy of the estimated sign department.
display of the external display lamps. If the
function is strange, this setting can be mod- Set value
Model
ified to be less value (1 ton). In this case, C1 C2 C3 C4
the time delay to display the lamps after HM400-1/HM400-2 100 100 100 100
loading might be longer. HM300-1 100 100 100 100
HM300-2 105 105 105 100
12) Externa display lamps check mode
This is used for the local installation of pay-
load meter. See LOCAL INSTALLATION.
13) Machine Code

" 0 " d en o te s H M4 0 0 - 2, HM 4 0 0- 2R or
HM400-1.
" 2 " d en o te s H M3 0 0 - 2, HM 3 0 0- 2R or
HM300-1.
14) Payload unit

Payload meter has 2 units for payload dis-
play. '0' means 'metric ton', '1' means 'short
ton (US ton)'.
15) Area code

If the area is in Australia, it has to be set '1'
and to be set '0' for the other area. It
impacts to the open ID in the download
data. If the area code is set '1' (Australia),
the open ID is not recorded in the download
data.
HM300-2R 15
Key operation
The chart below describes the key operation tree.
(Power on)
3sec 8888
8sec C0:00 Model selction code
3sec US:-- Weight unit
3sec dX:XX Machine ID code
3sec oX:XX Open ID code
(normal display)
empty 12:34 clock

loading 34.5 payload
run 3 distance
loaded 12:34 clock
stop 34.5 payload
run 12:34 clock
dumping 12 total payload
empty 12:34 clock
(Calibration run)
CAL/CLR switch (2 sec) CAL Calibration run mode
CAL/CLR switch (2 sec) CAL Calibration run ready
>9Km/h 13 elapsed time
30sec 0.5 calculated payload
MODE switch normal display
(Open ID)
MODE switch o0:00 Open ID
(Operator check mode)

MODE switch (2 sec) o.CHE
MODE switch Cd.dP
TOTAL/SFT switch Cd.dP memory card dump ready
TOTAL/SFT switch (blank) momory card dump
MODE switch d.000 Machine ID

MODE switch :0.4 calendar set
TOTAL/SFT switch :04 year
TOTAL/SFT switch 12:23 month:date
TOTAL/SFT switch 12:23 month:date
TOTAL/SFT switch 12:34 hour:min
TOTAL/SFT switch 12:34 hour:min
MODE switch aC:LE all clear
CAL/CLR switch (2 sec) aC:LE all clear ready
CAL/CLR switch (2 sec) : executing
(Service check mode)

MODE switch +
C.HEC
LIGHT/INC switch
(Service input signal check mode)
CAL/CLR switch +
TOTAL/SFT switch (2 sec) S.CHE
CAL/CLR switch 11.50 Pressure sensor [FL] [V]

MODE switch S.CHE return to S.CHE by MODE switch
CAL/CLR switch 21.50 Pressure sensor [FR] [V]
CAL/CLR switch 31.50 Pressure sensor [RL] [V]
CAL/CLR switch 41.50 Pressure sensor [RR] [V]
CAL/CLR switch 53.00 Inclinometer [V]
CAL/CLR switch 63.80 Backup battery [V]
CAL/CLR switch 78.31 R-terminal [V]
CAL/CLR switch 83.00 Articulate sensor [V]
CAL/CLR switch 9312 Pressure sensor [FL] [MPa]
CAL/CLR switch a312 Pressure sensor [FR] [MPa]
CAL/CLR switch b312 Pressure sensor [RL] [MPa]
CAL/CLR switch C312 Pressure sensor [RR] [MPa]
CAL/CLR switch d3.12 Inclinometer[deg]
CAL/CLR switch E12.3 Articulate sensor [deg]
CAL/CLR switch F 1 Neutral signal
CAL/CLR switch H 1 Body seated signal
CAL/CLR switch J12.3 Velocity [km/h]
CAL/CLR switch L34.5 Current payload [t]
CAL/CLR switch P 2.3 Calibrate load [t]
CAL/CLR switch U 1 Vehicle state mode
CAL/CLR switch G18.0 Sensor power supply [V]
CAL/CLR switch y27.2 Power supply
CAL/CLR switch S.CHE Service check mode
16 HM300-2R
MODE switch C.HEC
(Service setting mode)

TOTAL/SFT switch +
S.SEL
LIGHT/INC switch (2 sec)
CAL/CLR switch 1. 5 Loading completion travel distance [m]

MODE switch S.SEL return to S.SEL by MODE switch
CAL/CLR switch 2. 10 Loading start threshold [t]
CAL/CLR switch 3. 0.0 Payload offset [t]
CAL/CLR switch 4.100 Payload gain [%]
CAL/CLR switch 5. 0.0 Loading payload offset [t]
CAL/CLR switch 6. 05 Travel mode min. speed [km/h]
CAL/CLR switch 7. 05 Travel mode max incline [deg]
CAL/CLR switch 8. 50 Green lamp threshold [%]
CAL/CLR switch 9.090 Orange lamp threshold [%]
CAL/CLR switch A.105 Red lamp threshold [%]
CAL/CLR switch b. 2 Store mode
CAL/CLR switch C. 2.0 Stopper-hit threshold [t]
CAL/CLR switch d. 50 Dump completion threshold [%]
CAL/CLR switch E. 1.0 Stable payload threshold [t]
CAL/CLR switch F. 0 External lamps check mode
Machine Code
CAL/CLR switch H.000
0: HM400
payload unit
CAL/CLR switch J.000
0: ton, 1: short ton
Area code
CAL/CLR switch L.000
1: Australia, 0: other
CAL/CLR switch P.100 C1
CAL/CLR switch U.100 C2
CAL/CLR switch G.100 C3
CAL/CLR switch y.100 C4
CAL/CLR switch S.SEL
MODE switch C.HEC
(Service calibration mode)

CAL/CLR switch (2 sec) CAL.0
(Service calibration check mode)
CAL/CLR switch YY year of calibration
MODE switch CAL.0 Return to CAL.0 by MODE switch
CAL/CLR switch MM:DD Month:Date of calibration
CAL/CLR switch HH:mm Hour:Min. of calibration
CAL/CLR switch 4XXX Pressure sensor [FL] [MPa]
CAL/CLR switch 5XXX Pressure sensor [FR] [MPa]
CAL/CLR switch 6XXX Pressure sensor [RL] [MPa]
CAL/CLR switch 7XXX Pressure sensor [RR] [MPa]
CAL/CLR switch 8XX.X Calibration payload [t]
CAL/CLR switch CAL.0
(Inclinometer calibration)
CAL/CLR switch +
CAL.1
TOTAL/SFT switch (2 sec)
3sec CAL.2
CAL/CLR switch (2sec) CAL.2
3sec CHEC
MODE switch C.HEC
(Forcibly initialize mode)

CAL/CLR switch +
TOTAL/SFT switch +
LIGHT/INC switch (2 sec) AC:LE Forcibly initialize ready
CAL/CLR switch (2 sec) AC:LE execution
completed normal display
HM300-2R 17
Key operation and the display includes Service check mode

1) Power on procedure
2) Normal display Service check mode has
3) Calibration run mode 1) Service input signal check mode
4) Open ID input 2) Service calibration data mode
5) Operator check mode 3) Service setting mode
6) Service check mode 4) Forcibly initialize mode
1) to 5) are explained in Operation and Mainte- 1) To enter the service check mode
nance Manual. The key switch operation for 6)Ser- When the display is in normal display mode,
vice check mode is explained in this section. press [MODE] switch (1) and [LIGHT/INC]
switch (2) simultaneously for more than 2 sec-
onds, 'CHEC' is flashing. This means service
check mode.
2) To return to the normal display mode

Press [MODE] switch (1), then the display is re-
turned to normal display.
18 HM300-2R
1. Service input signal check mode 2) To check the signal input

• Then press [CAL/CLR] switch (1), then
1) To enter the service input signal check mode '1X.XX' (the most left digit is flashed) is dis-
• When the display is in service check mode played. The most left digit flashed shows the
('CHEC' is flashed), press [CAL/CLR] switch number of the item. X.XX means the voltage
(1) and [TOTAL/SFT] switch (2) simulta- of the pressure sensor for the front left sus-
neously for more than 2 seconds. pension cylinder.
• 'S.CHE' is flashed. This means the service • Press [CAL/CLR] switch (1) to see the next
input signal check mode. content according to the table. When [CAL/
CLR] is pressed at the last content of power
supply voltage 'y27.2', the display is re-
turned to 'S.CHE'.
• If you want to check the signal again, press
[CAL/CLR] switch (1) again.
Display Contents
11.50 Pressure sensor [FL][V]
21.50 Pressure sensor [FR][V]
31.50 Pressure sensor [RL][V]
41.50 Pressure sensor [RR][V]
53.00 Inclinometer [V]
63.80 Backup battery [V]
78.31 R-terminal [V]
83.00 Articulate sensor [V]
9312 Pressure sensor [FL] [MPa]
a312 Pressure sensor [FR] [MPa]
b312 Pressure sensor [RL] [MPa]
C312 Pressure sensor [RR] [MPa]
d3.12 Inclinometer [deg]
E12.3 Articulate sensor [deg]
F 1 Neutral signal
H 1 Body seated signal
J12.3 Velocity [km/h]
L34.5 Current payload [t]
P 2.3 Calibrate load [t]
U 1 Vehicle state mode
G18.0 Sensor power supply [V]
y27.2 Power supply
3) To return to the service check mode

Press [MODE] switch (3) at any process above,
the display is returned to service check mode
and 'CHEC' is flashed
HM300-2R 19
2. Service calibration data mode 4) To enter the inclinometer calibration mode

• When the display is 'CAL0' flashed, press
1) To enter the service calibration data mode [CAL/CLR] switch (1) and [TOTAL/SFT]
• When the display is in the service check switch (2) simultaneously for more than 2
mode ('CHEC' is flashed), press [CAL/CLR] seconds.
switch (1) for more than 2 seconds. • 'CAL1' is flashed. See LOCAL INSTALLA-
• 'CAL0' is flashed. This means the service TION about the detail of this procudure.
calibration data mode.
Key operation Display
CAL/CLR switch +
CAL.1
TOTAL/SFT switch (2 sec)
3sec CAL.2
CAL/CLR switch (2 sec) CAL.2
3sec CHEC
2) To check the calibration data

• Then press [CAL/CLR] switch (1), then 'XX'
is displayed. XX means the year of the cali-
bration executed.
• Press [CAL/CLR] switch (1) to see the next
content according to the table. When [CAL/
CLR] switch (1) is pressed at the last content
of calibration paylaod [8XX.X], the display is
returned to 'CAL0'.
• If you want to check the signal again, press
[CAL/CLR] switch (1) again.
Display Content
YY Year of calibration
MM:DD Month:Date of calibration
HH:mm Hour:Min. of calibration
4XXX Pressure sensor [FL] [MPa]
5XXX Pressure sensor [FR] [MPa]
6XXX Pressure sensor [RL] [MPa]
7XXX Pressure sensor [RR] [MPa]
8XX.X Calibration payload [t]
3) To return to the service check mode

Press [MODE] switch (3) at any process above.
'CHEC' is flahsed and the display is returned to
the service check mode.
20 HM300-2R
3. Service setting mode 2) To modify the parameter setting

• The most left digit flashed shows the num-
1) To enter service setting mode ber of the item selected. The 3 right digits
• When the display is in the service check are the parameter value. The flashed digit in
mode ('CHEC' is flashed), press [TOTAL/ this 3 digits is the one which is selected to be
SFT] switch (2) and [LIGHT/INC] switch (3) modified.
simultaneously for more than 2 seconds. • Press [TOTAL/SFT] switch (2) to change the
• '5.5EL' is flashed. Press [CAL/CLR] switch digit to be modified. The flashed digit moves
(1) to move to the next item. from right to left. Press [LIGHT/INC] switch
(3) to increase the value one by one.
• If [LIGHT/INC] switch (3) is pressed when
the flashed digit is '9', then change to '0'.
Display Item
1. 5 Loading completion travel distance [m]
2. 10 Loading start threshold [t]
3. 0.0 Payload offset [t]
4.100 Payload gain [%]
5. 0.0 Loading payload offset [t]
6. 05 Travel mode min. speed [km/h]
7. 05 Travel mode max incline [deg]
8. 50 Green lamp threshold [%]
9.090 Orange lamp threshold [%]
A.105 Red lamp threshold [%]
b. 2 Store mode
C. 2.0 Stopper-hit threshold [t]
d. 50 Dump completion threshold [%]
E. 1.0 Stable payload threshold [t]
F. 0 External display lamps check mode
H.000 Machine Code 0: HM400, 2: HM300
J.000 Payload unit 0: ton, 1: short ton
L.000 Area code 1: Australia, 0: other
P.100 C1
U.100 C2
G.100 C3
y.100 C4
3) To return to service check mode

Press [MODE] switch (4) then 'CHEC' is flashed
and the display is returned to the service check
mode.
HM300-2R 21
4. Forcibly initialization mode
• Press [CAL/CLR] switch (1), [TOTAL/SFT]

switch (2) and [LIGHT/INC] switch (3) simul-
taneously for more than 2 seconds, then
'ACLE' is flashed.
• This means the forcibly initialize mode is
ready. Press [CAL/CLR] switch (1) for more
than 2 seconds, 'ACLE' is lighted up and the
forcibly initialize mode is started.
• If you want to cancel the process when
'ACLE' is flashed, press [MODE] switch (4)
then 'CHEC' is flashed.
• Several seconds after the forcibly initialize
mode is started, power on process is started.
It means that the forcibly initialization is com-
pleted.
a Do not carry out this forcibly initialize mode

if not necessary. All the data including the
calibration data is cleared.
a After the execution of this mode, all proce-
dure for local installation is necessary.
22 HM300-2R
HM300-2R 23
Error code table

External
Problems if Panel Error code
NO. Content Explanation display Trouble shooting Remarks
this happen display recorded
lamps
When engine
Battery voltage Change the battery
Drop in backup is shut off, F-09
1
battery voltage
lower than the
stored data flashes — 000-009
to new one
nominal
might be lost
It impacts to
the function Check the signal
Disconnection Voltage of R- and F-18 condition display
2
at R terminal terminal out of range performance flashes — 000-018 check the
of payload connector PM1,
meter D01A, D01B
Check the signal

condition display
Abnormality in Voltage of sensor check the
It impacts to F-20 ALL
3 sensor power power lower than
the accuracy flashes flash
000-020 connector PM2 or (*1)
source(18V) the nominal the harness for
Suspension
pressure sensors.
Short circuit or
Check the signal
disconnection in
front left Voltage of pressure It impacts to F-21 ALL condition display
4
suspension sensor out of range the accuracy flashes flash
000-021 check the (*1)
pressure sensor connector SUFL,
system JPLM, PM2
Short circuit or
disconnection in Check the signal
condition display
front right Voltage of pressure It impacts to F-22 ALL
5 suspension sensor out of range the accuracy flashes flash 000-022 check the (*1)
connector SUFR,
pressure sensor JPLM, PM2
system
Short circuit or Check the signal

disconnection in
rear left Voltage of pressure It impacts to F-23 ALL condition display
6 suspension sensor out of range the accuracy flashes flash 000-023 check the (*1)
connector SURL,
pressure sensor JPLM, PM2
system
Short circuit or Check the signal

disconnection in
condition display
rear right Voltage of pressure It impacts to F-24 ALL
7
suspension sensor out of range the accuracy flashes flash
000-024 check the (*1)
connector SURR,
pressure sensor
system JPLM, PM2
Short circuit
Check the signal
with power
condition display
source for front Voltage of pressure It impacts to F-25 ALL
8
left suspension sensor out of range the accuracy flashes flash
000-025 check the (*1)
connector SUFL,
pressure sensor
JPLM, PM2
system
Short circuit
Check the signal
with power
condition display
source for front Voltage of pressure It impacts to F-26 ALL
9
right suspension sensor out of range the accuracy flashes flash
000-026 check the (*1)
connector SUFR,
pressure sensor
JPLM, PM2
system
Short circuit
Check the signal
with power
condition display
source for rear Voltage of pressure It impacts to F-27 ALL
10
left suspension sensor out of range the accuracy flashes flash
000-027 check the (*1)
connector SURL,
pressure sensor
JPLM, PM2
system
Short circuit
Check the signal
with power
condition display
source for rear Voltage of pressure It impacts to F-28 ALL
11
right suspension sensor out of range the accuracy flashes flash
000-028 check the (*1)
connector SURR,
pressure sensor
JPLM, PM2
system
24 HM300-2R
External
Problems if Panel Error code
NO. Content Explanation display Trouble shooting Remarks
this happen display recorded
lamps
Check the signal

Short circuit or
Voltage of condition display
disconnection in It impacts to F-31 ALL
12
inclinometer
inclinometer out of
the accuracy flashes flash
000-031 check the (*1)
range connector PCL,
system
JPLM, PM2
External
Short circuit in Check the relay
display lamp F-41 ALL
13 green external — 000-041 RPM,RPMG or
doesn't work flashes flash
display lamp harness
correctly
External
14 yellow external — 000-042 RPM,RPMY or
correctly
External
15 red external — 000-043 RPM,RPMR or
correctly
Cycle data is Download the

Cycle data Old data is L:FUL
16
memory FULL
recorded for more
over-written flashes
— 000-011 cycle data and (*2)
than 2,600 cycles clear the data
Engine data is Download the

Engine data Old data is E:FUL
17
memory FULL
recorded for more
over-written flashes
— 000-012 Engine data and (*3)
than 105 times clear the data
Calibration run
Payload meter F.CAL ALL Carry out the
18 not yet carried — —
doesn't work. flashes flash calibration run
out
Inclinometer Carry out the

Payload meter F.ICL ALL
19 calibration not — — inclinometer
doesn't work. flashes flash
yet carried out calibration
Accuracy Move the vehicle

Equalizer bar hit when loading F-FL ALL for the equalizer
20
to the stopper
—
becomes very flashes flash
—
bar not to be hit to
(*4)
bad the stopper
Too much Accuracy

F-AC ALL Steer the vehicle
21 articulated when — when dumping
flashes flash
—
straight
(*5)
dumping becomes bad
*1. Calibration run cannot be carried out when *3. Engine ON/OFF data
this has occurred. 1) If more than 105 sets are recorded
(less than 10 sets remaining) : E:FUL
*2. Cycle data memory FULL. flashes.
1) If more than 2,600 cycles are recorded
(less than 300 cycles remaining), L:FUL 2) If more sets are recorded, sets 116 and
flashes. 117 are recorded, the oldest ON/OFF
data is deleted in turn to make space to
2) If more cycle are recorded. Cycles record the new set.
2,901 and 2,902 are recorded, the older
cycle data is deleted in turn to make 3) This warning occur, please download
space to recorded the new cycle. the data and clear the all data (see
Forcibly initialization mode)
3) If this warning occur, please download
the data and clear the all data (see
Forcibly initialization mode)
HM300-2R 25
*4. Equalizer bar hit the stopper

1) If the equalizer bar hit the stopper, the
accuracy would become very bad. The
payload meter detect this hit when the
empty dump truck is stopped at the
loading spot.
2) If the error code ‘F-FLEis displayed in

the payload meter display panel, please
move forward the dump truck a little bit
and stop the dump truck until the ‘F-
FLdisappears. When move the dump
truck forward, please shift the transmis-
sion to drive range. When stop the
dump truck, please shift the transmis-
sion to Neutral range after the dump
truck is completely stopped.
*5. Too much articulated when dumping

When the dumping mode is selected, the
payload is calculated just before dumping. If
the dump truck is articulated too much, the
accuracy tends to worse. The articulated an-
gle is more than 22.5 degree (half of full
range), this fault code is activated. If this
fault code is activated, please steer the
dump truck to be straight.
26 HM300-2R
Local installation
1. Preparation
1) Before this procedure is carried out, check the suspension length. If the suspension length is out of
nominal range, charge or discharge the suspension gas and check the suspension length again to be
within nominal range. This process is very important to keep the accuracy of payload meter. This pro-
cess has to be done very carefully.
2) Check the dump body to be empty. If mud is on the dump body or on the chassis, clean it. It impacts
the accuracy.
3) The procedure below has to be carried out with Installation checklist for articulate dump truck payload
meter.
4) Calibration needs about 120m straight course with flat and horizontal ground.
5) The more straight, the more accurate. The more flat and horizontal, the more accurate.
6) Park the dump truck on the flat and horizontal ground.
7) Set the articulate straight. Mark the dump truck position on the ground.
8) Turn off engine.
• If 'press switch' without 'for more than 2 seconds' in the direction below, press switch for 0.5 seconds to
1 seconds.
• If you make a mistake of switch operation, MODE switch is effective for recovering in most situations.
• If you fail to the procedure below, turn off the key and start from the beginning again.
2. Payload meter controller check

1) Turn on the key switch.
2) Display '8.8.:8.8.' and buzzer sounds for 3 seconds.
3) Display 'C0:00' (it means machine model code = 0 [HM400-2]) for about 8 seconds. Buzzer sounds 1
second again (error detection for F.ICL, and F.CAL).
4) Display 'd0:00' (it means machine ID = 0) for 3 seconds.
5) Display 'o0:00' (it means open ID = 0) for 3 seconds.
6) Display 2 fault codes, 'F.ICL (inclinometer is not calibrated)' and 'F.CAL (calibration run is not exe-
cuted)' alternately. 'F-.FL' might be flashed, it's no problem.
7) If there are the other fault codes displayed, please check.
HM300-2R 27
3. External display lamp check 2) Press [CAL/CLR] switch. The display is 'J._
1) Press [MODE] switch and [LIGHT/INC] _ 0' ('J' means 'payload weight unit setting
switch simultaneously for more than 2 sec- mode'. '0' means metric ton unit). If you
onds. The display flashes 'CHEC' (it means want to change the unit to short ton, press
service check mode). [TOTAL/SFT] switch, then the display is 'J._
_ 1' (short ton).
2) Press [TOTAL/SFT] switch and [LIGHT/
INC] switch simultaneously for more than 2 3) Press [CAL/CLR] switch. The display is 'L._
seconds. The display flashes 'S.SEL' (it _ 0' ('L' means 'area setting mode'. '0'
means service setting mode). means 'except Australia'). If the area is
Australia, press [TOTAL/SFT] switch, then
3) Press [CAL/CLR] switch 15 times. The dis- the display is 'L._ _ 1' (Australia).
play is changing from '1._ _ 5' to 'f._ _ 0' ('f'
4) Press [CAL/CLR] switch. The display is
means 'external display lamp check mode').
'P.100' ('P' means 'machine C1 setting
The symbol '_' above means the 'space'.
mode). If you want to change the C1 value
to '105', press 'LIGHT/INC' switch 5 times,
4) Make sure that all the external lamps has to then the display is 'P.105'.
be flashed (it means error 'F.CAL' and Press [CAL/CLR] switch. The display is
'F.ICL' to be detected). 'U.100' ('U' means 'machine C2 setting
mode). If you want to change the C2 value
5) Press [LIGHT/INC] switch. The display is to '105', press 'LIGHT/INC' switch 5 times,
'f._ _ 1'. Make sure that only the green lamp then the display is 'U.105'.
has to be turned on. Press [CAL/CLR] switch. The display is
'G.100' ('G' means 'machine C3 setting
6) Press [LIGHT/INC] switch. The display is mode). If you want to change the C3 value
'f._ _ 2'. Make sure that only the yellow to '105', press 'LIGHT/INC' switch 5 times,
lamp has to be turned on. then the display is 'G.105'.
Set value
7) Press [LIGHT/INC] switch. The display is Model
'f._ _ 3'. Make sure that only the red lamp C1 C2 C3 C4
has to be turned on. HM400-1/HM400-2 100 100 100 100
HM300-1 100 100 100 100
8) Press [LIGHT/INC] switch. The display is HM300-2 105 105 105 100
'f._ _ 0'. Make sure that all the lamps has to
be flashed. 5) Press [MODE] switch. The display flashes
'CHEC' (it means service check mode).
9) If the lamps does not work correctly, please
check the connector around the lamps or 5. Input signal check
around the relay circuit. 1) Start engine.
4. Setting 2) Press [CAL/CLR] switch and [TOTAL/SFT]

1) Press [CAL/CLR] switch. The display is switch simultaneously for more than 2 sec-
'H.__0' ('H' means 'machine code setting onds. The display flashes 'S.CHE' (it
mode' and '0' means HM400-2 and '2' means service input signal check mode).
means HM300-2). If you want to change
the machine code to '2', press 'TOTAL/SFT' 3) Press [CAL/CLR] switch. The display is '1X
switch twice, then the display is 'H.__2' . XX' ('1' is flashed). The right 3 digit shows
(HM300). the voltage of front left suspension pressure
sensor. Write down the value on the check
Machine model Model sheet. ). If the value is out of range, check
0 HM400-1, HM400-2 the wiring or sensor install.
2 HM300-1, HM300-2
4) Press [CAL/CLR] switch. The display is '2X
. XX' ('2' is flashed). The right 3 digit shows
the voltage of front right suspension pres-
sure sensor. Write down the value on the
check sheet. ). If the value is out of range,
check the wiring or sensor install.
28 HM300-2R
5) Press [CAL/CLR] switch. The display is '3X 12) Press [CAL/CLR] switch. The display is 'H_
. XX' ('3' is flashed). The right 3 digit shows _ 1' ('H' is flashed). The most right digit
the voltage of rear left suspension pressure shows the body seated signal ( 1 : seated, 0
sensor. Write down the value on the check : not seated ). Raise the dump body and the
sheet. ). If the value is out of range, check display on payload meter has to be 'H_ _ 0'.
the wiring or sensor install. Lower the dump body and the display on
payload meter has to become 'H_ _ 1'.
6) Press [CAL/CLR] switch. The display is '4X (Check on the check sheet. ). If the value is
. XX' ('4' is flashed). The right 3 digit shows not correct, check the wiring or sensor
the voltage of rear right suspension pres- install.
sure sensor. Write down the value on the
check sheet. ). If the value is out of range, 13) Press [CAL/CLR] switch. The display is 'J_
check the wiring or sensor install. _.0' ('J' is flashed). The most right digit
shows the velocity. Put the shift lever to 2nd
7) Press [CAL/CLR] switch. The display is '5X position and move the vehicle with full throt-
. XX' ('5' is flashed). The right 3 digit shows tle pedal. The display on payload meter has
the voltage of Inclinometer. ). If the value is to be around 12 Km/h. (Check on the check
out of range, check the wiring or sensor sheet. ). If the value is not correct, check
install. the wiring.
8) Press [CAL/CLR] switch. The display is '6X 14) Press [MODE] switch. The display flashes
. XX' ('6' is flashed). The right 3 digit shows 'CHEC'. Press [Mode] switch again. Display
the voltage of the backup battery. Write 2 error codes, 'F.ICL(inclinometer is not cal-
down the value on the check sheet. ). If the ibrated)' and 'F.CAL(calibration run is not
value is out of range, the backup battery executed)' alternately. 'F-.FL' might be
has to be replaced to new one. flashed, it's no problem.
9) Press [CAL/CLR] switch. The display is '7X 6. Inclinometer & articulate sensor calibration
. XX' ('7' is flashed). The right 3 digit shows 1) Start engine.
the voltage of R terminal. The voltage of R
terminal has to be more than 24V, but the 2) Inclinometer will be calibrated by measuring
maximum value of this display is around 2 opposite direction of the vehicle and by
8.3V. If the display is around 8.3V, it's OK. If averaging sensor inputs of these 2 times.
the value is out of range, check the wiring. The longitudinal incline of the ground must
be canceled. But the more horizontal the
10) Press [CAL/CLR] switch. The display is '8X ground is, the more accurate. Please find
. XX' ('8' is flashed). The right 3 digit shows the flat and horizontal area for this calibra-
the voltage of articulate sensor. (write down tion. The accuracy of the inclinometer
the value on the check sheet. ). If the value impacts the accuracy of payload meter.
is out of range, check the wiring or sensor This process has to be done very carefully.
install.
11) Press [CAL/CLR] switch 6 times. The dis-

play is 'F_ _ 1' ('F' is flashed). The most
right digit shows the neutral signal ( 1 : neu-
tral, 0 : other ). Move the shift lever to 'D'
range. The display on payload meter has to
be 'F_ _ 0'. Return the shift lever to 'N'
range. The display on payload meter has to
be 'F_ _ 1'. (Check on the check sheet. ). If
the value is not correct, check the wiring.
HM300-2R 29
3) Make sure the articulate to be straight. The 2) Park the dump truck on the flat and horizon-
articulate sensor will be calibrated as tal ground. Calibration run needs about 100
'straight' at this position. Please set the m straight and flat course.
articulate to be straight carefully.
3) Press [CAL/CLR] switch for more than 2
4) Press [MODE] switch and [LIGHT/INC] seconds. ' CAL.' will be flashed.
switch simultaneously for more than 2 sec-
onds. The display flashes 'CHEC' (it means 4) If you are ready to start, press [CAL/CLR]
service check mode). switch. ' CAL' will be lighted up.
5) Press [CAL/CLR] switch for more than 2 5) Shift the transmission to 2nd range.
seconds. The display flashes 'CAL.0' (ser-
vice calibration data check mode) 6) Press throttle pedal full. After the velocity
becomes over 9Km/h, the display counts up
6) Press [CAL/CLR] switch and [TOTAL/SFT] the elapsed time (seconds). Calibration run
switch simultaneously for more than 2 sec- needs 30 seconds run.
onds. 'CAL.1' (it means Inclinometer cali-
bration mode) will be displayed and the 7) After 30 seconds counted up, the current
calibration for Inclinometer and articulate calculated payload [ton] will be displayed.
sensor are executed for 3 seconds. 'CAL.2'
will be flashed after 3 seconds. 8) Stop the dump truck gently, shift the trans-
mission to neutral, turn on the parking
7) Turn around the dump truck and park the brake and release the retarder brake or ser-
dump truck with opposite direction on the vice brake. Do not change the transmission
exactly same position above. to neutral before the dump truck is stopped.
9) Write down the current payload. The dis-

played payload has to be around 0 ton
because the dump truck is empty.
10) Press [MODE] switch, then the display has

to be 'clock'. If 'F.-FL' is still flashed, please
move the dump truck and stop it gently. 'F.-
FL' must be distinguished. Do not change
the transmission to neutral before the dump
truck is stopped.
11) Write down the current payload.
8) Press [CAL/CLR] switch for more than 2 12) All external display lamp has to be turned
seconds. 'CAL.2' will be turned on and the off.
calibration for Inclinometer and articulate
sensor are calibrated for 3 seconds again 13) This calibration run has to be done periodi-
for opposite direction. 'CHEC' will be cally by the customer. Please induce the
flashed after the calibration is finished. way to do it to the customer.
9) Press [MODE] switch. The error code 8. Clock set

'F.ICL' must be turned off and only 'F.CAL' is 1) Clock is set for Japanese standard time.
flashed. This means the inclinometer cali- The date and the hour might be modified to
bration was successfully finished. 'F-.FL' the local time.
might be flashed, it's no problem.
2) Press [MODE] switch for more than 2 sec-
7. Calibration run onds. The display flashes 'oCHE' (it means
1) The weight of the empty dump truck has to operator check mode).
be calibrated because the weight of empty
dump truck might be different by the vessel 3) Press [MODE] switch. The display is 'd000'
and attachment options. (it means machine ID).
30 HM300-2R
4) Press [MODE] switch. The display is '_ _ 2) Each method has its pros and cons. The
YZ' ('Z' is flashed, YZ means lower 2 digits method to be recorded has to be decided
of year. 'YZ' for 2003 is '03'). by the site condition and the customers
request.
5) If 'Z' has to be corrected, press [LIGHT/
INC] switch, then 'Z' is increased. 3) The general guide line is as below
(1) Traveling method is the most accurate
6) Press [TOTAL/SFT] switch. The display is '_ for almost site.
_ YZ' ('Y' is flashed, YZ means lower 2 dig- (2) If all the haul road is very rough or the
its of year. 'YZ' for 2003 is '03'). distance of haul road is less than 200 m,
a. If the ground of the dumping area is
7) If 'Y' has to be corrected, press [LIGHT/ flat and the incline is less than ±5°.,
INC] switch, then 'Y' is increased. dumping method can be selected.
b. If the ground of the dumping area is
8) Press [TOTAL/SFT] switch. The display is not flat or the incline is more than
'MM:dd' ('MM' is flashed, MM means month, ±5°., the dumping method cannot
dd means day). be selected.
(3) If the customer wants to have the pay-
9) If 'MM' has to be corrected, press [LIGHT/ load data at the loading spot, loading
INC] switch, then 'MM' is increased. method can be selected.
10) Press [TOTAL/SFT] switch. The display is 4) Press [MODE] switch and [LIGHT/INC]
'MM:dd' ('dd' is flashed, MM means month, switch simultaneously for more than 2 sec-
dd means day). onds. The display flashes 'CHEC' (it means
service check mode).
11) If 'dd' has to be corrected, press [LIGHT/
INC] switch, then 'dd' is increased. 5) Press [TOTAL/SFT] switch and [LIGHT/
INC] switch simultaneously for more than 2
12) Press [TOTAL/SFT] switch. The display is seconds. The display flashes 'S.SEL' (it
'HH.mm' ('HH' is flashed, HH means hour, means service setting mode).
mm means minutes ).
6) Press [CAL/CLR] switch 11 times. The dis-
13) If 'HH' has to be corrected, press [LIGHT/ play is changing from '1._ _ 5' to 'b._ _ 2' ('b'
INC] switch, then 'HH' is increased. means 'store mode setting', '2' means 'trav-
eling method'). If you want to change the
14) Press [TOTAL/SFT] switch. The display is store mode, press [LIGHT/INC] switch.
'HH:mm' ('mm' is flashed ). Then the display is changing to 'b._ _ 3'
(loading method) o 'b _ _ 1' (dumping
15) If 'mm' has to be corrected, press [LIGHT/ method) o 'b._ _ 2' (traveling mode). Write
INC] switch, then 'mm' is increased. down the mode you set on the check sheet.
16) Press [MODE] switch. The display is 7) After the mode is selected, press [MODE]
'A.CLE' ('CLE' is flashed). switch. The display flashes 'CHEC' (it
means service check mode).
17) Press [MODE] switch. The clock has to be
displayed. 8) Press [MODE] switch again. The display
shows the clock.
9. Set store mode
1) This payload meter has 3 measurement
method, dumping method, traveling method
and loading method, are implemented.
These 3 methods are carried out for corre-
sponding stage of each cycle. But only the
payload by 1 method is stored and can be
downloaded. Which mode to record can be
set with the switch of the payload meter
controller.
HM300-2R 31
10. Trial test

1) Try 1 cycle including loading, traveling and dumping with almost 100% payload.
2) See "Method of using accurately".
3) Check the display working correctly as the table below.
Gearshift Payload
Condition of machine Dump body position External display lamp
lever position display panel
Stopped N Seated Time OFF

When empty
Payload display and

Stopped N Seated Payload
display of estimate
During loading
Traveling
Traveling (*1) Except N Seated OFF
distance
Stopped N Seated Payload Payload display

When loaded
Total payload
When dumping N Seated o Unseated OFF
(*2)
When abnormal-
— — — See "Error code table"
ity is happened
*1. When load is less than 50% of correct weight, display shows 0 t.
*2. The aggregate weight display is shown in units of 100 t. (rounded to the nearest 100)
4) Download the data. Check the data in the cycle data (payload, dumping time) to be correct.
11. Data clear

1) Press [MODE] switch for more than 2 seconds. The display flashes 'oCHE' (it means operator check
mode).
2) Press [MODE] switch. The display is 'd000' (it means machine ID).
3) Press [MODE] switch. The display is '_ _ YZ' ('Z' is flashed, YZ means lower 2 digits of year. 'YZ' for
2003 is '03').
4) Press [MODE] switch. The display is 'A.CLE' ('CLE' is flashed).
5) Press [CAL/CLR] switch for more than 2 seconds. The display is 'A.CLE' ('A.CLE' is flashed).
6) Press [CAL/CLR] switch for more than 2 seconds. The display is 'A.CLE' ('A.CLE is lighted up). All
clear of the cycle data and fault history will be started.
7) After all clear, the display becomes clock set.
8) Turn off engine.
32 HM300-2R
HM300-2R 33
© 2008 KOMATSU
All Rights Reserved
34 HM300-2R
SEN02674-01

HM300-2R


Sensors, switches ........................................................................................................................................... 2
KOMTRAX terminal system (If equipped) ..................................................................................................... 10
HM300-2R 1
Sensors, switches
Accelerator sensor
1. Pedal
2. Connector
Outline
Accelerator signal Idle validation signal
• This is installed under the operator’s cab. The • This is installed under the accelerator pedal.
accelerator pedal and accelerator sensor are When the accelerator pedal is released, signal
connected by a link. When the accelerator pedal 2 (No. 5 pin) is connected to the ground; when
is depressed, the movement is passed through the accelerator pedal is depressed, signal 3
the link and rotates the shaft of the potentiome- (No. 6 pin) is connected to the ground.
ter inside the accelerator sensor. The engine controller then detects the condi-
As a result, the resistance changes. A fixed tion.
voltage is impressed between the No. 1 – 3 pins
of the potentiometer. A voltage signal corre-
sponding to the angle of the accelerator pedal is
sent from the No. 2 pin to the engine controller.
2 HM300-2R
Retarder oil temperature sensor
1. Thermistor
2. Plug
3. Wiring harness
4. Connector
Function
• The retarder oil temperature sensor is installed
on the retarder pipe. It converts a temperature
change into a change of thermistor resistance,
and transmits a signal to the transmission con-
troller. The transmission controller transmits the
signal via the network to the machine monitor
panel, and the machine monitor panel displays a
temperature level. The temperature level dis-
played on the monitor panel reaches a predeter-
mined position, the lamp flashes and the
warning buzzer sounds.
Steering oil temperature sensor
1. Sensor
2. Terminal
3. Wiring harness
4. Connector
Function
• The steering oil temperature sensor is installed
to the steering and hoist piping. The sensor por-
tion detects the temperature, and when the oil
temperature goes above the specified level, the
warning lamp lights up and a message is dis-
played on the character display of the monitor
panel.
HM300-2R 3
Fuel level sensor
1. Connector
2. Wire resistor
3. Arm
4. Float
Function
• The fuel sensor is installed to the side face of the
fuel tank. The float moves up and down accord-
ing to the fuel level. This movement of the float
is transmitted by the arm and actuates a variable
resistance. This sends a signal to the monitor
panel to indicate the remaining fuel level. When
the display of the monitor panel reaches a cer-
tain level, a warning lamp flashes.
4 HM300-2R
Tilt sensor
1. Magnetic resistance particle

2. Leaf spring
3. Damper oil
Function
• The tilt sensor is installed to the rear of the chas-
sis. A magnet supported by a leaf spring is in-
stalled to a case charged with damper oil. It uses
the position in relation to the magnetic resis-
tance element to detect the tilt angle of the chas-
sis.
The magnet is supported by the leaf spring, so
it does not detect the front-to-rear tilt of the
chassis.
HM300-2R 5
Air cleaner clogging sensor
1. Indicator
2. Spring
3. Adapter
Function
• The air cleaner clogging sensor is installed to
the outlet port of the air cleaner. If the air cleaner
becomes clogged and reaches the set pressure
(negative pressure), the maintenance warning
lamp lights up to warn of the abnormality.
6 HM300-2R
Hydraulic oil level sensor
1. Connector
2. Float
3. Switch
Function
• The hydraulic oil level sensor is installed to the
side face of the hydraulic tank. When the oil
goes below the specified level, the float goes
down, the switch is turned OFF, and the mainte-
nance caution lamp lights up to warn of the ab-
normality.
HM300-2R 7
Body position sensor
1. Bearing
2. Brush assembly
3. Connector
Function
• The body position sensor is installed to the rear
of the chassis. When the angle of the dump
body changes, the shaft rotates through the link
installed to the dump body, and the dump body
angle is detected.
8 HM300-2R
HM300-2R 9
KOMTRAX terminal system (If equipped)
• The KOMTRAX terminal transmits various kinds

of machine information wirelessly. Persons to
operate the KOMTRAX can refer to the informa-
tion at office to provide various kinds of services
for customers.
a To provide the services, you need to make

an arrangement for starting the KOMTRAX
terminal service separately.
Information transmittable from KOMTRAX termi-

nal system includes the following.
1. Travel history
2. Service meter
3. Position information
4. Error history
and others.
10 HM300-2R
KOMTRAX communication modem
1. DRC connector (40 poles) connecting part Outline

2. (Not connected) • The KOMTRAX terminal can obtain various
3. GPS antenna connector connecting part kinds of machine information from network sig-
4. Orbcomm nals or input signals in the machine, and trans-
mit the information via the communication
antenna. The terminal is equipped with a CPU
(central processing unit), and has wireless com-
munication and GPS functions as well.
• The terminal is provided with a LED lamp and a
7-segment display lamp as a display unit. The
display unit is used for inspection and mainte-
nance.

• DRC connector
Pin No. Signal name Input/output Pin No. Signal name Input/output
1 232C (OCH) control signal Input 21 Inspection mode Input
2 232C (OCH) control signal Output 22 Inspection mode Input
3 232C (OCH) control signal Input 23 232C (OCH) control signal Input
4 232C (OCH) receiving Input 24 (if equipped) Input
5 232C (OCH) transmitting Output 25 (if equipped) Input
6 CAN shield GND — 26 (if equipped) Input
7 CAN signal (L) Input/output 27 C terminal input (Hi side) Input
8 CAN signal (H) Input/output 28 R terminal input Input
9 S-NET shield GND — 29 EXGND —
10 S-NET signal Input/output 30 (if equipped) Output
11 232C (OCH) shield GND — 31 (if equipped) (5V MAX) Input
12 Writing signal Input 32 (if equipped) (5V MAX) Input
13. 232C (ICH) receiving Input 33 232C (OCH) control signal Input
14. 232C (ICH) transmitting Output 34 (if equipped) Input
15. 232C (OCH) control signal Output 35 (if equipped) Output
16. (if equipped) Input 36 ACC Input Input
17. (if equipped) Input 37 Power supply GND (if equipped) —
18. (if equipped) Output 38 Power supply GND (if equipped) —
19. (if equipped) Output 39 Permanent power supply (12V/24V) Input
20. Relay output Output 40 Permanent power supply (12V/24V) Input
HM300-2R 11
© 2008 KOMATSU
All Rights Reserved
12 HM300-2R
SEN03418-01
HM300-2R

20 Standard value table 1

Standard service value table
Standard value table for engine ...................................................................................................................... 2
Standard value table for chassis ..................................................................................................................... 3
HM300-2R 1
SEN03418-01 20 Standard value table
Standard value table for engine 1

Engine SAA6D125E-5
Cate- Standard value for Service limit

Item Measurement conditions Unit
gory new machine value
Power mode 2,200 ± 50 2,200 ± 50
High idle
Economy mode 2,100 ± 50 2,100 ± 50
Power mode 970 ± 25 970 ± 25
Engine speed Low idle rpm
Economy mode 700 + 50/0 700 + 50/0
Power mode 2,000 2,000
Rated speed
Economy mode 1,900 1,900
kPa Min. 107 87
Air boost pressure At rated output
{mmHg} {Min. 800} {650}
Whole speed range
Exhaust temperature °C Max. 700 700
(intake air temperature: 20°C)
% Max. 45
At sudden acceleration (Low o High) (Bosch —
{Max. 4.5}
index)
Exhaust gas color Bosch
At rated output Max. 1.5 —
index
Bosch
At high idle Max. 1.0 —
Engine
index
Intake valve mm 0.33 —
Valve clearance
Exhaust valve mm 0.71 —
Compression Engine oil temperature: 40 – 60°C MPa Min. 2.9 2.0
pressure Engine speed: 200 – 250 rpm {kg/cm2} {Min. 30} {20}
At rated output kPa Max. 1.47 2.94
Blow-by pressure
Engine coolant temperature: Min. 70°C {mmH2O} {Max. 150} {300}
At rated output
SAE0W30E0S MPa 0.29 – 0.69 0.18
Engine oil temperature:
{kg/cm2} {3.0 – 7.0} {1.8}
Min. 80°C SAE5W40E0S
Engine oil pressure SAE10W30DH
At low idle
SAE15W40DH MPa Min. 0.08 0.05
Engine oil temperature: SAE30DH {kg/cm2} {Min. 0.8} {0.5}
Min. 80°C
Oil temperature All speed range (inside oil pan) °C 90 – 110 120
Deflection when pressed with finger force of
Fan belt tension mm 13 – 16 13 – 16
approx. 58.8 N {6 kg}.
Alternator belt Deflection when pressed with finger force of
mm 13 – 16 13 – 16
tension approx. 58.8 N {6 kg}.
2 HM300-2R
Standard value table for chassis 1

• Point 150mm Starting to 29.4 ± 4.9 29.4 ± 4.9
Accelerator pedal
from pedal ful- depress {3.0 ± 0.5} {3.0 ± 0.5}

crum N
Operating effort
Fully {kg} 58.8 +– 4.9
4.9 58.8 +– 4.9
4.9
depressed {6.0 +– 0.49 {6.0 +– 0.49
0.49} 0.49}
• Point 150mm from pedal

Travel mm 45 ± 5 45 ± 5
fulcrum
F1 o F2 • Engine coolant tempera- 2,100 ± 50 2,100 ± 50
F2 o F3 ture: Within operating 2,080 ± 50 2,080 ± 50
Shift up
range
F3 o F4 2,100 ± 50 2,100 ± 50
(Acceleration : small)
• Transmission oil tempera-

Accelerator full
F4 o F5 ture: 60 – 80 °C 2,080 ± 50 2,080 ± 50

F5 o F6 • Hydraulic oil tempera- 2,100 ± 50 2,100 ± 50
ture: 45 – 55 °C
F6 o F5 1,300 ± 35 1,300 ± 35
F5 o F4
Shift down
1,320 ± 35 1,320 ± 35
F4 o F3 1,300 ± 35 1,300 ± 35
F3 o F2 1,320 ± 35 1,320 ± 35
F2 o F1 1,300 ± 35 1,300 ± 35
F1 o F2 1,980 ± 50 1,980 ± 50
Engine
F2 o F3 2,000 ± 50 2,000 ± 50
Shift up
Automatic shift control
F3 o F4 2,050 ± 50 2,050 ± 50
(Acceleration : large)
Engine speed
Accelerator full
Power mode
F4 o F5 2,080 ± 50 2,080 ± 50
F5 o F6 rpm 2,100 ± 50 2,100 ± 50
F6 o F5 1,300 ± 35 1,300 ± 35
F5 o F4
Shift down
1,320 ± 35 1,320 ± 35
F4 o F3 1,300 ± 35 1,300 ± 35
F3 o F2 1,320 ± 35 1,320 ± 35
F2 o F1 1,300 ± 35 1,300 ± 35
F1 o F2 1,840 ± 50 1,840 ± 50
F2 o F3 1,780 ± 50 1,780 ± 50
Shift up
F3 o F4
Accelerator partial
F4 o F5 1,750 ± 50 1,750 ± 50
F5 o F6
F6 o F5 1,080 ± 35 1,080 ± 35
F5 o F4
Shift down
1,100 ± 35 1,100 ± 35
F4 o F3 1,080 ± 35 1,080 ± 35
F3 o F2 1,100 ± 35 1,100 ± 35
F2 o F1 1,080 ± 35 1,080 ± 35
HM300-2R 3

F1 o F2 • Engine coolant tempera-
F2 o F3 ture: Within operating
Shift up
(Acceleration : small )
F3 o F4 range 1,950 ± 50 1,950 ± 50

Accelerator full
F4 o F5 • Transmission oil tempera-

F5 o F6 ture: 60 – 80 °C
F6 o F5 • Hydraulic oil tempera-
Shift down
F5 o F4 ture: 45 – 55 °C
F4 o F3 1,180 ± 35 1,180 ± 35
F3 o F2
F2 o F1
F1 o F2
F2 o F3 1,900 ± 50 1,900 ± 50
Shift up
(Acceleration : large)
F3 o F4
Accelerator full
F4 o F5
Economy mode
1,950 ± 50 1,950 ± 50
Engine speed
F5 o F6
Engine
F6 o F5 rpm
Shift down
F5 o F4
F4 o F3 1,180 ± 35 1,180 ± 35
F3 o F2
F2 o F1
F1 o F2 1,840 ± 50 1,840 ± 50
F2 o F3 1,780 ± 50 1,780 ± 50
Shift up
F3 o F4
Accelerator partial
F4 o F5 1,750 ± 50 1,750 ± 50
F5 o F6
F6 o F5 1,080 ± 35 1,080 ± 35
F5 o F4
Shift down
1,100 ± 35 1,100 ± 35
F4 o F3 1,080 ± 35 1,080 ± 35
F3 o F2 1,100 ± 35 1,100 ± 35
F2 o F1 1,080 ± 35 1,080 ± 35
4 HM300-2R

F1 o F2 • Engine coolant tempera- 2,183 ± 50 2,183 ± 50
Coast mode (Accelerator idle)
F2 o F3 ture: Within operating 2,187 ± 50 2,187 ± 50

Shift up range
F3 o F4 2,201 ± 50 2,201 ± 50
• Transmission oil tempera-
F4 o F5 ture: 60 – 80 °C 2,200 ± 50 2,200 ± 50
F5 o F6 • Hydraulic oil tempera-
F6 o F5 ture: 45 – 55 °C 1,080 ± 35 1,080 ± 35
F5 o F4
Shift down
1,100 ± 35 1,100 ± 35
F4 o F3 1,080 ± 35 1,080 ± 35
F3 o F2 1,100 ± 35 1,100 ± 35
F2 o F1 1,080 ± 35 1,080 ± 35
F1 o F2 2,183 ± 50 2,183 ± 50
F2 o F3 2,187 ± 50 2,187 ± 50
Shift up
F3 o F4 2,201 ± 50 2,201 ± 50
Braking mode
F4 o F5
2,200 ± 50 2,200 ± 50
F5 o F6
F6 o F5
rpm 1,350 ± 35 1,350 ± 35
Engine speed
F5 o F4
Shift down
Engine
F4 o F3 1,349 ± 35 1,349 ± 35
F3 o F2 1,350 ± 35 1,350 ± 35
F2 o F1 1,342 ± 35 1,342 ± 35
F6 o F5
F5 o F4
Down shift inhibit
F4 o F3 1,350 ± 50 1,350 ± 50
speed
F3 o F2
F2 o F1
F1, F2 1,200 ± 35 1,200 ± 35
Auto lock-up
Set
R1, R2 1,200 ± 35 1,200 ± 35
F1, F2 1,200 ± 35 1,200 ± 35
Reset
R1, R2 1,200 ± 35 1,200 ± 35
Power
1,940 ± 100 1,940 ± 100
Torque converter mode
stall speed Economy
1,780 ± 100 1,780 ± 100
mode
Overrun prevention actuation
2,450 ± 50 2,450 ± 50
speed
rpm
Overrun prevention cancel
2,150 ± 50 2,150 ± 50
speed
HM300-2R 5

• Center of lever grip N 21.6 ± 8.8 Max. 19.6
Gearshift
Operating effort • Between each position {kg} {2.2 ± 0.9} {Max. 2.0}
lever
Travel mm 24.0 ± 1 24.0 ± 2
• Torque converter oil 2.55 ± 0.2 2.55 ± 0.2

temperature: Low idle {26 ± 2.0} {26 ± 2.0}
Power train main relief MPa
pressure Within operating range {kg/cm2} 2.55 ± 0.2 2.55 ± 0.2
• Gearshift lever: N High idle {26 ± 2.0} {26 ± 2.0}
Torque converter • Torque converter oil temperature: 0.91 ± 0.10 0.91 ± 0.10
inlet port pressure Within operating range {9.3 ± 1.0} {9.3 ± 1.0}
• Engine speed: High idle
Torque converter 0.49 ± 0.05 0.49 ± 0.05
outlet port pressure {5.0 ± 0.5} {5.0 ± 0.5}
Torque converter lock- 2.16 ± 0.15 2.16 ± 0.15

up clutch pressure {22.0 ± 1.5} {22.0 ± 1.5}
Transmission Lo 2.45 ± 0.15 2.45 ± 0.15
clutch pressure {25.0 ± 1.5} {25.0 ± 1.5}
Oil pressure
Transmission Hi 2.45 ± 0.15 2.45 ± 0.15

clutch pressure {25.0 ± 1.5} {25.0 ± 1.5}
Transmission 1st MPa 2.45 ± 0.15 2.45 ± 0.15
clutch pressure {kg/cm2} {25.0 ± 1.5} {25.0 ± 1.5}
Transmission 2nd 2.35 ± 0.15 2.35 ± 0.15
clutch pressure {24.0 ± 1.5} {24.0 ± 1.5}
Transmission 3rd 2.45 ± 0.15 2.45 ± 0.15
Power train
clutch pressure {25.0 ± 1.5} {25.0 ± 1.5}

Transmission R 2.45 ± 0.15 2.45 ± 0.15
clutch pressure {25.0 ± 1.5} {25.0 ± 1.5}
Inter-axle differential 2.35 ± 0.15 2.35 ± 0.15
lock clutch pressure {24.0 ± 1.5} {24.0 ± 1.5}
Transmission Min 0.1 Min 0.1
lubricating pressure
(reference) {Min 1.0} {Min 1.0}
• Flat ground
F1 6.8 ± 5% 6.8 ± 5%
• Engine coolant temperature:
Within operating range
F2 • Torque converter oil temperature: 10.7 ± 5% 10.7 ± 5%
• Dump body: Unloaded
F3 16.1 ± 5% 16.1 ± 5%
• Travel resistance: 3.3%
Travel speed
F4 25.3 ± 5% 25.3 ± 5%
km/h
F5 38.1 ± 5% 38.1 ± 5%
F6 58.1 ± 5% 58.1 ± 5%
R1 7.6 ± 5% 7.6 ± 5%
R2 18.0 ± 5% 18.0 ± 5%
• Standard tire: 23.5 – R25 front center,rear front center,rear

MPa
Tire inflation pressure • Dump body: Unloaded 2 0.343 0.402 0.343 0.402
{kg/cm }
{3.50} {4.1} {3.50} {4.1}
6 HM300-2R

For • Gas temperature (atmosphere tem- 4.4 ± 0.15 4.4 ± 0.15
Gas pressure
Accumulator
front perature): 20 ± 5°C {45 ± 1.5} {45 ± 1.5}

Nitrogen gas brake MPa
2
pressure For rear {kg/cm }
4.4 ± 0.15 4.4 ± 0.15
parking
{45 ± 1.5} {45 ± 1.5}
brake
• Point 150mm from pedal fulcrum N Max. 294 Max. 294
Operating effort
{kg} {Max. 30.0} {Max. 30.0}
Brake
pedal
Travel mm 44.5 ± 5 44.5 ± 5
• Point 10mm from tip of lever N 5.9 – 9.8 3.0 – 14.7

Operating effort
Retarder
{kg} {0.6 – 1.0} {0.3 – 1.5}

lever
°
Travel 78 ± 1 78 ± 2
(degree)
• Wheel brake actuation pressure: 11.77 + 0.29 11.77 + 0.29
Charge valve cut-in 0 0
Actuation pressure when brake is
pressure {120 + 3.0 {120 + 3.0
operated for first time after en- 0 } 0 }
gine is stopped
Charge valve cut-out 20.59 +– 0.98 20.59 +– 0.98
• Drop in wheel brake actuation 0.49 0.49
Oil pressure
pressure pressure: {210 +– 10 {210 +– 10

0 } 0 }
Drop in pressure 5 minutes after MPa
Wheel brake specified oil pressure (4.9MPa {kg/cm2} 4.9 ± 0.49 4.9 ± 0.49
actuation pressure {50kg/cm2}) is applied {50 ± 5} {50 ± 5}
Drop in wheel brake • Parking, exhaust brake actuation Max. 0.49 Max. 0.49
Brakes
actuation pressure pressure: {Max. 5} {Max. 5}

Engine at high idle
Parking brake Parking brake switch: ON 3.92 ± 0.4 3.92 ± 0.4
cancel pressure Exhaust brake switch: ON {40 ± 4.0} {40 ± 4.0}
Foot brake • Engine speed: High idle

Min 1,440 Min 1,440
braking performance • Gearshift lever: D
Wheel brake
• Torque converter stall speed rpm

Retarder brake
Min 1,470 Min 1,470
braking performance
• Flat, dry road surface
Foot brake braking • When load is 27.3t m Max. 22.3 Max. 22.3
distance • Travel speed: 32km/h
• Engine at high idle
Braking performance • Gearshift lever: D rpm Min 1,540 Min 1,540
Parking
brake
• Engine stall speed

• When load is 27.3t
Braking slope angle % Min. 25 Min. 25
• Slope angle (sin θ)
• 9 ± 1% downhill slope
Emergency brake braking
• When load is 27.3t m Max. 102 Max. 102
distance • Travel speed: 50 ± 3km/h
HM300-2R 7

• Engine speed: Low idle N Max. 29.4 Max. 35.3
Operating effort • Gearshift lever: N (stopped) {kg} {Max. 3.0} {Max. 3.6}
• Measure at circumference of steer-
Steering wheel
Play ing wheel mm 20 – 50 20 – 50

• Operating effort:
When turning at 10rpm
Steering
No. of turns • Play: Turns 4.3 ± 0.3 4.3 ± 0.6

Until point where tires start to move
• No. of turns: Lock - lock Sec. Max. 6 Min. 6
Turning time
• Turning time: Lock - lock
• Hydraulic oil temperature: 20.59 + 0.98 20.59 + 0.98
MPa 0 0
Steering relief pressure 45 – 55°C {kg/cm2}
• Engine speed: High idle {210 + 10
0 } {210 + 10
0 }
• Horizontal
Installed length (a) mm 163 ± 10 163 ± 10
Suspension cylinder
road surface
Front
• Dump body: MPa 5.88 ± 0.49 5.88 ± 0.49

Pressure Unloaded {kg/cm2} {60 ± 5.0} {60 ± 5.0}
Installed length (a) mm 101 ± 5 101 ± 5

Rear
MPa 0.98 ± 0.15 0.98 ± 0.15

Pressure
{kg/cm2} {10 ± 1.5} {10 ± 1.5}
• Engine stopped HOLD o Max. 29.4 Max. 35.3
• Center of grip RAISE {Max. 3.0} {Max. 3.6}
RAISE o Must return smoothly when engine is

HOLD at high idle
HOLD o Max. 29.4 Max. 35.3
FLOAT N {Max. 3.0} {Max. 3.6}
Dump lever operating effort {kg}
FLOAT o Max. 29.4 Max. 35.3
HOLD {Max. 3.0} {Max. 3.6}
FLOAT o Max. 29.4 Max. 35.3

LOWER {Max. 3.0} {Max. 3.6}
LOWER o Must return smoothly when engine is

FLOAT at 2,000rpm
Dump
• Hydraulic oil temperature:

Lifting time 12 ± 1.5 12 ± 1.5
70 – 90°C
• Engine speed: High idle Sec.
• Lowering time when operating 12 ± 1.5 12 ± 1.5
Lowering time
FLOAT
Dump body

70 – 90°C
• Hold at point where No. 2 cylinder
Hydraulic drift is extended 100mm mm Max. 85 170
• Engine stopped
• Downward movement at tip of
dump body over 5 minutes
• Hydraulic oil temperature: 20.59 + 0.98 20.59 + 0.98
MPa 0 0
Dump main relief pressure 45 – 55°C {kg/cm2}
• Engine speed: High idle {210 + 10
0 } {210 + 10
0 }
8 HM300-2R

3.4 ± 0.49 3.4 ± 0.49
45 – 55°C {35 ± 5} {35 ± 5}
• Engine speed: High idle
Dump
MPa
Dump pilot relief pressure • Hydraulic oil temperature: {kg/cm2}
45 – 55°C 2.6 ± 0.49 2.6 ± 0.49
• Engine speed: Low idle {27 ± 5} {27 ± 5}
(Reference value)
HM300-2R 9

© 2009 KOMATSU
All Rights Reserved
10 HM300-2R
SEN03419-01

HM300-2R

30 Testing and adjusting 1

Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting............................................................................................. 3
Sketches of special tools ................................................................................................................................ 8
Measuring engine speed................................................................................................................................. 9
Measuring intake air pressure (boost pressure) ........................................................................................... 10
Measuring exhaust temperature ....................................................................................................................11
Measuring exhaust gas color ........................................................................................................................ 13
Adjusting valve clearance ............................................................................................................................. 14
Measuring compression pressure................................................................................................................. 16
Measuring blow-by pressure......................................................................................................................... 18
Measuring engine oil pressure...................................................................................................................... 19
Handling of fuel system devices ................................................................................................................... 20
Releasing residual pressure from fuel system .............................................................................................. 20
Testing fuel pressure..................................................................................................................................... 21
Testing fuel return and leak amount.............................................................................................................. 22
Bleeding air from fuel circuit.......................................................................................................................... 25
Testing fuel circuit for leakage....................................................................................................................... 27
HM300-2R 1
SEN03419-01 30 Testing and adjusting
Testing and adjusting alternator belt tension................................................................................................. 28

Testing and adjusting air conditioner compressor belt tension...................................................................... 28
2 HM300-2R
Tools for testing, adjusting, and troubleshooting 1
Sym-
Q'ty
Testing and adjusting item Part No. Part name Remarks
bol
Measuring intake air -101 – 199.9 kPa
A 799-201-2202 Boost gauge kit 1
pressure (boost pressure) {-760 – 1,500 mmHg}
Measuring exhaust temper-
B 799-101-1502 Digital thermometer 1 -99.9 – 1,299 °C
ature
1 799-201-9001 Handy smoke checker 1
Measuring exhaust color C Commercially Bosch index 0 – 9
2 Smoke meter 1
available
Commercially
Adjusting valve clearance D Clearance gauge 1
available
0 – 7.0 MPa {0 – 70 kg/cm²}
1 795-502-1590 Compression gauge 1
Measuring compression Kit part No.: 795-502-1205
E
pressure 795-471-1420 Adapter 1
2 For 125E-5
6217-71-6112 Gasket 1
Measuring blow-by pressure F 799-201-1504 Blow-by checker 1 0 – 5.0 kPa {0 – 500 mmH2O}
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6.0, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm²}
Measuring engine oil
G Pressure gauge:
pressure 790-261-1204 Digital hydraulic tester 1
60 MPa {600 kg/cm²}
Pressure gauge:
2 799-401-2320 Hydraulic tester 1
1.0 MPa {10 kg/cm²}
Pressure gauge:
1 799-101-5002 Hydraulic tester 1 2.5, 6.0, 40, 60 MPa
{25, 60, 400, 600 kg/cm²}
Testing fuel pressure H Pressure gauge:
2 790-261-1204 Digital hydraulic tester 1
60 MPa {600 kg/cm²}
(Being
3 Adapter 1 8 × 1.25 mm o R1/8
established)
1 6151-51-8490 Spacer 1 Inner diameter: 14 mm
2 6206-71-1770 Joint 1 Joint section diameter: 10mm
Commercially
3 Hose 1 ø 5 mm × 2 – 3 m
available
Testing fuel return and leak Commercially
J 4 Hose 1 ø 15 mm × 2 – 3 m
amount available
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
HM300-2R 3
Sym-
Q'ty
bol
Pressure gauge:
{25, 60, 400, 600 kg/cm²}
Pressure gauge:
790-261-1204 Digital hydraulic tester 1
60 MPa {600 kg/cm²}
Pressure gauge:
799-401-2320 Hydraulic tester 1
Measuring power train oil 1.0 MPa {10 kg/cm²}
K
pressure 799-101-5220 Nipple 1
M10 × P1.25
07002-11023 O-ring 1
799-101-5260 Nipple 1
M12 × P1.5
07002-11223 O-ring 1
799-101-5230 Nipple 1
M14 × P1.5
07002-11423 O-ring 1
Testing and adjusting brake
L 793-520-1805 Brake test kit 1
oil pressure
1 792-610-1700 Gas charge tool —
792-610-1310 Nipple (For Russia) GOST
Testing of accumulator nitro- 792-610-1320 Nipple (For USA) CGA No. 351
gen gas pressure and pro-
cedure for charging P 792-610-1330 Nipple (For USA) ASA B-571-1965
accumulator with nitrogen 2 DIN 477-1963
gas 792-610-1350 Nipple (For Germany) NEN 3268-1966
SIS-SMS 2235/2238
792-610-1360 Nipple (For UK) BS 341 Part 1-1962
Pressure gauge:
Testing and adjusting {25, 60, 400, 600 kg/cm²}
M
steering circuit oil pressure
Pressure gauge:
60 MPa {600 kg/cm²}
1 792-610-1000 Suspension tool 1
2 792-610-1130 • Pump 1
3 792-610-1110 • Hose 1
4 792-610-1120 • Joint 1
5 07020-21732 • Fitting 1
N2 – N6: Pump assembly
6 792-610-1140 • Joint 1
Kit part No.: 792-610-1100
Testing and adjusting
N 7 792-610-1250 • Valve 1 N7 – N13:
suspension cylinder
8 792-610-1260 • Nipple 1 Charging tool assembly
Kit part No.: 792-610-1200
9 792-610-1480 • Stem 1
10 792-610-1640 • Joint 1
11 792-610-1400 • Regulator 1
12 792-610-1430 • Gauge 1
13 792-610-1440 • Gauge 1
Method of tilting cab up T 792-454-1100 Pump assembly 1
Pressure gauge:
Testing and adjusting dump {25, 60, 400, 600 kg/cm²}
O
circuit oil pressure
Pressure gauge:
60 MPa {600 kg/cm²}
4 HM300-2R
Sym-
Q'ty
bol
79A-264-0021 Push-pull scale 1 0 – 300 N {0 – 30 kg}
Operating effort Q
79A-264-0091 Push-pull scale 1 0 – 500 N {0 – 50 kg}
Commercially
Stroke and hydraulic drift R Scale 1
available
Commercially
Work equipment speed S Stopwatch 1
available
Voltage and resistance T 79A-264-0311 Tester 1
799-601-4101
or T-adapter kit 1
799-601-4201
799-601-4130 • T-adapter 1 For Ne sensor
799-601-4330 • Socket 1 For G (Bkup) sensor
799-601-4240 • Socket 1 For Atomospheric sensor
799-601-4250 • Socket 1 For boost pressure sensor
799-601-9420 • T-adapter 1 For common rail pressure sensor
799-601-4150 • T-adapter 1 For oil pressure sensor
For boost (intake) temperature
795-799-5540 • Socket 1
sensor
Engine related controller, For coolant temperature sensor
795-799-5530 • Socket 1
sensor and actuator diagno- – For fuel temperature sensor
sis 799-601-9430 • Socket 1 For supply pump PCV
799-601-9020 • T-adapter 1 For injector, RES for supply pump*
799-601-4260 • T-adapter 1 For controller (4-pole)
For controller (50-pole)
799-601-4211 • T-adapter 1
(799-601-4101 only)
For controller (60-pole)
799-601-4220 • T-adapter 1
(799-601-4101 only)
For 60-pole
799-601-4350 • T-adapter 1
(799-601-4101 only)
799-601-9030 • T-adapter 1 DT3 For network pull up resistor*
DT12 For inter mediate connector
799-601-9120 • T-adapter 1
to injectors*
799-601-9000
or T-adapter kit 1 For HD30 adapter
Wiring harness diagnosis of 799-601-9100
machine 799-601-9320 • T-box 1 For HD • DT
–
(inter mediate connector
799-601-9220 • For HD30-18 1 14P
with operator cab)
799-601-9250 • For HD30-24 adapter 1 9P
799-601-9290 • For HD30-24 adapter 1 31P
799-601-7000
or
Wiring harness diagnosis of
799-601-7100
machine
– or T-adapter kit 1 For X, SWP, M, S adapter
(controller, sensor, valve,
799-601-7400
light diagnosis)
or
799-601-8000
HM300-2R 5
Sym-
Q'ty
bol
799-601-7040 • For X adapter 1 X4P
SW6P
799-601-7050 • For SWP adapter 1
(799-601-8000 is not include)
SW8P
799-601-7060 • For SWP adapter 1
(799-601-8000 is not include)
799-601-7090 • For M adapter 1 M2P
799-601-7110 • For M adapter 1 M3P
799-601-7120 • For M adapter 1 M4P
799-601-7130 • For M adapter 1 M6P
799-601-7140 • For S adapter 1 S8P
799-601-7180 • For AMP040 adapter 1 A8P (799-601-7400 only)
799-601-7310 For SWP adapter 1 SW12P
799-601-7320 For SWP adapter 1 SW16P
799-601-7360 For relay adapter 1 REL-5P
799-601-7370 For relay adapter 1 REL-6P
799-601-7500 T-adapter kit 1 For 070 adapter
799-601-7520 • For 070 adapter 1 07-12P
799-601-7540 • For 070 adapter 1 07-18P
799-601-7550 • For 070 adapter 1 07-20P
Wiring harness diagnosis of 799-601-9000
machine or T-adapter kit 1 For DT adapter
– 799-601-9200
(controller, sensor, valve,
light diagnosis) 799-601-9020 • For DT adapter 1 DT2P *%
799-601-9030 • For DT adapter 1 DT3P
799-601-9040 • For DT adapter 1 DT4P *%
799-601-9050 • For DT adapter 1 DT6P
• For DT adapter
799-601-9060 1 DT8PGR
(Gray)
• For DT adapter
799-601-9070 1 DT8PB
(Black)
• For DT adapter
799-601-9080 1 DT8PG
(Green)
• For DT adapter
799-601-9110 1 DT12PGR
(Gray)
• For DT adapter
799-601-9120 1 DT12PB
(Black)
• For DT adapter
799-601-9130 1 DT12PG
(Green)
• For DT adapter
799-601-9140 1 DT12P
(Brown)
799-601-9300 T-adapter kit 1 For DRC adapter
799-601-9350 • For DRC adapter 1 DRC-40
799-601-9360 • For DRC adapter 1 DRC-24
21mm deep socket
Removal and installation of
Commercially (MITOLOY 4ML 21 or equivalent)
engine coolant temperature – Socket 1
available Applicable engine serial No.:
sensor
560001-564999
6 HM300-2R
Sym-
Q'ty
bol
19mm deep socket
(MITOLOY 4ML 19 or equivalent)
engine coolant temperature – 795T-981-1010 Socket 1
Applicable engine serial No.:
sensor
565000 and up
*: Included in 799-601-9000 and 799-601-9200

*%: Included in 799-601-4101 and 799-601-4201
HM300-2R 7
Sketches of special tools 1

Note) Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
Socket
8 HM300-2R
Measuring engine speed 1

k Set chocks to the tires.
k Before starting measurement, check that
there is no one in the surrounding area.
a Measure the engine speed under the following

conditions.
q Coolant temperature:
q Hydraulic oil temperature: 45 – 55°C
q Torque converter oil temperature:
60 – 80°C
1. Measuring engine speed (low idle and high

idle)
1) Switch to the monitoring function of ser-
vice mode 1 and display the engine
speed. For details, see “Special function
of machine monitor (EMMS)“ in the Test-
ing and adjusting section.
a Monitoring item: ENG SPEED
2) Start the engine, set the measurement

conditions, and measure the engine
speed.
2. Measuring torque converter stall speed

a See “Measuring torque converter stall
speed“ (mentioned later).
HM300-2R 9
Measuring intake air pressure 5. Turn the parking brake switch ON, depress the
brake pedal, then set the gear shift lever to the
(boost pressure) 1 D position.
a Measuring instrument for intake air pressure k If the gear shift lever is operated to any
position other than the D position, the
Symbol Part No. Part name
machine may move off even if the
A 799-201-2202 Boost gauge kit brake is being depressed, so always
measure at the D position.
k When installing and removing the measur-
ing instrument, take care not to touch a hot 6. Depress the accelerator pedal gradually, run
part. the engine at high idle and stall the torque con-
verter, then measure the air supply pressure.
1. Open the engine hood. k There is danger of damage to the inter-
nal parts of the transmission, so never
2. Remove the air boost pressure measurement operate the gear shift lever to any posi-
plug (1). tion other than the D position during
the stall operation.
a After completing the measurement, lower
the engine speed to low idle, then return
the gear shift lever to the N position.
3. Fit nipple and hose [1], then connect to boost

gauge A.
7. After completing the measurement, remove

the measuring instrument and set to the origi-
nal condition.
4. Run the engine at mid-range speed or above

to bleed the oil from inside the hose.
a Insert the connection of the hose and
pressure gauge about half way, repeat the
action to open the self-seal portion at the
hose end, and bleed the oil.
a If Pm kit (A) is available, the air bleeding
coupling (790-261-1130) in it may be
used.
a If there is oil inside the hose, the gauge
will not work, so always bleed the oil.
10 HM300-2R
Measuring exhaust temperature 1 4. When measuring the exhaust temperature at

torque converter stall, implement below proce-
a Measuring instrument for exhaust temperature
dure.
Symbol Part No. Part name a To prevent the torque converter from over-
B 799-101-1502 Digital thermometer
heating, use the full stall (torque converter
stall + hydraulic relief) to stabilize the
k
exhaust temperature, then stall only the
Install and remove the measuring instru-
torque converter and measure the temper-
ment after the exhaust manifold is cooled.
ature.
1) Start the engine and raise the temperature
1. Open the engine hood and remove the turbo-
of the coolant to the operating range.
charger heat insulation cover.
2) Turn the parking brake switch ON, depress
the brake pedal, then set the gear shift
2. Remove exhaust temperature measurement
lever to the D position.
k If the gear shift lever is operated to
plug (1).
any position other than the D posi-
tion, the machine may move off
even if the brake is being
depressed, so always measure at
the D position.
3) Depress the accelerator pedal gradually,
run the engine at high idle and stall the
torque converter. At the same time, oper-
ate the dump lever to the LOWER position
and relieve the oil pressure (full stall).
a Continue until the exhaust tempera-
ture reaches the standard value of
650°C.
k There is danger of damage to the
3. Install sensor [1] and connect it to digital ther- internal parts of the transmission,
mometer B. so never operate the gear shift
a Clamp the wiring harness of the tempera- lever to any position other than the
ture gauge at a suitable place to prevent it D position during the stall opera-
from touching any hot part. tion.
4) When the temperature stabilizes at near
the target temperature, return the dump
lever to NEUTRAL and measure the tem-
perature with only the torque converter
stalled.
a The exhaust temperature will start to
go down from the full stall condition,
so measure the temperature when it
stabilizes.
a If the exhaust temperature does not
go down but rises, make the set tem-
perature at full stall higher.
a After completing the measurement,
lower the engine speed to low idle,
then return the gear shift lever to the
N position.
HM300-2R 11
5) After completing measurement, remove

the measuring equipment and set to the
original condition.
5. When measuring the maximum value for the

exhaust temperature during actual operation,
do as follows.
Carry out actual work and record the maximum
exhaust temperature during operation.
a Set the temperature gauge to the PEAK
mode. The maximum temperature is auto-
matically recorded.
6. Detach the measurement tool after the mea-

surement, and make sure that the machine is
back to normal condition.
12 HM300-2R
Measuring exhaust gas color 1

a Exhaust gas color measurement instruments
1 799-201-9001 Handy smoke checker
C Commercially
2 Smoke meter
available
k When installing and removing the measur-

ing instrument, take care not to touch a hot
part.
a If an air source and an electric power source

are not available in the field, use handy smoke 2) Connect the probe hose, accelerator
checker C1. When recording official data, etc., switch outlet and air hose to the Smoke
use smoke meter C2. Meter C2.
a Restrict the supplied air pressure
1. Measuring with handy smoke checker C1 below 1.5 MPa {15 kg/cm²}.
1) Stock a sheet of filter paper to smoke 3) Connect the power cable to an outlet of
checker C1. power.
2) Insert the exhaust gas intake pipe in the a Before connecting the cable, check
exhaust pipe. that the power switch of the smoke
3) Start the engine and raise the temperature meter is turned OFF.
of the coolant to the operating range. 4) Fit a filtering paper by loosening the suc-
4) Let the exhaust gas stay on the filtering tion pump cap nut.
paper by operating a handle of Handy a Fit the filtering paper securely so that
Smoke Checker C1, when the engine air may not leak.
speed is suddenly accelerated or kept at 5) Turn ON the power switch of smoke meter
high idle. C2.
5) Remove the filtering paper and compare it 6) Start the engine and raise the temperature
with the attached scale to make a judge- of the coolant to the operating range.
ment. 7) As increasing the engine speed rapidly or
running it at high idle, press the accelera-
2. Measuring with smoke meter C2 tor pedal of smoke meter C2 and collect
1) Insert probe (1) of the Smoke Meter C2 the exhaust gas with the filtering paper.
into the exhaust gas pipe outlet, and fas- 8) Put the polluted filtering paper on non-pol-
ten it to the outlet with a clip. luted filtering paper (more than 10 sheets)
in the filtering paper holder, and read the
indicated value.
9) Detach the measurement tool after the
measurement, and make sure that the
machine is back to normal condition.
HM300-2R 13
Adjusting valve clearance 1

a Adjusting instrument for valve clearance
Commercially
D Clearance gauge
available
1. Open the engine hood and remove all cylinder

head covers (1).
5. While No.1 cylinder is at compression top dead

center, adjust the valve clearance of q mark in
the below figure according to the following pro-
cedure.
2. Remove belt protection cover and loosen the

tension of the fan belt and alternator belt.
a To confirm the timing mark.
3. Remove radiator under cover.
4. Rotate the crankshaft forward to bring the

stamped “1.6TOP“ line (a) of the damper to
pointer (2) and set the No. 1 cylinder to the 6. To adjust the valve clearance, insert clearance
compression top dead center. gauge D into clearance between rocker arm
a Rotate the crankshaft with the mounting (5) and crosshead (6), and adjust the valve
bolt of the crankshaft pulley (width across clearance with adjustment screw (3).
flats: 24 mm), and be sure to rotate it only a With the clearance gauge inserted, turn
forward to prevent the bolt from loosening. the adjustment screw so that clearance
a When No. 1 cylinder is at the top dead gauge can move with a light force.
center, its rocker arm can be manually
moved as much as the valve clearance. If
it cannot be moved, that means that No. 1
cylinder is not yet at the top dead center.
In that case, rotate it by one more turn.
14 HM300-2R
7. While holding adjustment screw (3), tighten

locknut (4).
3 Locknut:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a After tightening the locknut, check the
valve clearance again.
a It is also allowed to adjust respective cylin-

ders in the firing order by turning the crank-
shaft 120° at a time.
q Firing order: 1 – 5 – 3 – 6 – 2 – 4
8. After finishing adjustment, return the removed

parts.
3 Cylinder head cover mounting bolt:
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
a Adjust the belt tension referring to “Testing
and adjusting fan belt and alternator belt
tension“.
HM300-2R 15
Measuring compression pressure1

a Compression pressure measurement tools
1 795-502-1590 Compression gauge
E 795-471-1420 Adapter
2
6217-71-6112 Gasket
k When measuring the compression pres-

sure, take care not to burn yourself on the
exhaust manifold, muffler, etc. or get
caught in a rotating part.
a Measure the compression pressure after the

5. Install adaptor E2 to mounting hole of injector
engine is warmed up.
and connect compression gauge E1.
(Engine oil temperature: 40 – 60°C)
a Fit the gasket to the adapter end without
fail.
1. Open the engine hood. a Fix the adapter with the injector holder.
3 Holder mounting bolt:
2. Remove cylinder head cover (1). 58.8 – 73.5 Nm {6.0 ± 7.5 kgm}
a Apply a little amount of engine oil to the
connecting parts of the adapter and gauge
so that air will not leak easily.
6. Install rocker arm assembly (2) and adjust

valve clearance.
3 Rocker arm assembly mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a For the adjustment, refer to the section,
“Adjustment of valve clearance“.
3. Set cylinder to be tested at compression top

dead center and remove rocker arm assembly
(2).
a For the adjustment, refer to the section,
“Adjustment of valve clearance“.
4. Disconnect fuel high-pressure tube (3) and

injector wiring harness (4) and remove injector
(5).
a Before disconnecting the fuel high-pres-
sure tube, loosen all center clamps. 7. Referencing “Special functions of machine
a Disconnect the terminal of the injector wir- monitor“, set the no injection cranking and the
ing harness on the injector side and the engine speed measurement mode.
bracket on the rocker housing side and k Be sure to set no injection cranking
pull them outside the rocker arm housing mode. Otherwise engine may start and
(Loosen the 2 terminal nuts alternately). this may create a dangerous condition.
a After removing holder from injector, lead a
wire under the fuel pipe which comes out
sideways from the injector and pull up the
wire to remove injector (do not ply the
upper part of the injector to remove it).
16 HM300-2R
8. Rotate the engine with the starting motor and

measure the compression pressure.
a Read the pressure gauge pointer when it
is stabilized.
9. After finishing testing, remove the testing tools

and return the removed parts.
a Install the injector, injector wiring harness,
and fuel high-pressure tube according to
the following procedure.
1) Install O-ring and gasket to injector (11).
2) Fit holder (12) to injector (11) to tempo-
rarily assemble them as a unit to the cylin-
der head.
3) Tighten mounting bolt (13) with spherical
washer (14) to install injector to cylinder
head.
2 Spherical part of washer:
Engine oil (SAE30DH)
3 Mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
4) Install wiring harness (15) to the rocker
arm housing and fix it with mounting bolt
(16).
5) Insert wiring harness (15) into holder (17).
6) Alternately tighten 2 nuts at wiring harness
(15) end to injector (11).
3 Nut:
2.0 – 2.4 Nm {0.2 – 0.24 kgm}
7) Tighten tube (18) to injector (11).
3 Sleeve nut:
39.2 – 49 Nm {4 – 5 kgm}
8) Tighten the clamping bolt of the fuel pip-
ing.
3 Clamping bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
3 Rocker arm assembly mounting

bolts:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a Adjust valve clearance referring to
“Adjusting valve clearance“.
3 Cylinder head cover mounting bolt:
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
HM300-2R 17
Measuring blow-by pressure 1 6. Detach the measurement tool after the mea-
1. Open the engine hood. back to normal condition.
2. Install nozzle and hose [1] to blow-by hose (1)

under the body and connect the hose to blow-
by checker F.
3. Start the engine and raise the temperature of

the coolant to the operating range.
4. Turn the parking brake switch ON, depress the

D position.
k If the gear shift lever is operated to any
machine may move off even if the
brake is being depressed, so always
measure at the D position.
5. Depress the accelerator pedal gradually, run

the engine at high idle and stall the torque con-
verter, then measure the blow-by pressure.
k There is danger of damage to the inter-
operate the gear shift lever to any posi-
tion other than the D position during
a After completing the measurement, lower
the engine speed to low idle, then return
the gear shift lever to the N position.
18 HM300-2R
Measuring engine oil pressure 1 3. Install nipple [1] of hydraulic tester G1 and con-
nect it to hydraulic tester G2.
a Engine oil pressure measurement tools
799-101-5002 Hydraulic tester
1
G 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
1. Open the engine hood and remove clamp

bracket (2).
4. Start the engine and raise the temperature of

the engine to the operating range.
5. Measure the engine oil pressure at low idle

and also at high idle.
2. Remove the oil pressure measurement plug

(1) on the cylinder block.
6. Detach the measurement tool after the mea-

back to normal condition.
HM300-2R 19
Handling of fuel system devices 1 Releasing residual pressure from

a Precautions for checking and maintaining fuel fuel system 1
system a Pressure is generated in the low-pressure cir-
The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause a Between Feed pump – Fuel filter – Fuel
trouble. supply pump
When checking and maintaining the fuel sys- High-pressure circuit:
tem, take care more than the past. If dust, etc. Between Fuel supply pump – Common rail
sticks to any part, wash that part thoroughly – Fuel injector
with clean fuel. a The pressure in both low-pressure circuit and
a Precautions for replacing fuel filter cartridge high-pressure circuit lowers to a safety level
Be sure to use the Komatsu genuine fuel filter automatically 30 seconds after the engine is
cartridge. stopped.
Since the common rail fuel injection system a Before checking the fuel system and installing
(CRI) consists of more precise parts than the and removing its parts, the residual pressure in
conventional fuel injection pump and nozzle, it the fuel system must be released completely.
employs a high-efficiency special filter to pre- Accordingly, observe the following.
vent foreign matter from entering it. k When inspecting the fuel line or removing
If a filter other than the genuine one is used, or installing a equipment of fuel system,
the fuel system may have a trouble. Accord- wait for at least 30 seconds after the engine
ingly, never use such a filter. is stopped to release the remaining pres-
sure in the fuel system before starting oper-
ation. (There is still pressure remaining in
the circuit, so do not start operations imme-
diately after the engine is stopped.)
20 HM300-2R
Testing fuel pressure 1 3. Start the engine and measure the fuel pressure
with the engine running at high idle.
a Testing tools for fuel pressure a If the fuel pressure is in the following
Symbol Part No. Part name range, it is normal.
1 799-101-5002 Hydraulic tester Engine speed Fuel pressure
2 790-261-1204 Digital hydraulic tester 0.15 – 0.3 MPa
H High idle
(Being {1.5 – 3 kg/cm²}
3 Adapter
established)
a Measure the fuel pressure only for the low-

pressure circuit between the feed pump-fuel fil-
ter-fuel supply pump.
k The high-pressure circuit between fuel sup-
ply pump-common rail-fuel injector is
under extremely high pressure, so it cannot
be measured.
1. Remove fuel pressure inspection plug (1)

located at the fuel filter head.
4. After finishing testing, remove the testing tools

and return the removed parts.
2. Install adapter H3 and nipple [1] of hydraulic

tester H1, and connect to hydraulic tester H2.
HM300-2R 21
Testing fuel return and leak amount 1
a Testing instruments of fuel return and leak 1. Preparatory work

amount 1) Remove tube (3) between common rail (1)
Symbol Part No. Part name and return block (2).
1 6151-51-8490 Spacer
2 6206-71-1770 Joint
Commercially
3 Hose
available
J Commercially
4 Hose
available
Commercially
5 Measuring cylinder
available
Commercially
6 Stopwatch
available
a Since the fuel flows out during the check, pre-

pare approx. 20 l oil pan (receiver).
22 HM300-2R
2) Insert spacer J1 to return block (2) side

and retighten it with the currently removed
joint bolt.
a Be sure to provide a gasket to both
ends of the spacer.
3) Insert joint J2 to common rail (1) side and
tighten again the removed joint bolt.
a Be sure to fit the gaskets to both ends
of the joint.
4) Connect the inspection hose J3 to the end
of joint J2.
a Bind connecting portion with wire so
that the inspection hose should not
come off.
5) When the testing is completed, stop the
a Now the preparation for testing pres-
engine.
sure limiter leak amount is completed.
3. Testing injector return amount
a During testing injector return amount,
keep a hose end connected to pressure
limiter and insert the other end to oil pan
(receiver).
Disconnect both ends of injector return
tube.
1) Disconnect fuel return hose (4) from return
block (2).
a Install oil stopper plug to the fuel hose
(4) side and fix hose.
q Plug: 07376-70315
2. Testing pressure limiter leakage amount

1) Adjust the route of inspection hose J3 to
remove its sag and insert the hose end
into the oil pan (receiver).
2) Referencing “Measuring engine speed“,
set up the condition necessary for check-
ing the engine speed.
3) Run the engine and keep at 1,600 rpm
under no load.
4) When the engine speed is stabilized,
check the leakage amount per minute with
measuring cylinder J5.
a The leakage also can be judged by
testing for 20 seconds and triples its
leakage amount.
a If the leakage from the pressure lim-
iter is in the following range, it is nor-
mal.
Engine speed Leakage
(rpm) (cc/min)
1,600 Max. 10
HM300-2R 23
2) Connect inspection hose J4 to return

block (2) side.
a Bind connecting portion with wire so
that the inspection hose should not
come off.
3) Adjust the route of inspection hose J4 to
remove its sag and insert the hose end
into the oil pan (receiver).
7) When the testing is completed, stop the

engine.
4. Operations after completion of testing

If all the tests are completed, remove the
instruments and set to the original condition.
4) Referencing “Measuring engine speed“,

set up the condition necessary for check-
ing the engine speed.
5) Start the engine and run the engine at the
rated output.
6) When the engine speed is stabilized,
check the return amount per minute with
measuring cylinder J5.
a It also can be judged by testing for 20
seconds and triples its return amount.
a If the supply pump is not supplying
fuel, the engine speed may not rise.
In this case, record the engine speed,
too, during the test.
a If the return rate (spill) from the injec-
tor is in the following range, it is nor-
mal.
Rated output speed Return (Spill) limit
(rpm) (cc/min)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
24 HM300-2R
Bleeding air from fuel circuit 1 a If the switch is turned "OFF" position while
the lamp is blinking, the lamp goes off and
a Bleed air from the fuel circuit in the following the electric priming pump stops.
k
cases according to this procedure. While the electric priming pump is in
q When the fuel filter is replaced operation, pressure is applied to the
q When fuel is used up fuel circuit. Do not loosen the air
q When the engine is started for the first bleeding plug at this time, since the
time after the fuel piping or supply pump is fuel may spout out.
replaced
a If the fuel filter was replaced, do not fill the
main filter and prefilter with the fuel.
1. Turn the starting switch to the "OFF" position.
2. Check that the fuel valve on the fuel tank side

is open.
3. Open the engine hood and direct the end of air

bleeder piping lever (1) toward the rear of the
engine to open the circuit valve.
5. After the specified time (approx. 7 minutes),

lamp (4) goes off and the electric priming pump
stops automatically.
a If only the fuel filter was replaced, the air
bleeding work is completed now.
6. If the fuel was used up or the fuel piping or

supply pump was replaced and there is not fuel
in the fuel circuit, turn switch (3) "ON" again
after the electric priming pump stops automati-
cally.
4. Turn "ON" switch (3) of electric priming pump 7. When lamp (4) goes off, the air bleeding work
(2) installed above the oil filter. is completed.
a The electric priming pump operates and
lamp (4) blinks. 8. Direct the end of air bleeder piping lever (1)
toward the left of the engine to close the circuit
valve.
a The electric priming pump has a timer in it

to start and stop itself automatically (See
the following figure).
a The electric priming pump stops while the
lamp is blinking. This phenomenon is not
abnormal, however.
HM300-2R 25
9. Start the engine with the starting motor.

a Do not operate the starting motor continu-
ously for more than 20 seconds.
q Run the engine at low idle for about 5 min-
utes to bleed all air from the fuel circuit.
q After stopping the engine, check that the
air bleeding valve is closed.
10. If the engine does not start, start it according to

k When starting the engine, check that
there is no person around the engine.
a Perform the following procedure with the
air bleeding valve closed. (Do not open
the air bleeding valve after step 7.)
a If the engine does not start, wait for at
least 2 minutes before trying to start
again.
1) Turn the electric priming pump switch
"ON".
2) While the electric priming pump is operat-
ing, start the engine.
q If the engine does not start, repeat
the above operation.
a Do not operate the starting motor
continuously for more than 20 sec-
onds.
a If the engine does not start, wait for at
least 2 minutes before trying to start
again.
3) After the engine starts, keep it running for
at least 5 minutes to bleed all air from the
fuel circuit.
4) Stop the engine and check that the air
bleeding valve is closed.
5) From now on, start the engine as usual.
26 HM300-2R
Testing fuel circuit for leakage 1 9. Inspect the fuel piping and devices for fuel
leakage.
k Very high pressure is generated in the high- a Check mainly around the high-pressure
pressure circuit of the fuel system. If fuel circuit parts coated with the color checker
leaks while the engine is running, it is dan- for fuel leakage.
gerous since it can catch fire. a If any fuel leakage is detected, repair it
After testing the fuel system or removing and inspect again from step 1.
and installing its components, check for a If no fuel leakage is detected, check is
fuel leakage according to the following pro- completed.
cedure.
a Clean and degrease the engine and the parts
around it in advance so that you can test it eas-
ily for fuel leakage.
1. Spray color checker (developer) over the fuel

supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
2. Run the engine at a speed less than 1,000 rpm

and stop it after its rotation is stabilized.
3. Inspect the fuel piping and devices for fuel

leakage.
a Check mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If any fuel leakage is detected, repair it
and inspect again from step 1.
4. Run the engine at low idle.

leakage.
for fuel leakage.
6. Run the engine at high idle.

leakage.
for fuel leakage.
8. Run the engine at high idle to apply load to the

engine.
a When checking while the components to
be checked are mounted on the machine,
stall the torque converter or relieve the
hydraulic pump.
HM300-2R 27
Testing and adjusting alternator Testing and adjusting air

belt tension 1 conditioner compressor belt
1. Testing tension 1
Measure the deflection when the belt is 1. Testing
pushed with a finger at the middle point Measure the deflection when the belt is
(marked by the arrow) between the alternator pushed with a finger at the middle point
pulley and fan pulley. between compressor pulley and crank pulley.
a Pushing force: a Pushing force:
Approx. 58.8 N {Approx. 6 kg} Approx. 58.8 N {Approx. 6 kg}
a Deflection: Approx. 10 mm a Deflection: 10mm
2. Adjusting
a If the deflection is out of the standard 2. Adjusting
range, adjust it according to the following a If the deflection is out of the standard
procedure. range, adjust it according to the following
1) Loosen mounting bolt and nut (5) of alter- procedure.
nator (1) and mounting bolt (6) of adjust- 1) Loosen nut (2) of compressor assembly
ing rod (2). (1) mounting bolt and loosen nut (3) of
2) Loosen locknut (3) and move alternator adjusting rod mounting bolt.
(1) by turning adjustment nut (4) to adjust 2) Loosen locknut (4) and move compressor
the belt tension. assembly (1) by turning adjustment nut (5)
3) Tighten locknut (3). to adjust the belt tension.
4) Tighten mounting bolt and nut (5) of alter- 3) Tighten locknut (4).
nator (1) and mounting bolt (6) of adjust- 4) Tighten nut (2) of compressor assembly
ing rod (2). (1) mounting bolt and tighten nut (3) of
a After completing adjustment, check adjusting rod mounting bolt.
the tension of belt again. a After completing adjustment, check
the tension of belt again.
28 HM300-2R
HM300-2R 29

© 2009 KOMATSU
All Rights Reserved
30 HM300-2R
SEN03420-01
HM300-2R


Measuring torque converter stall speed.......................................................................................................... 3
Measuring power train oil pressure................................................................................................................. 4
Adjusting transmission speed sensor ........................................................................................................... 12
Testing and adjusting brake oil pressure....................................................................................................... 14
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas ..........18
Testing brake performance ........................................................................................................................... 21
Bleeding air from brake circuit ...................................................................................................................... 22
Measuring wear of wheel brake disc............................................................................................................. 23
Measuring wear of parking brake pad........................................................................................................... 24
Method for emergency release of parking brake .......................................................................................... 26
Testing and adjusting steering circuit oil pressure ........................................................................................ 27
Testing and adjusting suspension cylinder.................................................................................................... 29
Method of tilting cab up................................................................................................................................. 33
Testing and adjusting dump circuit oil pressure ............................................................................................ 35
Adjusting body positioner sensor .................................................................................................................. 38
Procedure for adjusting length of spring in body heating spherical joint....................................................... 39
HM300-2R 1
Handling engine controller high voltage circuit.............................................................................................. 39

Adjusting transmission controller .................................................................................................................. 40
Method for emergency escape at electrical system failure ........................................................................... 41
2 HM300-2R
Measuring torque converter stall 5. When the torque converter oil temperature
goes above 90°C, run the engine immediately
speed 1 at low idle and return the gear shift lever to the
k Stop the machine on level ground, turn the N position.
parking brake switch ON, and set chocks to
k Never operate the gear shift lever with
the tires.
the accelerator pedal depressed. Oth-
erwise it may create a large shock and
1. Switch the machine monitor display to the
may also cause to shorten the service
monitoring function of service mode 1 and dis-
life of the machine.
play the following 2 items at the same time with
the monitoring function.
a Monitoring items 6. Run the engine at a medium speed, and when
[1] Code No. 01001 : Engine speed the torque converter oil temperature goes
[2] Code No. 30100 : Torque converter oil down to approx. 80°C, run at low idle.
temperature a Keep the gear shift lever at the N position.
a Refer to “Special functions of machine
monitor (EMMS)“ for the operating method. 7. Repeat Steps 3 – 6 and equalize the oil tem-
perature in the torque converter and transmis-
sion.
8. At the same time as repeating Steps 3 and 4,

measure the stall speed when the torque con-
verter oil temperature is 80°C.
a Measure the stall speed 2 – 3 times.
a The stall speed may vary according to the fol-

lowing conditions, so always measure the stall
speed at the time of delivery.
1) Variations according to the engine serial
number
2) Variations due to atmospheric pressure
2. Start the engine and raise the temperature of and temperature
the torque converter oil and hydraulic oil. 3) Variations due to the torque consumed by
a Torque converter oil temperature: accessories
60 – 80°C 4) Variations due to characteristics of the
Hydraulic oil temperature: 45 – 55°C torque converter
5) Variations due to the method of measuring
3. Turn the parking brake switch ON, depress the the stall
D position.
a If the gear shift lever is operated to any
machine may move off even if the brake is
being depressed, so always measure at
the D position.
4. Depress the accelerator pedal gradually, run

the engine at high idle and stall the torque con-
verter to raise the torque converter oil temper-
ature.
k There is danger of damage to the inter-
operate the gear shift lever to any posi-
tion other than the D position during
HM300-2R 3
Measuring power train oil pressure 1
a Measuring tools for power train oil pressure

Sym-
Part number Part name
bol
790-261-1204 Digital hydraulic tester
799-401-2320 Hydraulic gauge
799-101-5220 Nipple
K 07002-11023 O-ring
799-101-5260 Nipple
07002-11223 O-ring
799-101-5230 Nipple
07002-11423 O-ring
4 HM300-2R
a List of oil pressure measuring points and Power train overall

gauges to be used. 1. Measuring power train main relief pressure
Gauge 1) Tilt the cab up.
No. Oil pressure reading (MPa 2) Remove oil pressure measurement plug
{kg/cm²}) (1), then install nipple and hose [1].
1 Power train main relief pressure 6.0 {60} a Pull the hose out to the rear of the
transmission.
2 Torque converter inlet pressure 6.0 {60}
3 Torque converter outlet pressure 1.0 {10}
Torque converter lockup clutch
4 6.0 {60}
pressure
5 Transmission Lo clutch pressure 6.0 {60}
6 Transmission Hi clutch pressure 6.0 {60}
7 Transmission 1st clutch pressure 6.0 {60}
8 Transmission 2nd clutch pressure 6.0 {60}
9 Transmission 3rd clutch pressure 6.0 {60}
10 Transmission R clutch pressure 6.0 {60}
Inter-axle differential lock clutch
11 6.0 {60}
pressure
a The transmission lubrication pressure is repre-

sented by the torque converter outlet port pres-
sure, so there is no need to measure it.
a (13): Remote measuring points
3) Tilt the cab down and return it to its origi-

nal position.
4) Connect oil pressure gauge K.
of the torque converter oil to the operating
k Stop the machine on level ground, turn the range.
parking brake switch ON, and set chocks to 6) While keeping the gear shift lever at the N
the tires. position, measure the oil pressure at low
k Install and remove the measuring instru- idle and high idle.
ments after the oil temperature lowers fully.
k When measuring the oil pressure while
traveling, make sure that there is a wide
travel area and pay attention to keep the
safety in the surrounding area.
a When tilting the cab up or down, see “Method
of tilting cab up“ for details.
a When measuring ECMV-related hydraulic oil
pressure, install and remove the nipple, hoses
and gauge for the measurement from the rear
underside of the cab.
HM300-2R 5
7) After finishing measurement, remove the Torque converter related

measuring instrument and reinstall the 2. Measuring torque converter inlet pressure
removed parts. 1) Attach hose [1] for oil pressure measure-
ment to hydraulic oil pressure measuring
coupler (2).

range.
4) While keeping the gear shift lever at the N
position, measure the oil pressure at high
idle.
5) After finishing measurement, remove the

measuring instrument and reinstall the
removed parts.
6 HM300-2R
3. Measuring torque converter outlet pressure 7) After finishing measurement, remove the
1) Tilt the cab up. measuring instrument and reinstall the
2) Remove oil pressure measurement plug removed parts.
(3), then install nipple [2] and hose [1].
a Pull the hose out to the rear of the 4. Measuring torque converter lockup clutch
transmission. pressure
1) Remove oil pressure measuring plug (4),
then install nipple and hose for measure-
ment.

range.
4) Turn the parking brake OFF, depress the
brake pedal, then set the gear shift lever
to position 1.
5) Release the brake, travel at high idle, and
measure the oil pressure when the lockup
pilot lamp lights up.
k In F1, the maximum travel speed
3) Tilt the cab down and return it to its origi-
nal position. reaches to approx. 6.2 km/h, so
travel the machine with enough
care of the safety in the surround-
ing area.
range.
6) While keeping the gear shift lever at the N
position, measure the oil pressure at high
idle.

removed parts.
HM300-2R 7
Transmission related 5. Measuring transmission Lo clutch pressure

a Table of gear shift lever positions, speed 1) Remove oil pressure measuring plug (5),
ranges, and clutches actuated then install nipple and hose for measure-
ment.
Gear shift lever Clutch
Travel speed
R3 R2 R1 N D 5 4 3 2 1 Lo Hi 1st 2nd 3rd R
Q Q Q Q Q F1 q q
Q Q Q Q Q F2 q w
Q Q Q Q F3 w q
Q Q Q F4 w w
Q Q F5 w q
Q F6 w w
Q N
Q R1 w q
Q R2 w w
Q R3 w w
range.
a The Q mark indicates the travel speed ranges 4) Turn the parking brake OFF, depress the
that are actuated for each position of the gear brake pedal, then set the gear shift lever
shift lever. to position 1.
a The w mark and q mark indicate the clutches
5) Release the brake and measure the oil
that are actuated for each travel speed.
pressure when traveling at high idle.
a The q mark indicates the travel gear speed
when measuring the oil pressure for each k In F1, the maximum travel speed
clutch. reaches to approx. 6.2 km/h, so
ing area.

removed parts.
8 HM300-2R
6. Measuring transmission Hi clutch pressure 7. Measuring transmission 1st clutch pres-

1) Remove oil pressure measuring plug (6), sure
then install nipple and hose for measure- 1) Remove oil pressure measuring plug (7),
ment. then install nipple and hose for measure-
ment.

3) Start the engine and raise the temperature 2) Connect oil pressure gauge K.
of the torque converter oil to the operating 3) Start the engine and raise the temperature
range. of the torque converter oil to the operating
4) Turn the parking brake OFF, depress the range.
brake pedal, then set the gear shift lever 4) Turn the parking brake OFF, depress the
to position 2. brake pedal, then set the gear shift lever
5) Release the brake, travel at high idle, and to position 1.
measure the oil pressure when the shift 5) Release the brake and measure the oil
indicator displays [2]. pressure when traveling at high idle.
k In F2, the maximum travel speed k In F1, the maximum travel speed
reaches to approx. 9.8 km/h, so reaches to approx. 6.2 km/h, so
travel the machine with enough travel the machine with enough
care of the safety in the surround- care of the safety in the surround-
ing area. ing area.
6) After finishing measurement, remove the 6) After finishing measurement, remove the
measuring instrument and reinstall the measuring instrument and reinstall the
removed parts. removed parts.
HM300-2R 9
8. Measuring transmission 2nd clutch pres- 9. Measuring transmission 3rd clutch pres-
sure sure
1) Remove oil pressure measuring plug (8), 1) Remove oil pressure measuring plug (10),
then install nipple and hose for measure- then install nipple and hose for measure-
ment. ment.
2) Connect oil pressure gauge K. 2) Connect oil pressure gauge K.

3) Start the engine and raise the temperature 3) Start the engine and raise the temperature
of the torque converter oil to the operating of the torque converter oil to the operating
range. range.
4) Turn the parking brake OFF, depress the 4) Turn the parking brake OFF, depress the
brake pedal, then set the gear shift lever brake pedal, then set the gear shift lever
to position 3. to position 5.
5) Release the brake, travel at high idle, and 5) Release the brake, travel at high idle, and
measure the oil pressure when the shift measure the oil pressure when the shift
indicator displays [3]. indicator displays [5].
k In F3, the maximum travel speed k In F5, the maximum travel speed
reaches to approx. 15.2 km/h, so reaches to approx. 37.5 km/h, so
travel the machine with enough travel the machine with enough
care of the safety in the surround- care of the safety in the surround-
ing area. ing area.
6) After finishing measurement, remove the 6) After finishing measurement, remove the
measuring instrument and reinstall the measuring instrument and reinstall the
removed parts. removed parts.
10 HM300-2R
10. Measuring transmission reverse clutch 11. Measuring inter-axle differential lock clutch
pressure pressure
1) Remove oil pressure measuring plug (7), 1) Remove oil pressure measuring plug (11),
then install nipple and hose for measure- then install nipple and hose for measure-
ment. ment.
2) Connect oil pressure gauge K. 2) Connect oil pressure gauge K.

3) Start the engine and raise the temperature 3) Start the engine and raise the temperature
of the torque converter oil to the operating of the torque converter oil to the operating
range. range.
4) Turn the parking brake OFF, depress the 4) While keeping the gear shift lever at the N
brake pedal, then set the gear shift lever position, move the inter-axle differential
to position R1. lock switch to the “MANUAL“ position.
5) Release the brake and measure the oil 5) Measure the oil pressure while the engine
pressure when traveling at high idle. is running at high idle.
k In R1, the maximum travel speed
reaches to approx. 6.2 km/h, so
ing area.

removed parts.

removed parts.
HM300-2R 11
Adjusting transmission speed sensor 1
a There are 4 speed sensors installed to the 4) Tighten nut (3) with sensor (1) fixed.
transmission. Adjust each sensor according to 3 Nut: 49.0 – 68.6 Nm {5 – 7 kgm}
CN3 : Input shaft speed sensor
CN4 : Intermediate shaft speed sensor
CN5 : Output shaft R speed sensor
B09 : Output shaft F speed sensor
a For the input shaft speed sensor, tilt up the cab
before carrying out adjustment.
a For the intermediate shaft speed sensor and
output shaft F speed sensor, remove the trans-
mission and front differential assembly before
carrying out adjustment.
1. Adjusting input shaft speed sensor (CN3)

1) Remove input shaft speed sensor (1) and
check that its tip is free from steel chips
and flaws, and then reinstall it temporarily 2. Adjusting intermediate shaft speed sensor
to the original position. (CN4)
2 Threaded portion: 1) Remove intermediate shaft speed sensor
Gasket sealant (LG-5) (4) and check that its tip is free from steel
2) Screw in sensor (1) until its tip touches the chips and flaws, and then reinstall it tem-
addendum of input shaft gear (2). porarily to the original position.
2 Threaded portion:
3) Return sensor (1) by 1/2 – 1 turn from that
Gasket sealant (LG-5)
position.
a At this time, clearance (a) between 2) Screw in sensor (4) until its tip touches the
the sensor tip and addendum is 0.75 addendum of intermediate shaft gear (5).
– 1.5 mm.
12 HM300-2R
3) Return sensor (4) by 1/2 – 1 turn from that 4. Adjusting output shaft F speed sensor
position. (B09)
a At this time, clearance (b) between 1) Remove output shaft F speed sensor (10)
the sensor tip and addendum is 0.75 and check that its tip is free from steel
– 1.5 mm. chips and flaws, and then reinstall it tem-
4) Tighten nut (6) with sensor (4) fixed. porarily to the original position.
3 Nut: 49.0 – 68.6 Nm {5 – 7 kgm} 2 Threaded portion:
2) Screw in sensor (10) until its tip touches
the addendum of front output shaft gear
(11).
3) Return sensor (10) by 1/2 – 1 turn from
that position.
a At this time, clearance (d) between
the sensor tip and addendum is 0.75
– 1.5 mm.
4) Tighten nut (12) with sensor (10) fixed.
3 Nut: 49.0 – 68.6 Nm {5 – 7 kgm}
3. Adjusting output shaft R speed sensor

(CN5)
1) Remove output shaft R speed sensor (7)
and check that its tip is free from steel
chips and flaws, and then reinstall it tem-
porarily to the original position.
2 Threaded portion:
2) Screw in sensor (7) until its tip touches the
addendum of rear output shaft gear (8).
3) Return sensor (7) by 1/2 – 1 turn from that
position. 5. Confirming sensor input signal
a At this time, clearance (c) between After completing adjustment, confirm that each
the sensor tip and addendum is 0.75 transmission shaft speed is displayed normally
– 1.5 mm. with the monitoring function of the machine
4) Tighten nut (9) with sensor (7) fixed. monitor.
3 Nut: 49.0 – 68.6 Nm {5 – 7 kgm} a Refer to “Special functions of machine
monitor (EMMS)“ for the monitoring func-
tion details.
HM300-2R 13
Testing and adjusting brake oil 2) Start the engine.

pressure 1 3) Measure the cut-in pressure at high idle.
1] Pump the brake pedal repeatedly to
a Equipment for testing and adjusting brake oil gradually lower the pressure inside
pressure the accumulator.
Symbol Part No. Part name 2] Measure the pressure at the point
L 793-520-1805 Brake test kit
where the indicator of oil pressure
gauge L stops going down and starts
k
to go up again.
Stop the machine on level ground, turn the
4) Measure the cut-out pressure at high idle.
Measure the oil pressure when the pres-
the tires.
sure goes up after the cut-in and the indi-
cator of pressure gauge L stops.
Inspection
1. Measuring charge valve cut-in pressure
and cut-out pressure
a Measure the charge valve oil pressure at
remote pressure pickup port (1).
5) Remove the measurement tool after the

2. Measuring wheel brake actuating pressure

1) Install hose [1] and connect oil pressure and drop in pressure
gauge L. a Implement the same procedure for the
a Use a 40 MPa {400 kg/cm²} oil pres- front brake circuit and center brake circuit.
sure gauge.
1) Remove air bleeder (2) of the slack
adjuster.
14 HM300-2R
2) Install brake test kit L and bleed the air 3. Measuring actuating pressure of parking
from the brake circuit. brake
a For details, see “Bleeding air from 1) Disconnect hose (3) of the parking brake
brake circuit“ section. cylinder.
k Check that the parking brake
switch is ON before carrying out
the operation.
3) Measure the actuating pressure of the foot

brake under the following conditions.
1] Run the engine for several minutes at
low idle to charge the accumulator,
2) Install adapter [1], nipple and hose [2],
then stop the engine.
and connect oil pressure gauge L.
2] Depress the brake pedal fully and a Use a 6.0 MPa {60 kg/cm²} oil pres-
measure the oil pressure. sure gauge.
4) Measure the actuating pressure of the
retarder brake under the following condi-
tions.
2] Turn the starting switch ON.
3] Pull the retarder lever fully and mea-
sure the oil pressure.
5) Measure the drop in pressure of the foot
brake under the following conditions.
a Check that the actuating pressure of
both the foot brake and the retarder
are normal before starting to mea-
sure.
2] Depress the brake pedal fully and
measure the oil pressure.
a Keep the brake pedal depressed.
3] Measure the oil pressure after 5 min-
utes and calculate the drop in pres-
sure.
a Bleed the air from the brake circuit
referring to “Bleeding air from brake
circuit“ section.
HM300-2R 15
3) Start the engine and operate the parking Adjustment

brake switch several times at high idle to Adjusting charge valve cut-in pressure and cut-
bleed air from the circuit. out pressure
4) Stop the engine and turn the starting a If the charge valve cut-in pressure or cut-out
switch ON. pressure are not proper, adjust the R1 relief
5) Measure the oil pressure when parking valve of charge valve (5) according to the fol-
brake switch is turned OFF. lowing procedures.
a Both cut-in pressure and cut-out pressure
change by adjusting the R1 relief valve.
1. Remove the mudguard sheet in the left front

tire housing.

k Check that the parking brake
switch is ON before carrying out
the operation.
16 HM300-2R
2. Loosen locknut (6).
3. Turn adjustment screw (7) to adjust the oil

pressure.
a Adjustment screw:
q When turned clockwise, the oil pres-
sure is heightened.
q When turned counterclockwise, the
oil pressure is lowered.
4. While fixing adjustment screw (7), tighten lock-

nut (8).
3 Locknut: 10.2 Nm {1.0 kgm}
a After completing the adjustment, check
the oil pressure again following to the pro-
cedure for measurement.
HM300-2R 17
Testing of accumulator nitrogen

gas pressure and procedure for
charging accumulator with
nitrogen gas 1
a Testing instrument
Symbol Part No. Part name Remarks
1 792-610-1700 Gas charge tool —
792-610-1310 Nipple GOST

(For Russia)
Nipple
792-610-1320 CGA No. 351
(For USA)
P Nipple
2 792-610-1330 ASA B-571-1965
(For USA) 7. Connect gas charge tool P1 to valve (4) of
DIN 477-1963 accumulator (1) according to the following pro-
792-610-1350 Nipple NEN 3268-1966 cedure.
(For Germany)
SIS-SMS 2235/2238
1) Turn handle (a) of gas charge tool P1 to
792-610-1360 Nipple (For UK) BS 341 Part 1-1962
the left until it stops.
Nitrogen gas cylinder (c) must be
k
q
Put on proper protection gear (goggles, connected even when you measure
leather gloves and protective clothes) so only the gas pressure.
that the leaking nitrogen gas will not touch q Close the valve of nitrogen gas cylin-
your skin or clothes and work on the wind- der (c) and handle (b).
ward side as long as possible. For connection of nitrogen gas cylin-
k
q
When handling nitrogen gas in a room or der (c) and gas charge tool P1, see
another place which is not ventilated well, "Procedure for charging accumulator
ventilate the work place forcibly and observe with nitrogen gas".
the Oxygen Deficiency Prevention Rules of
2) Connect gas charge tool P1 to valve (4) of
the Labor Safety and Sanitation Law.
k
accumulator (1).
Since the accumulator is charged with
high-pressure nitrogen gas, wrong han-
dling of it can cause an explosion and
injury or death. When handling the accu-
mulator, observe the following strictly.
q Do not bring fire near the accumulator or
put the accumulator in fire.
q Do not drill, weld or gas-cut the accumulator.
q Do not give impacts to the accumulator by
hitting or rolling.
q When discarding accumulator, discharge it
of the nitrogen gas.
Testing of accumulator nitrogen gas pressure

a The nitrogen gas pressure in the accumulator
disconnected from the machine can be mea-
sured according to the following procedure, too.
5. Stop the engine and press the brake pedal
repeatedly to lower the oil pressure in the
brake circuit to zero.
a Generally, if the brake pedal is pressed 30
times, the reaction force to the brake
pedal is lost and the oil pressure is low-
ered to zero.
6. Remove valve guard (2) and cap (3) from
accumulator (1).
18 HM300-2R
8. Turn handle (a) of gas charge tool P1 to the left 3. Connect gas charge tool P1 and nitrogen gas
and read the gauge. cylinder (c) to valve (4) of accumulator (1)
a Since the indicated value varies with the according to the following procedure.
ambient temperature, correct it by the fol- 1) Turn handle (a) of gas charge tool P1 to
lowing formula. (The unit of each value in the left until it stops.
the formula is °C.) 2) Turn handle (b) to the left to open.
Indicated gas pressure = 3) Connect gas charge tool P1 to valve (4) of
Standard gas pressure x ((273 + t)/ accumulator (1).
(273 + 20))
4) Connect gas charge tool P1 and nitrogen
Standard gas pressure =
gas cylinder (c).
Indicated gas pressure/((273 + t)/
q There are 2 types of threads of nitro-
(273 + 20))
gen gas cylinders, W22-14 thread
t = Gas temperature at time of charge (°C)
(mail screw, type A) and W23-14
Reference: t may be assumed to be ambi-
thread (female screw, type B). When
ent temperature.
using a gas cylinder of W23-14 thread
(female screw, type B), connect the
9. If the gas pressure is too high or too low, adjust hose by using the adapter. (The
it referring to "Procedure for charging accumu- adapter is attached to gas charge tool
lator with nitrogen gas". P1.) [For Japan]
a Each time the pressure is measured, some q Use nipple P2 to connect the hose,
nitrogen gas is discharged and the pres- depending on the specification of the
sure lowers. Add nitrogen gas by the loss. nitrogen gas cylinder. [For overseas]
10. Remove gas charge tool P1 from accumulator

(1) and return the removed parts. See "Proce-
dure for charging accumulator with nitrogen
gas".
Procedure for charging accumulator with nitro-

gen gas
a The disconnected from the machine can be
charged with nitrogen gas according to the fol-
lowing procedure, too.
1. Stop the engine and press the brake pedal
repeatedly to lower the oil pressure in the
brake circuit to zero.
a Generally, if the brake pedal is pressed 30
times, the reaction force to the brake
pedal is lost and the oil pressure is low-
ered to zero.
2. Remove valve guard (2) and cap (3) from

accumulator (1).
4. Open nitrogen gas cylinder (c) slightly to dis-

charge nitrogen gas at pressure of 0.19 – 0.29
MPa {2 – 3 kg/cm²}.
5. After nitrogen gas starts flowing out of handle

(b), close handle (b).
HM300-2R 19
6. Turn handle (a) slowly to the right to open

valve (4) of accumulator (1) gradually.
a If handle (a) is turned too much, the valve
core of the accumulator will be damaged
and gas will leak. Accordingly, operate
handle (a) carefully.
7. Open the valve of nitrogen gas cylinder (c) fur-

ther to charge the accumulator with nitrogen
gas.
8. During the work, close the valve of nitrogen

gas cylinder (c) and check the nitrogen gas
pressure in the accumulator. 13. In a week after charging the accumulator with
a Since the indicated value varies with the nitrogen gas, check that the nitrogen gas pres-
ambient temperature, correct it by the fol- sure has not lowered.
lowing formula. (The unit of each value in a Check the functions in 5 minutes after
the formula is °C.) stopping the engine. (If the engine is
Indicated gas pressure = stopped for more than 5 minutes, the
Standard gas pressure x ((273 + t)/ brake circuit pressure lowers and the func-
(273 + 20)) tions cannot be checked accurately.)
Standard gas pressure = 1) Stop the machine on a level place and set
Indicated gas pressure/((273 + t)/ the parking brake switch in the "PARK"
(273 + 20)) position.
t = Gas temperature at time of charge (°C)
2) Start the engine and run it at medium
Reference: t may be assumed to be ambi-
speed for 1 minute and then stop it.
ent temperature.
3) Turn the starting switch to the ON position
and press the brake pedal repeatedly.
9. After the accumulator is charged to the stan-
Count the number of presses until the
dard pressure, close the valve of nitrogen gas
brake oil pressure caution lamp lights up.
cylinder (c).
q If number of presses is less than 5:
q If the accumulator is charged too much,
Accumulator gas pressure may have
turn handle (b) to the left slowly with the
lowered.
valve of nitrogen gas cylinder (c) closed to
q If number of presses is 5 or more:
release the nitrogen gas gradually to
Accumulator gas pressure is normal.
adjust.
10. Remove gas charge tool P1 from valve (4) of

accumulator (1) according to the following pro-
cedure.
1) Turn handle (a) to the left to close the
valve of the accumulator.
2) Turn handle (b) to the left to open and dis-
charge nitrogen gas remaining in gas
charge tool P1 and hoses.
3) Remove gas charge tool P1 from valve (4)
of the accumulator.
11. Apply soap water to valve (4) of the accumula-

tor to check that nitrogen gas is not leaking.
12. Install cap (3) and valve guard (2) to accumula-

tor (1).
3 Cap: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
20 HM300-2R
Testing brake performance 1

k Stop the machine on level ground and turn
the parking brake switch ON.
1. Testing braking performance of foot brake

1) Start the engine and turn the parking
brake switch OFF.
2) Depress the brake pedal fully, then set the
gear shift lever to the D position.
a Do not set the gear shift lever to the
position other than D, when testing
the foot brake performance.
3) Depress the accelerator pedal gradually
and check that the machine does not 4) After completing the test, run the engine at
move when the torque converter is stalled low idle and set the gear shift lever to the
at the specified speed. N position.
3. Testing braking performance of parking
brake
k If the machine starts to move, it can
cause a serious personal injury. Should
the machine start moving during the
performance test, reduce the engine
speed immediately, move the gear shift
lever to the N position and depress the
brake pedal.
1) Turn the parking brake switch ON and
start the engine.
2) Set the gear shift lever to the D position.
the foot brake performance.
4) After completing the test, run the engine at
low idle and set the gear shift lever to the and check that the machine does not
N position. move when the torque converter is stalled
at the specified speed.
2. Testing braking performance of retarder 4) If the machine moves at a revolution lower
brake than specified, adjust the clearance of the
1) Start the engine and turn the parking brake pad referring to "2. Adjusting pad
brake switch OFF. clearance" in "Measuring wear of parking
2) Pull the retarder lever fully, then set the brake pad".
gear shift lever to the D position.
the retarder brake performance.
and check that the machine does not
move when the torque converter is stalled
at the specified speed.
5) After completing the test, run the engine at

low idle and set the gear shift lever to the
N position.
HM300-2R 21
Bleeding air from brake circuit 1 4) Bleed the air from the retarder brake cir-
cuit as follows.
a If a brake circuit part is removed and installed, 1] Pull the retarder lever fully and hold it
bleed air from the brake circuit according to the in position.
2] Loosen air bleeder (1) approx. 1/2
a When bleeding the air from the wheel brake
turn, then drain the oil mixed with the
circuit, always bleed the air from the slack
air.
adjuster section first, then bleed the air from
the wheel brake section. 3] When no more air comes out with the
oil, tighten air bleeder (1).
3 Air bleeder:
1. Bleeding air from slack adjuster section of
10 – 20 Nm {1 – 2 kgm}
wheel brake circuit
a Implement the same procedure for the 5) After completing the adjustment, set to the
front brake circuit and center brake circuit. original condition.
In case of bleeding the air from the front
brake circuit, however, the brake oil pres- 2. Bleeding air from wheel brake section of
sure caution lamp may light up while foot brake circuit.
bleeding the air. If that happens, tighten a Implement the same procedure for the
the air bleeder, accumulate hydraulic oil front brake circuit and center brake circuit.
pressure in the accumulator by pumping 1) Connect air bleed hose [1] to air bleeder
the service brake pedal 8 to 10 times, and (2).
then bleed the air. Oil pressure accumulat-
ing signals are received from the rear
(center) brake circuit. Hence the circuit is
so designed that the oil pressure is not
accumulated in the front brake (low pres-
sure), even if the brake oil pressure cau-
tion lamp lights up. For this reason, air
bleeding takes place without accumulating
the oil pressure, resulting in not effective
air bleeding.
1) Connect air bleed hose [1] to air bleeder (1).
2) Start the engine and run it at low idle.

3) Depress the brake pedal fully and hold it in
position.
4) Loosen air bleeder (1) approx. 1/2 turn,
then drain the oil mixed with the air.
5) When no more air comes out with the oil,
tighten air bleeder (1).
3. Bleeding air from parking brake circuit

1) Start the engine and run it at low idle.
2) Start the engine and run it at low idle. 2) Turn the parking brake switch ON and
3) Bleed the air from the brake pedal circuit OFF several times.
as follows. a The air is automatically bled with this
1] Depress the brake pedal fully and operation.
hold it in position.
2] Loosen air bleeder (1) approx. 3/4
turn, then drain the oil mixed with the
air.
3] When no more air comes out with the
oil, tighten air bleeder (1).
3 Air bleeder:
10 – 20 Nm {1 – 2 kgm}
22 HM300-2R
Measuring wear of wheel brake a With a new machine, the initial mark (a) on
rod (2) is aligned with the end face of
disc 1 guide (3).
k Stop the machine on level ground, turn the The adjustment position may move out of
parking brake switch ON, and set chocks to alignment, so do not loosen the locknut of
the tires. guide (3) except when replacing the disc.
k Carry out the measure when the brake oil a Limit mark (b) indicates the wear limit for
temperature is less than 60°C. the disc.
k When the disc comes close to the wear lim- If limit mark (b) reaches the end face of
it, carry out the measure more frequently. guide (3), the disc has reached the wear
Be sure to test a braking performance of re- limit.
tarder brake at the same time.
1. Check that the brakes other than parking brake

are not being applied.
2. Turn the starting switch ON and check that the

retarder oil pressure caution lamp has not
lighted up.
a If the lamp lights up, the oil pressure in the
brake circuit has dropped, so start the
engine and run it at approx. 2,000 rpm.
When the lamp goes out, stop the engine.
3. Remove cap nut (1) of the gauge.

6. Install cap nut (1) of the gauge.
3 Cap nut: 29.4 – 39.2 Nm {3 – 4 kgm}
4. Depress the brake pedal fully and hold it in

position.
a If the engine is running, the brake cooling
oil is actuated and the measuring cannot
be carried out accurately, so always stop
the engine before carrying out the mea-
suring.
5. Push in rod (2) of the gauge until it contacts the

piston and judge the amount of wear.
a There are three lines (A, B and C) on the
rod. For HM300-2 model, use mark A and
mark B for the front brake and the center
brake respectively.
HM300-2R 23
Measuring wear of parking brake

pad 1
k Stop the machine on level ground, turn the
the tires.
a Before carrying out the measuring, start the
engine and raise up the dump body to the
stroke end. Then insert the lock pin and stop
the engine.
1. Measuring wear of pad

1) Turn the starting switch ON and the park-
ing brake switch OFF to release the park-
ing brake.
2) Remove the top cover of the parking
brake.
3) Release the parking brake by turning
adjustment nut (1) clockwise.
4) Remove left and right brackets (2), then
remove two each of springs (3) and (4).
5) Remove two pads (5).
6) Measure thickness (a) of pad (5).
a Thickness limit of pad: 1.5 mm
a If either the front or rear pad has
reached the thickness limit, replace
both pads at the same time.
24 HM300-2R
2. Adjusting pad clearance

a When the parking brake does not work
properly, or when the brake pads were
replaced with new ones, adjust the clear-
ance of the brake pad in the following
manner.
k Keep hydraulic oil pressure at a high
level while in adjustment so that the
parking brake may not be automatically
applied and also hang a warning tag on
t h e pa r k i n g b r a k e s w i t c h s o t h a t
nobody may operate the machine by
mistake.
k Do not smear the surfaces of brake
pads or brake discs with oil or grease. 6) Start the engine.
1) Turn the starting switch ON and the park- 7) Release the parking brake and check the
ing brake switch OFF to release the park- clearance of the pad again.
ing brake. a Clearance (total of (b) and (c)):
2) Install 2 pads (5). 1.88 ± 0.08 mm
3) Install 2 each of springs (3) and (4) to left a If the clearance is not correct, carry
and right brackets (2), then install left and out the adjustment again from Step
right brackets (2). 3).
a There are two types of springs, so 8) Tighten the mounting bolts of left and right
check the color, and be careful not to brackets (2).
mistake the mounting position. a Be careful not to let the mounting
Spring (3): Black position move out of alignment.
Spring (4): Yellow 9) Check the clearance between pad (5) and
a Tighten the bracket mounting bolts disc (6) again.
temporarily by 2 – 3 turns. a Standard clearance (total of (b) and
4) While pushing down lock (7), turn adjust- (c)): 1.88 ± 0.08 mm
ment nut (1) counterclockwise until brake a If the clearance on one side is narrow,
pad (5) comes into close contact with move the mounting position of the left
brake disc (6). and right brackets to adjust.
5) While measuring clearance (b) and (c)
between brake pad (5) and brake disc (6),
push down lock (7) and turn adjustment
nut (1) clockwise until the specified clear-
ance in between is obtained.
a Standard clearance (total of (b) and
(c)): 1.88 ± 0.08 mm
HM300-2R 25
Method for emergency release of

parking brake 1
a If any problem occurs in the electrical system
or hydraulic system of the parking brake and
the parking brake is not released, it is possible
to release the brake temporarily as follows.
k If any problem occurs in the hydraulic sys-
tem, there is a strong possibility that the
wheel brake will not work properly, so after
releasing the parking brake, always tow the
machine at low speed to a safe place.
k When carrying out the operation to release
the parking brake, stop the machine on
level ground and check that the surround-
ing area is safe before starting the opera-
tion. If the parking brake must be released
o n a slo p e i n an eme rg e n cy o r o t h e r
unavoidable situation, set chocks to the
tires securely.
1. In order to create a gap between the pad and

disc, turn the parking brake adjustment nut (1)
clockwise while pushing down the lock of the
nut.
2. Tow the machine to a safe place.

k After moving the machine, set chocks
securely to the tires.
26 HM300-2R
Testing and adjusting steering 2) Start engine and operate the steering up
to either left or right stroke end.
circuit oil pressure 1
3) Measure the oil pressure when the steer-
a Equipments for testing and adjusting steering ing circuit pressure is relieved with the
circuit oil pressure engine at high idle.
M

the tires.
1. Measuring steering relief oil pressure

a Measure the steering relief pressure at
remote pressure pickup port (1).

2. Adjusting steering relief oil pressure

a If the steering relief oil pressure is not cor-
rect, adjust relief valve (2) of the flow amp
valve as follows.
1) Install hose [1] and connect oil pressure

gauge M.
a Use a 40 MPa {400 kg/cm²} oil pres-
sure gauge.
HM300-2R 27
1) Remove plug (3) and then locknut (4).

2) Turn adjustment screw (5) and adjust oil
pressure.
a Adjustment screw:
q When turned clockwise, the oil
pressure is heightened.
q When turned counterclockwise,
the oil pressure is lowered.
3) Tighten locknut (4) and install plug (3).
a After completing the adjustment,
check the oil pressure again following
to the procedure for measurement.
28 HM300-2R
Testing and adjusting suspension

cylinder 1
a Equipments for testing and adjusting suspen-
sion cylinder
1 792-610-1000 Suspension tool
2 792-610-1130 • Pump
3 792-610-1110 • Hose
4 792-610-1120 • Joint
5 07020-21732 • Fitting
6 792-610-1140 • Joint
N 7 792-610-1250 • Valve
8 792-610-1260 • Nipple
9 792-610-1480 • Stem
10 792-610-1640 • Joint
11 792-610-1400 • Regulator
12 792-610-1430 • Gauge
13 792-610-1440 • Gauge

the tires.
1. Testing cylinder length

Test the installation length of the suspension
cylinder under the following conditions.
q On a level road surface
q Stop engine.
q Dump body unloaded
a Installation dimension a of front cylinder:
163 ± 10 mm
Installation dimension b of rear cylinder:
101 ± 5 mm
a If the length of the cylinder is not correct,
adjust it according to the steps 2 to 5.
HM300-2R 29
2. Releasing nitrogen gas a Specified front oil volume length a:

1) Set a hydraulic jack under the frame of the 113 ± 3 mm
machine and raise it until tires come a Specified rear oil volume length b:
slightly off the ground. 57 ± 3 mm
a Use a 490,000 N {50 ton} jack. k Operate the hydraulic jack care-
k Set the jack securely under the fully.

frame. 2) Remove oil level valve (2).
a When carrying out work at the front, 3) Remove the valve body from air supply
jack up the front frame until front tires valve (3), then install joint N6.
come slightly off the ground. 4) Install fitting N5 to joint N4, then connect
a When carrying out work at the rear, hose N3 and pump N2.
jack up the frame until either center or 5) Operate pump N2 to release the gas from
rear tires come slightly off the ground. the mounting port of oil level valve (2).
2) Remove cover (1). a Keep sending oil to let the inside oil
3) Loosen oil level valve (2) slowly, and when flow out from the mounting port until
the nitrogen gas starts to come out, hold the oil without air bubbles flow out.
the valve in that position. a Front cylinder oil charge amount (ref-
a If oil spurts out from the valve togeth- erence): 3.0 l
er with the nitrogen gas, tighten the a Rear cylinder oil charge amount (ref-
valve slightly until no more oil comes erence): 2.2 l
out and take time to release the nitro- 6) Install oil level valve (2).
gen gas slowly. 3 Oil level valve:
39.2 – 49.0 Nm {4 – 5 kgm}
7) Remove suspension tools N2 – N5, then
install air supply valve (3).
3 Air supply valve:
39.2 – 49.0 Nm {4 – 5 kgm}
4) Operate the hydraulic jack to lower the

frame slowly until the suspension cylinder
is retracted to the specified oil volume
length.
k Operate the hydraulic jack care-
fully to prevent the suspension cyl-
inder from being retracted too far
and suffering damage.
a Specified front oil volume length a:
113 ± 3 mm
a Specified rear oil volume length b:
57 ± 3 mm
3. Adjusting oil level

a Adjust the oil level after completing the
release of nitrogen gas.
1) Check that the suspension cylinder is the
specified oil volume length.
30 HM300-2R
4. Charging with nitrogen gas

a Charge with nitrogen gas after completing
the adjustment of oil level.
1) Remove the cap at the top of air supply
valve (3).
2) Connect suspension tools N7 – N12 as
shown in the diagram.
a Connect joint N10 to the air supply
valve.
a Before installing the regulator, blow
the filter at the mouthpiece thoroughly
with nitrogen gas (min. 0.98 MPa {10
kg/cm²}) to prevent the entry of dirt or
dust.
3) Open the valve of nitrogen gas cylinder [1]
and check the pressure (internal pressure
of the cylinder) indicated by gauge N12.
a The indicated pressure must be
higher than the internal pressure of
the cylinder by at least 0.98 MPa {10
kg/cm²}.
a Cylinder internal pressure
(front) : 5.88 MPa {60 kg/cm²}
(rear) : 0.98 MPa {10 kg/cm²}
4) Turn the handle of regulator N11 gradually
to the left and set the pressure indicated in
gauge N13.
k Never charge the cylinder with ni-
trogen gas at a pressure of more 5. Adjusting cylinder length
than 3.9 MPa {40 kg/cm²} and ex- a Adjust the cylinder length after completion
tend the cylinder fully to the stroke of the nitrogen gas charging.
end. a Carry out the adjusting of cylinder lengths
5) Operating valve N7 and the handle of joint on a level road surface with the dump
N10, charge the suspension cylinders with body unloaded.
nitrogen gas. 1) Move the machine about 15 m forward,
a Charge nitrogen gas into the left and and stop suddenly. Next, move in reverse
right cylinders at the same time. and stop the machine suddenly at the
6) When the length of the left and right cylin- original point. Repeat this procedure 3 to
ders reaches the specified installation 4 times. Finally, apply the retarder brake a
length, turn the handle of regulator N11 to little at a time and stop gently.
the left to cease charging with nitrogen a Stop the machine as gently as possi-
gas. ble using a retarder brake in order to
a Installation length a of front cylinder : ease the sliding resistance (friction of
163 ± 10 mm packings and bushings) of cylinders.
Installation length b of rear cylinder : 2) Measure the installed length of the cylin-
101 ± 5 mm der.
7) Return the handle of joint N10 fully and a Installation length a of front cylinder :
discharge the gas inside the hose by loos- 163 ± 10 mm
ening the air bleeding plug of valve N7. Installation length b of rear cylinder :
8) Disconnect suspension tools N7 – N12. 101 ± 5 mm
a Be careful not to lose the O-ring of air 3) If the installation length is too long, adjust
supply valve. by discharging nitrogen gas through oil
9) Install the cap at the top of air supply valve level valve (2).
(3). a Slightly loosen the oil level valve and
discharge an amount of gas which will
10) Install the covers of suspension cylinders.
not make the cylinder move.
HM300-2R 31
a If gas is discharged to the point of

making the cylinder move, the
installed length may become shorter
than the specified installation length.
4) After completing the adjustment, repeat
steps 1) and 2) above and check the cylin-
der length again.
5) Check for any leakage of gas from oil level
valve (2), air supply valve (3), and the cyl-
inder's gland area.
a Use soapy water to check for leakage
of gas.
Note 1: Testing after changing oil and gas

If the machine is operated after changing
the oil and gas, the gas merges with the oil
inside the cylinder up to saturation point
resulting in reducing the volume of gas,
and sometimes lessening the length of the
cylinder below the permissible value.
For this reason, test the installation length
of the cylinder in 48 hours time after chang-
ing the oil and the gas, and adjust the gas if
it is below the specified dimension.
Note 2: Testing cylinder length according to change
in ambient temperature
Since the gas in the suspension expands or
contracts according to the change in the
ambient temperature when the machine is
o per ati ng, the len gth of the cy li nder
changes.
For this reason, in regions where there are
great temperature differences during the
year, carry out daily inspections and adjust
so that the installation length of the cylinder
is within the specified range.
32 HM300-2R
Method of tilting cab up 1 1. Preparatory work:

1) Open the engine hood.
a Equipment for tilt cylinder 2) Take out a lock bar (2) from the storage
(Uselessness for external crane) place at engine left side.
Symbol Part number Part name
T 792-454-1100 Pump assembly
k When tilting the cab, observe the following

precautions to prevent a serious injury or
fatal accident caused by fall of the cab.
k To prevent interference between the cab
and the dump body, set the steering in a
st raight ahea d pos ition a nd stop the
machine on the level ground.
k Lock the dump lever with the dump lever
lock knob.
k Turn the parking brake switch ON and
3) Remove 4 mounting bolts from each of the
chock the wheels.
k
left and right mounts at the front of cab.
Set the lock bar to the frame and lock front
4) Move pin (3) at the cab rear mount from
and rear frame.
hole (4) to hole (5).
q Precautions in tilting cab
k When tilting the cab, check that the lock
lever is fixed securely.
k Do not start the engine while the cab is
tilted.
k When it is obliged to start the engine for
testing etc., check that there is nobody
under the cab.
k Do not operate the gear shift lever or dump
lever.
k Do not give a large shock to the machine.
k Do not tilt the cab while it is loaded.
2. Tilting cab up
a When carrying out inspection and mainte-
Method using tilt cylinder
nance work around the hydraulic pump or at
a External hydraulic pump assembly T is
the top of the torque converter or transmission,
necessary.
tilt the cab up to the rear of the machine as the
1) Disconnect cylinder hose (1) at quick cou-
following.
pler (Q)
a As there are the following two methods of tilt- .
ing the cab up, select either method which
matches the operating site conditions.
q Method using tilt cylinder
a The external hydraulic pump assem-
bly T is necessary.
q Method using external crane
HM300-2R 33
2) Exchange female quick coupler (F) to

male quick coupler (M) of external hydrau-
lic pump assembly.
a It is possible to get male quick cou-
pler (M) by removing it from (Q) on
the machine.
a Connecting adapter (Unit of male and
female qui ck c oupler ( Q) . Both
m a c h i n e s i d e a n d t o ol s i d e a r e
same.): 56B-54-16391 (Size of hose
connection end: RC 1/4)
3) Connect cylinder hose (1) to the external

hydraulic pump assembly.
4) Operate the external hydraulic pump and
tilt the cab up.
a Operate the pump within the specified
pressure.
Specified pump pressure:
20.6 – 34.3 MPa {210 – 350 kg/cm²}
Method using external crane

1) Fit sling [1] to the hook of the cab mount.
2) Raise the cab (6) to tilt it up.
3. Fixing cab in position

1) Pull lock lever (2-1) and set lock bar (2)
with the care the direction of the lock bar
(2) at the front left of the cab. 4. Tilting cab down
2) Lower the cab (6) slowly and fix it in the a Tilt the cab down in the reverse order for
position. tilting the cab up.
k Check that the lock lever closes a After tilting the cab down, tighten the
and the cab (6) is held securely in mounting bolts and return the lock bar to
position by the lock bar (2). the storage place.
k When the cab is tilted up with the
tilt cylinder, release its hydraulic
pressure gradually, and lower the
cab slowly.
3) Remove the external pump or external
crane.
34 HM300-2R
Testing and adjusting dump 2) Start the engine and operate the dump
body up to either LOWER or RAISE stroke
circuit oil pressure 1 end.
a Equipments for testing and adjusting dump cir- 3) Operate the dump lever with the engine
cuit oil pressure running at high idle and measure the oil
pressure at RAISE relief or LOWER relief.
O

the tires.
1. Measuring dump main relief oil pressure

a Since the dump main circuit uses the
same hydraulic pump (basic pressure)
together with the steering circuit and the
steering circuit is structured to have a pri-
ority over others, before measuring it, it is
necessary to check that the steering cir- 4) Remove the measurement tool after the
cuit pressure is normal. measurement, and make sure that the
a Measure the dump main relief pressure at machine is back to normal condition.
remote pressure detection port (1).
2. Adjusting the dump main relief oil pressure
a If the dump main relief oil pressure is not
normal, adjust it with relief valve (1) of
hoist valve according to the following pro-
cedures.
1) Install hose [1] and connect oil pressure

gauge O.
a Use a 39.2 MPa {400 kg/cm²} oil
pressure gauge.
HM300-2R 35
1) Loosen locknut (2) and adjust it turning 3) Install a nipple and hose [1], and connect
adjustment screw (3). oil pressure gauge O.
a Adjustment screw: a Use a 5.9 MPa {60 kg/cm²} oil pres-
q When turned clockwise, the oil sure gauge.
a If the adjustment screw is rotated 1
turn, the pressure is heightened or
lowered by 4.2 MPa {42.8 kg/cm²}.
4) Start the engine and measure the oil pres-

sure with the engine running at high idle.
(with the dump lever at neutral position)
2) While holding adjustment screw (3) with a

screw driver, tighten locknut (2).
3 Locknut tightening torque:
29.4 – 39.2 Nm {3 – 4 kgm}
3. Measuring dump pilot relief oil pressure

1) Remove the hydraulic oil tank side cover.
2) Remove oil pressure measurement plug
(1). 5) Remove the measurement tool after the
36 HM300-2R
4. Adjusting the dump pilot relief oil pressure

a If the dump pilot relief oil pressure is not
normal, adjust it with relief valve (1)
according to the following procedures.
1) Remove the cap, loosen locknut (2), and

adjust it turning adjustment screw (3).
a Adjustment screw:
q When turned clockwise, the oil
a If the adjustment screw is rotated 1
turn, the pressure is heightened or
lowered by 1.8 MPa {18.6 kg/cm²}
2) While holding adjustment screw (3),
tighten locknut (2).
3 Locknut tightening torque:
40 Nm {4.1 kgm}
HM300-2R 37
Adjusting body positioner sensor1 6) Following to the checking procedure

above, verify the input voltage is within the
a If the body positioner rod was once discon- normal range.
nected and connected again or the body posi-
tioner sensor was once removed and installed
again, test and adjust the body positioner sen-
sor according to following procedures.
1. Checking the sensor input voltage

1) Switch the machine monitor display to the
monitoring function of service mode 1 and
let it display the body positioner sensor
input voltage.
a Monitoring items
Code No. 34400: BODY POSITION
a Refer to “Special functions of ma-
chine monitor (EMMS)“ for the oper-
ating method.
3. System calibrating operation
1) Start the engine and raise the hydraulic oil
temperature to 80 – 90°C.
2) Lower the dump body up to the LOWER
stroke end and keep the LOWER relief at
this position for at least 5 seconds.
a Check that the dump body pilot lamp
is not lighted up.
3) Raise the dump body up to the RAISE
stroke end and keep the RAISE relief at
this position for at least 5 seconds.
4) Run the engine at low idle and repeat the
dump body RAISE and FLOAT operations
10 times.
2) Start the engine.
a Both RAISE and FLOAT operations
3) Operate the dump lever and check the are to be performed up to stroke
monitoring voltage when the dump lever is ends.
operated up to the LOWER and RAISE
5) Run the engine at high idle and repeat the
stroke ends.
dump body RAISE and LOWER opera-
a LOWER stroke end: 0.40 – 0.60 V
tions 10 times.
a RAISE stroke end: 4.00 – 4.70 V
a Both RAISE and LOWER operations
are to be performed up to stroke
2. Adjusting link length ends.
a If the monitoring voltage is not within the
normal range, adjust it with the link length
according to the following procedures.
1) Loosen locknut (1).
2) Remove mounting bolt (2).
3) Turn rod end (3) and adjust the link length.
a Input voltage:
q Becomes lower when the link
becomes longer.
q Becomes higher when the link
becomes shorter.
a Change in voltage per 1 turn of rod
end: Approx. 0.04 V
4) Install mounting bolt (2).
5) Tighten locknut (1).
38 HM300-2R
Procedure for adjusting length of Handling engine controller high

spring in body heating spherical voltage circuit 1
joint 1 1. Disconnecting or connecting operation of the
a If the body heating bellows does not move connector between the engine controller and
smoothly while the machine is steered or oscil- the engine shall be performed only when the
lated, or if the bellows is replaced, adjust the starting switch is in the OFF position.
length of the spring according to the following
procedure. 2. Do not start the engine while the T adapter is
1. Adjust length a of spring (1) to be 60 ± 1 mm. inserted or connected to a connector between
(On both front side and rear side) the engine controller and the engine for diag-
At this time, check that dispersion of dimension nosis.
b of each stud is 1 mm or less. a You may turn the starting switch to the
a Standard dimension b of stud: 58 mm (ref- OFF or ON position but must not turn it to
erence) the START position.
2. After completing the adjustment

1) Check for a leakage of exhaust gas.
2) Check that the spherical joint swivels
smoothly without any sticking or scuffing.
HM300-2R 39
Adjusting transmission
controller 1
Adjusting transmission
a After carrying out any of the following opera-
tions, adjust the transmission in order to tune
the feeling of transmission and its controller.
q Transmission has been overhauled or
replaced.
q Transmission control valve has been re-
paired or replaced.
q Transmission controller has been re-
placed.
q Power train speed sensor has been re-
paired or replaced.
q Transmission oil temperature sensor has
been repaired or replaced.
q Transmission oil filter has been clogged
abnormally and repaired.
a For the adjusting operation of the transmission,
use the service function of the machine moni-
tor.
a Refer to “Special functions of machine monitor
(EMMS)“ for the details of the operating
method.
40 HM300-2R
Method for emergency escape at electrical system failure 1

If any problem occurs in the electrical system of the engine or transmission control system, it may disable the
engine to start or the machine to move off.
If such a problem occurs, temporarily restore the engine or transmission electrical system to move the
machine to a safe place, then carry out regular troubleshooting.
1. When any problem occurs in the engine control system and the engine cannot be started
a Decide the escape method according to the following flowchart.
a Refer to “Special functions of machine monitor (EMMS)“ for the method of checking the failure
code.
Note: If the engine cannot be started and the machine is towed, release the parking brake temporarily
referring to “Method for emergency release of parking brake“, since it cannot be released by operat-
ing the switch.
HM300-2R 41
2. When any problem occurs in the transmission control system and the machine cannot be started
a Check the failure code, and determine an adequate escape procedure from following table.
a Refer to “Special functions of monitor panel (EMMS)“ for the method of checking the failure code.
Failure Condition when Lever position for speed range to
Escape method Remarks
code failure occurs move off after escape operation
1500L0 Occurrence condition 2 Escape procedure 2 —
15G0MW Occurrence condition 7 Escape procedure 1 D – 1: F2 Occurrence condition 1:
Speed range remains fixed,
15H0MW Occurrence condition 7 Escape procedure 1 D – 1: F1, R1 – R2: R1 and when machine moves off
again, transmission does not
15J0MW Occurrence condition 7 Escape procedure 1 D – 1: F2, R1 – R2: R1 shift from the fixed speed
15K0MW Occurrence condition 7 Escape procedure 3 D – 1: F3, R1 – R2: R2 range.
If lever is positioned at N,
15L0MW Occurrence condition 7 Escape procedure 3 D – 1: F2, R1 – R2: R1 transmission shifts to neutral.
15M0MW Occurrence condition 7 Escape procedure 3 D – 1: F2, R1 – R2: R1 Occurrence condition 2:
15SBL1 Occurrence condition 7 Escape procedure 1 R1 – R2: R1 Transmission suddenly shifts
to neutral while traveling. And
15SBMA Occurrence condition 7 Escape procedure 1 D – 1: F2 after machine is stopped,
lever does not shift the trans-
15SCL1 Occurrence condition 7 Escape procedure 1 D – 1: F2
mission from neutral and
15SCMA Occurrence condition 7 Escape procedure 1 D – 1: F1, R1 – R2: R1 machine can not move off.
15SDL1 Occurrence condition 7 Escape procedure 1 D – 1: F1 Occurrence condition 3:

Transmission suddenly shifts
15SDMA Occurrence condition 7 Escape procedure 1 D – 1: F2, R1 – R2: R1
to neutral while traveling.
15SEL1 Occurrence condition 7 Escape procedure 1 D – 1: F2, R1 – R2: R1
Occurrence condition 4:
15SEMA Occurrence condition 7 Escape procedure 1 D – 1: F3, R1 – R2: R2 After engine is started, trans-
15SFL1 Occurrence condition 7 Escape procedure 1 D – 1: F3, R1 – R2: R2 mission stays in neutral even
if lever is operated, and
15SFMA Occurrence condition 7 Escape procedure 1 D – 1: F2, R1 – R2: R1 machine can not move off.
15SGL1 Occurrence condition 7 Escape procedure 1 D – 1: F5, R1 – R2: R3 or equivalent Occurrence condition 5:
15SGMA Occurrence condition 7 Escape procedure 1 D – 1: F2, R1 – R2: R1 Response to lever becomes
abnormal and lever does not
15SJMA Occurrence condition 1 Escape procedure 1 D – 1: F2, R1 – R2: R1 work as operated.
When lever is operated,
Normal travel possible if display
DAQ0KK Occurrence condition 1 Escape procedure 5 transmission shifts to neutral.
returns to normal (Note 1)
Normal travel possible if display Occurrence condition 6:
DAQ2KK Occurrence condition 1 Escape procedure 4
returns to normal (Note 1) Speed range remains fixed,
and when machine moves off
DAQ9KQ Occurrence condition 4 Escape procedure 6 — again, the transmission does
Normal travel possible if display not shift from the fixed speed
DAQRKR Occurrence condition 2 Escape procedure 5 range.
If lever is positioned at N,
DAQRMA Occurrence condition 4 Escape procedure 1 D – 1: F2, R1 – R2: R1 transmission shifts to neutral,
DB2RKR Occurrence condition 1 Escape procedure 1 D – 1: F2, R1 – R2: R1 and after that, it can not be
shifted.
DDTHKA Occurrence condition 1 Escape procedure 1 D – 1: F2
Occurrence condition 7:
DDTJKA Occurrence condition 1 Escape procedure 1 D – 1: F1 Speed range is fixed with
DDTKKA Occurrence condition 1 Escape procedure 1 D – 1: F2, R1 – R2: R1 appropriate clutches applied
for the travel.
DDTLKA Occurrence condition 1 Escape procedure 1 D – 1: F3, R1 – R2: R2 If appropriate clutches are not
available for the travel, trans-
DDTMKA Occurrence condition 1 Escape procedure 1 D – 1: F5, R1 – R2: R3 or equivalent mission shifts to neutral.
DDTNKA Occurrence condition 1 Escape procedure 1 R1 – R2: R1 If lever is positioned at N,
transmission shifts to neutral.
Normal travel possible if display
DF10KA Occurrence condition 5 Escape procedure 7
returns to normal (Note 1) Note 1:
Normal travel possible if display Even when the machine con-
DF10KB Occurrence condition 5 Escape procedure 7 dition is restored after a fail-
ure, the neutral condition is
DLF1KA Occurrence condition 1 Escape procedure 1 D – 1: F2, R1 – R2: R1 maintained until the lever is
returned to the N position.
DLF1LC Occurrence condition 1 Escape procedure 1 D – 1: F2, R1 – R2: R1
DLF2KA Occurrence condition 1 Escape procedure 1 D – 1: F2, R1 – R2: R1
42 HM300-2R
Failure Condition when Lever position for speed range to

Escape method Remarks
code failure occurs move off after escape operation
DLF2LC Occurrence condition 1 Escape procedure 1 D – 1: F2, R1 – R2: R1
DLT3KA Occurrence condition 6 Escape procedure 3 D – 1: F2, R1 – R2: R1
DXH1KA Occurrence condition 1 Escape procedure 1 D – 1: F2, R1 – R2: R1
DXH1KB Occurrence condition 1 Escape procedure 1 D – 1: F2, R1 – R2: R1
DXH1KY Occurrence condition 1 Escape procedure 1 D – 1: F2, R1 – R2: R1
DXH2KY Occurrence condition 7 Escape procedure 1 D – 1: F2
DXH3KY Occurrence condition 7 Escape procedure 1 D – 1: F1 Note 1:
Even when the machine con-
DXH4KA Occurrence condition 7 Escape procedure 1 D – 1: F3, R1 – R2: R2 dition is restored after a fail-
ure, the neutral condition is
DXH4KB Occurrence condition 7 Escape procedure 1 D – 1: F3, R1 – R2: R2 maintained until the lever is
DXH4KY Occurrence condition 7 Escape procedure 1 D – 1: F2, R1 – R2: R1 returned to the N position.

DXH5KY Occurrence condition 7 Escape procedure 1 D – 1: F3, R1 – R2: R2
DXH6KY Occurrence condition 7 Escape procedure 1 D – 1: F5, R1 – R2: R3 or equivalent
DXH7KA Occurrence condition 7 Escape procedure 1 D – 1: F2
DXH7KB Occurrence condition 7 Escape procedure 1 D – 1: F2
DXH7KY Occurrence condition 7 Escape procedure 1 R1 – R2: R1
Escape procedure 1:
1) Stop traveling and return the gear shift lever to the N position.
2) Operate the gear shift lever again and move the machine off.
a When operating the gear shift lever, release the accelerator pedal.
a N o D – 1 or N o R1 – R2
Escape procedure 2:
Tow the machine.
a Note: If the engine cannot be started and the machine is towed, release the parking brake temporarily
referring to “Method for emergency release of parking brake“, since it cannot be released by operating
the switch.
Escape procedure 3:
1) Stop traveling and return the gear shift lever to the N position.
2) Disconnect (pull out) emergency escape connectors A1 (female) and A1-F (male) and then connect
(insert) them again to set the machine in the emergency escape mode.
a Connectors A1 and A2 are installed in front of the transmission controller.
a Connect and disconnect the connectors with the starting switch ON or with the engine started.
3) Operate the gear shift lever and move the machine off again.
a When operating the gear shift lever, release the accelerator pedal.
a N o D – 1 or N o R1 – R2
a The emergency escape mode is maintained until the starting switch is turned OFF.
HM300-2R 43
Escape procedure 4:
Check the circuit breaker and fuse, and if they are normal, replace the transmission controller.
q Circuit breaker: No. 64, 65(80A)
q Fuse: BT3-No. 14 (10A)
Escape procedure 5:
Check the circuit breaker and fuse, and if they are normal, replace the transmission controller.
q Circuit breaker: Inside battery housing (30A)
Escape procedure 6:
Reset the model selection setting, thus reset the option items.
a For details of checking the model selection setting, refer to “Adjusting transmission controller“.
Escape procedure 7:
Check the fuse, and if it is normal, replace the gear shift lever.
44 HM300-2R
HM300-2R 45

© 2009 KOMATSU
All Rights Reserved
46 HM300-2R
SEN03421-01
HM300-2R


Setting and adjusting various equipments ...................................................................................................... 2
Special function of machine monitor (EMMS) ............................................................................................... 13
How to start operation of KOMTRAX terminal .............................................................................................. 47
Lamp display of KOMTRAX terminal ............................................................................................................ 50
Pm Clinic check sheet................................................................................................................................... 53
HM300-2R 1
Setting and adjusting various equipments 1

Setting items which are required after the replacement, disassembly and assembly, or additional
installation of controller or sensor has been performed.
q When any part listed below has been replaced, disassembled and assembled or additionally installed,
carry out the setting and initial adjustment of controller, sensor or solenoid etc.
Name of equipments Setting and adjusting items

• 1-1. Model selection setting
• 1-2. Setting the optional equipment
Machine monitor
• 1-3. OFF setting a maintenance function of corrosion resistor
• 3-1. Deletion of the electrical system failure history information
• 2-1. Adjusting a transmission ECMV electric current
Transmission unit
• 2-2. Reset the transmission initial learning and implement learning
• 1-2. Setting the optional equipment
Transmission controller • 2-1. Adjusting a transmission ECMV electric current
• 2-1. Adjusting a transmission ECMV electric current
Transmission ECMV solenoid
Retarder controller • 1-2. Setting the optional equipment
Disconnection and connection of a body
positioner rod, or the removal and installa- Refer to the corresponding chapter.
tion of a body positioner sensor
KOMTRAX • How to start using a KOMTRAX terminal
Adding or removing an optional equipment • 1-2. Setting an optional equipment
(Note) If the service meter, integrated odometer or integrated reverse odometer needs to be set, see the
Service News.
Model selection setting (1-1)

a Since setting is carried out in service mode,
switch to service mode by the following special
operation.
1) Checking screen display
Check that the machine monitor is in the
operator mode and the screen is display-
ing either of “service meter and integrated
odometer“, “action code“ or “failure code“.
2) Displaying ID input initial screen
Press the following 2 switches at the same
time for over 5 seconds to display the ini-
tial ID input screen (Fig. 1).
q [t] switch and [<] switch 3) Input and confirmation of ID
a If the switch is pressed for over 5 sec- Input the ID by operating each switch (Fig.
onds, a blank screen will appear. 2).
Confirm that the blank screen has a ID: 6491
been displayed then release the q [>] switch: Number at cursor goes up
switch. q [<] switch:
Number at cursor goes down
2 HM300-2R
q [U] switch:
Number at cursor is confirmed
q [t] switch:
Returns to initial screen (See Note)
Note: When the cursor is at the left side,
the screen returns to the normal
screen (operator mode).
If the cursor is not at the left side,
the cursor returns to the left side.
a If the switches are not operated on
the ID input screen for more than 60
seconds, the display returns automat-
ically to the normal screen.
a On the upper row of the model selec-

tion change screen, the present
selection value will be displayed.
a Refer to the table below for display
contents.
No. Model Display
1 HM400 HM400
2 HM400 (Tunnel specifications) HM400TN
3 HM350 HM350
4 HM350 (Tunnel specifications) HM350TN
5 HM300 HM300
4) Displaying menu initial screen 6 HM300 (Tunnel specifications) HM300TN
After confirming all 4 digits of the ID, the
menu initial screen of the service mode is a [>] switch to display the order of the
displayed (Fig. 3). item No. from small o large,
a Once the ID has been input and con- [<] switch for the order of the item No.
firmed, it remains effective until the from large o small.
starting switch is turned OFF. (Display the maximum next to the
minimum, and the minimum next to
the maximum)
6) For model selection change screen, oper-
ate the switch [<] and [>], and determine
the model by pressing the [ U ] switch
along with the objective model.
7) Return to the service mode after confirm-
ing that the model selection change
screen is the objective model, and turn off
the starting switch once and let more than
15 seconds pass.
a Unless the starting switch is turned off
for over 15 seconds, it will not record
5) Operate the [<], [>] switch from the initial the new model.
menu screen and display the model selec- a The selected model will be effective
tion function screen, then press the [ U ] the next time the starting switch is
switch for over 5 seconds to display the turned on.
model selection change screen.
a [U] must be pressed for over 5 sec-
onds, or it will not change to model
selection change screen.
HM300-2R 3
English Check
Check item Default Selected content
display item No.
HM300-2
Left-and-right differential
LR DIF LOCK 1 HM300TN-2 Select NO ADD and set.
lockup
is NO ADD
Accelerator connected
ACC RETARD 2 NO ADD Be sure to select NO.
retarder
Caution when body is up BODY UP CAU 5 NO ADD Be sure to select NO.
Dozing counter DUMP COUNT 6 NO ADD Be sure to select NO.
Set the speed compensation volume by tire size
and select as below according to the tire.
HM300/300TN-2
Japan (750/65-R25 E3) : 0%
Tire size compensation TIRE SIZE 8 0% Except Japan (23.5-R25 E3) : +1%
If speed display mismatch exists, adjust it with

this function.
Every time it is raised by 1%, compared to when
it is 0%, the vehicle speed will go up 1%.
Maintenance sensor SENSOR 10 NO ADD Be sure to select NO.
P brake interlock PARKING I.L. 11 NO ADD Be sure to select NO.
Select economy mode E1 MODE 12 ADD Be sure to select ADD.
Selection of unit Do not change the set value for non SI specifi-
SPEED(UNIT) 13 MPH
(MPH or km/h) cation machine monitor only.
Setting option device (1-2)

a Confirm that the model selection is done
before setting the option.
1) Setting will be done by the service mode,
therefor e r efer to the adjustment of
machine monitor (2) and switch to the ser-
vice mode screen.
a After changing the setting, as with the
model selection setting, unless the start-
ing switch is turned off for over 15 sec-
onds, it will not be recorded.
2) Option device is as above.
3) Operate the [>], [<] switch from the service
mode to display the option selection func-
a Because the left-and-right differential lock
tion screen, and press [U] switch for over
of HM300 is “only without“, press [ U ]
5 seconds to change the display to setting
switch from the upper screen to display
screen.
the next screen.
a Press [U] switch for over 5 seconds other-
wise it will not change to setting screen.
a Be sure to start from check item No. 1 for
option setting, also follow the below proce-
dure to set check item No. 1.
4 HM300-2R
4) Press [U] switch from the upper screen 7) Correction of tire size is as follows.
again to display the next screen, and non- 1] By the option setting procedure, dis-
set operation of differential lock will be play the tire size adjustment screen,
ended. then input the tire size adjustment
value.
a Input the value the same way as
inputting the ID.
2] Press the [U] switch and set.
5) Press [>] switch from the above screen to

move on to the next option setting.
a Confirm the option device installation con-
dition of the concerned machine, and set
each check item in the order following the
above table.
6) Display of option setting or not-setting.
1] If an option is not selected, option not
selected screen will be displayed (NO
ADD is displayed on lower left).
2] If option is set, option screen will be
displayed.
(ADD will be displayed on lower left)
a Set / not set of each option is changed
by pressing the [U] switch, ADD and
NO ADD will change every time the
switch is pressed.
a The setting of each option is carried

out by following the same procedure
for the above items 5) and 6).
HM300-2R 5
Deletion of electric system failure history infor- 3) Implement the switch operation following
mation (3-1) the display (Fig. 6).
1) Press the [U] switch once when the failure q [<] switch: Select YES
history information you wish to delete is q [>] switch: Select NO
displayed, and display the individual dele- q [t] switch: Execute
tion screen (Fig. 4). a An information which is active cur-
q [U] switch: Display the deletion screen rently (display is flashing) cannot be
2) Execute the switch operation following the deleted.
display screen. (Fig. 4).
q [<] switch: Select YES
q [>] switch: Select NO
q [t] switch: Execute
a An information which is active cur-
rently (display is flashing) cannot be
deleted.
q Deletion of all the failure history information

1) Press the [>] or [<] switch when the failure
history information is displayed, and dis-
play all the deletion menu screen (Fig. 5).
2) Press the [U] switch once and display all
deletion screen (Fig. 6).
q [U] switch:
Implement all deletion menu.
6 HM300-2R
Transmission ECMV current control (2-1) To check, operate the machine monitor and
Machine monitor has the function of “adjusting machine body, and perform in order the follow-
the different operational feel of each ECMV to ing check items (Fig. 2).
a constant level through the transmission con- a ( ) indicates each menu used for adjust-
troller“ and “learning function to keep certain ment.
gear shift feeling according to the change in 1] Adjusting individual difference of valves
individual wear of the transmission clutch“. (02: AUTO for ECMV TUNING)
If power train related operation such as the fol- 2] Resetting the stabilization of gear shift-
lowing is carried out, execute the adjustment ing feel learning data (01: TM TRIG-
operation. GER)
q If transmission is overhauled or changed 3] The initial learning of stabilization of
q If transmission valve is replaced gear shifting feel (monitoring function)
q Transmission controller has been replaced. a [MANUAL] menu of [02: ECMV TUN-
q When an abnormality occurred in the ING] is the function only used by
power train speed sensor and has been plants and not used by services.
repaired (refer to the below table for failure
code)
q If the transmission oil temperature sensor
is troubled and repaired (refer to the below
table for failure code)
q If the transmission oil filter is clogged and
repaired (refer to the below table for failure
code)
Preparatory work: ECMV oil temperature adjust-

ment
a Adjusting operation should be carried out with
specified oil temperature, confirming the
machine is not displaying abnormality, adjust
the ECMV oil temperature by following the next
procedure.
1) Menu selection
Select [Machine information monitoring
Failure code Device name function] on service mode menu (Fig.1).
DLF1KA Transmission input shaft speed
DLF1LC sensor
DLF2KA Transmission intermediate shaft
DLF2LC speed sensor
Transmission output shaft R
DLF3KA
speed sensor
Transmission valve oil tempera-
DGF1KX
ture sensor
15B0NX Transmission oil filter
HM300-2R 7
2) Sub menu display 5) Start the engine.

With the menu selected, press the [U] 6) Refer to the 10. Real time monitoring func-
switch and display the initial screen of the tion, and display “ECMV oil temperature“
sub menu (Fig. 2). (Fig.1).
q [U] switch: Execute the menu q TRANSMISSION No. 8
3) Operate the switch [<], [>], and align to the 7) Operate the torque converter stall, and
real time monitor selection screen of the raise the ECMV oil temperature up to 60 –
transmission controller. 70°C.
a Refer to the Measuring torque con-
verter stall speed.
8) Keep it in low idle for 3 minutes, and con-
firm that the ECMV oil temperature is sta-
ble between 60 – 70°C, then carry out the
adjustment.
Transmission ECMV current adjustment proce-

dure
a Correcting objects are HIG, LOW, REV, 1ST,
2ND and 3RD, and when started the correction
of all the above clutches will be automatically
carried out.
a Refer to “preparatory work“, and confirm the
4) When the [U] switch is pressed and set, ECMV oil temperature is at the specified tem-
the real time monitor application program perature.
version of the transmission controller is a Adjusting operation is automatically carried out
displayed. for the Lo, Hi, R, 1st, 2nd, and 3rd valve, 4
times each.
1) Turn the starting switch on, and set the
machine to next condition.
q Parking brake switch: ON
q AISS LOW switch: LOW (low speed)
q Gear shift lever: N position
q Engine: Low idle
q Accelerator pedal: OFF (Release)
2) Operate the machine monitor, and display the
adjustment menu screen (Fig.4).
q Adjustment menu: 02:
ECMV TUNING AUTO
8 HM300-2R
3) When the [U] switch is pressed to confirm the a Normal and abnormal results are displayed for
adjustment check item, the screen changes to each adjustment, and correct following the dis-
automatic compensation or manual compensa- play (Fig. 6).
tion selection screen, select the automatic q If “3-3 OK“ is displayed:
compensation (screen below). Adjustment is done without error.
(Adjustment value is recorded to the controller
when turning off the starting switch.)
q If “NG1“ is displayed (out of correction condi-
tion):
Adjust the ECMV oil temperature exactly, and
confirm the machine setting condition again,
then carry out from the procedure 1).
q If “NG2“is displayed (without fill):
Carry out troubleshooting of failure code
[15ST TMA] [DDTT TKA] and if the condition is
confirmed to be normal, then start again from
procedure 1).
q If “NG3“ is displayed (compensation value over):
Carry out troubleshooting of failure code
4) Re-confirm the machine condition, and press [15ST TL1] and if the condition is confirmed to
the [ U ] switch which starts the adjustment, be normal, then start again from procedure 1).
then the screen changes to IP ... (Fig.5).
q [U] switch: Execute the adjustment menu
a Adjustments should be carried out continu-

ously for 4 times to each objective clutch, and
display the screen as shown in the below table.
1st 2nd 3rd 4th

No. Valve
time time time time
1 Lo IP L-1 IP L-2 IP L-3 IP L-4
2 Hi IP H-1 IP H-2 IP H-3 IP H-4
3 R IP R-1 IP R-2 IP R-3 IP R-4
4 1st IP 1-1 IP 1-2 IP 1-3 IP 1-4
5 2nd IP 2-1 IP 2-2 IP 2-3 IP 2-4
6 3rd IP 3-1 IP 3-2 IP 3-3 IP 3-4
HM300-2R 9
Resetting and implementing learning of the a Confirm the initialization is completed dis-
transmission initial learning (2-2) play on lower screen after initialization.
q Initialization is done:
Resetting the stabilization of gear shifting feel
INITIAL STATUS
learning data
1) Operate the machine monitor, then display the
initialization menu screen from the service
mode (Fig.7).
q Initialization menu:01: TM TRIGGER
a Present initialization condition is displayed
on lower screen.
q Initialization is done:
INITIAL STATUS
q Initialization is not done: TUNED
a At the transmission adjustment, learning
data is initialized by the next operation
regardless of present initialization condi-
tion.
2) Press the [U] switch on this screen and dis- Beforehand preparation for transmission initial
play the initialization operation screen (Fig. 7). learning
q [U] switch: Execute the initialization menu a Align 2 item display selection screen (upper
screen) by [<], [>] switch operation from the
real time monitor screen, press [U] switch then
input the monitoring code of the transmission
control oil temperature and the trigger learning
display.
3) Carry out the switch operation following the

display (Fig. 8).
q [<] switch: Select YES
q [>] switch: Select NO
q [t] switch: Execute
Press the switch [U] to determine 2 items display.
10 HM300-2R
Initial learning of gear shift feel stabilization 6) Display both “Lo clutch fill condition“ and “1st
k Adjustment should be carried out in an clutch fill condition“ by the vehicle information
area with sufficient traveling space, and monitoring function, then confirm the fill condi-
pay attention to the surroundings for tion (Fig. 11. 12).
safety. q Lo clutch: TRANSMISSION No. 42
1) Display the “R clutch fill condition“ by the real q Hi clutch: TRANSMISSION No. 44
time monitoring function (Fig. 10). a Correction is completed, if the display is
q TRANSMISSION No. 47 “0“.
a If the display is “1“, repeat procedures 4)
and 5) until both becomes “0“.
2) Keep the gear shift lever at N position for 10

seconds at the low idle, then operate the gear
shift lever as follows.
a Gear shift lever operation: N o R1 o N
3) Confirm the fill condition by the monitoring dis-
play
a Move on to the next step if the display is
“0“.
a If the display is “1“, repeat procedure 2)
until it becomes “0“.
4) Travel with the gear shift lever at D position,
then shift up from F2 – F4.
a Shift up: F2 o F3 o F4
a Be careful not to shift up to F5.
When shifted up to F5, redo from F2.
5) Release the accelerator pedal after traveling
for 10 seconds at F4, then shift down from F4 –
F2 at coasting traveling.
a Shift down: F4 o F3 o F2
a Do not operate the brake during the coast-
ing travel.
HM300-2R 11
Off setting of maintenance function for corro- 4) Press the [>] switch then display the by item
sion resistor (1-3) timer deactivation/activation selection screen.
Turn off the maintenance function of corrosion
resistor for the machine not installed with corrosion
resistor.
1) Menu selection
Select maintenance function on service mode
menu screen.
q Maintenance check item No.1 screen is dis-
played if [U] switch is pressed.
5) If [U] switch is pressed on the selection screen

of the by item timer deactivation, the display
will become YES / NO, press the [<] switch to
then move the cursor to YES, and press
[t]switch.
2) Press the [U] switch then select the corrosion

resistor check item.
3) Press the [U] switch then display the mainte-
nance interval change screen.
6) Press [t] switch 3 times to return to the normal

screen.
12 HM300-2R
Special function of machine monitor (EMMS) 1
Normal function and special function of machine monitor (EMMS)

The machine monitor (EMMS) is equipped with normal and special functions, and displays various types of
information to the character display at the center of the monitor section.
Some items are displayed automatically according to the internal setting of the machine monitor, and some
are displayed according to the operation of the machine monitor switches.
1) Normal function: Operator mode
With this function, an operator can view and change the items displayed normally or displayed by the
operation of the switches.
2) Special function: Service mode
With this function, a serviceman can display and change the displayed items by the specified switching
operation for testing, adjusting and troubleshooting.
Operator mode Service mode

1 Replacement time display function of filter and oil 7 Electrical system failure history display function
2 Phone No. input function 8 Mechanical system failure history display function
3 Language selection function i
o 9 Real-time monitoring function
4 Action code display function 10 Reduced cylinder mode
5 Failure code display function 11 No injection cranking
6 Operation information display function 12 Filter and oil replacement time setting function
HM300-2R 13
Operator mode
a No. 2 – No. 5 is displayed endlessly by following the switch operation.
a During malfunctions, regardless of the displayed screen, it automatically returns to No. 6.
a If the switch is not operated for over 30 seconds regardless of the display screen, it automatically
returns to
q Moves to No. 1: If malfunction has not occurred.
q Moves to No. 6: If malfunction has occurred.
a Move from No. 7 to No. 1 with the switch operation; the switch must be operated for over 10 seconds,
otherwise it automatically moves to No. 6.
Service mode
a Display No. 8 – No. 14 endlessly by following the switch operation.
a By inputting and determining the ID once, it will be effective until the starting switch is turned off.
Character display portion Control switch section

16 characters can be displayed on each upper and All the display operation of the machine monitor is
lower row of the character display section, and operated by the machine monitor mode selector
depending on the contents displays the combina- switch (1) (2).
tion of the next figures, letters, and symbols. The following functions are adopted to the button of
1) Arabic numbers: 1,2,3, ... each switch.
2) Small letters: a, b, c, ... 1) U: Determine and execute
3) Large letters: A, B, C, ... 2) t: Cancel, release and determine
4) KATAKANA: A, I, U, ... (only YES and NO screen)
(Only for Japanese display) 3) >: Right, next and forward
5) Symbols: @, ¥ ,$, ... 4) <: Left, previous and return
6) Special letters:
14 HM300-2R
Operation and display of operator mode

1. Replacement time display function of filter
and oil
1) Replacement time display of filter and oil
(displayed automatically)
When replacement interval of various fil-
ters and oils are approaching, the
machine monitor automatically displays
the information to remind the operator of
maintenance (Fig. 3: example).
2) Replacement time reset (selection menu)

The machine monitor can reset the inter-
val time by operating the switch, if various
filters and oil maintenances are finished
(Fig. 4).
a For the details, see section “Struc-
ture, function and maintenance stan-
dard“, “Machine monitor system“.
a Replacement interval time setting can
be operated by the service mode.
HM300-2R 15
Flow of each mode and function
16 HM300-2R
2. Phone No. input function 4. Action code display function

Phone No. set in the machine monitor can be When abnormal situations occur, the machine
inputted, corrected and released by the switch monitor automatically displays the action code
operation (Fig. 5). depending on the extent of the abnormality in
a Phone No. is displayed together with order to remind the operator of proper remedy
“CALL“ when action code “E03“ is dis- (Fig. 7).
played. a Below figure shows the example of dis-
a For the details, see section “Structure, playing action code “E03“ and “CALL +
function and maintenance standard“, phone No.“ alternately.
“Machine monitor system“. a “CALL + phone No.“ is not displayed if the
action code “E01“ or "E02" is displayed.
3. Language selection function

Display language of the machine monitor can
be selected with the switch operation (Fig. 6).
a The Service mode function is not included
in the display selection function, therefore
always displayed in English
a For the details, see section “Structure,
function and maintenance standard“,
“Machine monitor system“.
HM300-2R 17
a Action code and remedy requested for an operator
Action
CALL + phone No. Remedy requested for an operator
code
E01 None • Test and maintenance when operation is finished or when the operator rotates.
• If related to an overrun is displayed:
Travel keeping the engine speed and machine speed down.
E02 None
• If related to an overheat is displayed:
Stop the machine and keep the engine with no-load medium speed running.
E03 Yes • Stop the engine and machine immediately and contact the service personnel.
5. Failure code display function a The following information is displayed in

By pressing the [>] button once when action the service code display function (Fig. 9).
code is displayed on the machine monitor, A: Failure code
present failure code is displayed (Fig. 8: exam- (4 digits of a section code + 2 digits of a
ple). symptom code)
q [>] Button: Display failure code. B: Controller code
(MON: Machine monitor)
(ENG: Engine controller)
(TM: Transmission controller)
(BK: Retarder controller)
C: Trouble occurring system
a Refer to “Failure code table“ for details of
displayed failure codes.
a Be cautious of the partial difference in the
displayed information for the failure code
display function and the failure history dis-
play function (service mode).
a Leaving the failure code display screen
without any switch operation for over 30
seconds, it automatically returns to the
a The failure codes which have been action code display screen.
detected in the past are separated into
electrical and mechanical systems and
recorded as failure history (refer to service
mode for a detail).
a If there are more than one, other failure
codes are displayed by pressing the [>]
button.
a After displaying all the failure codes by
pressing the [>] button, press [>] button
again to return to the service meter and
travel distance integrating meter screen.
Press the [>] button again, and the failure
code is displayed from the beginning.
Also, if it is not operated for over 10 sec-
onds, it automatically change to the action
code display screen.
18 HM300-2R
Failure codes table

Failure Applicable Action History
Failed section Symptom of failure
code equipment code classification
1500L0 Dual engagement TM E03 Mechanical system
15B0NX Transmission oil filter Clogging TM E01 Mechanical system
Operational error or incorrect
15F0KM R o F gear shift abuse 1 TM — Mechanical system
setting
15F0MB R o F gear shift abuse 2 Functional deterioration TM — Mechanical system
15F7KM Forward clutch disc abuse TM — Mechanical system
setting
15G0MW Slipping R clutch Slipping TM E03 Electrical system
15G7KM Reverse clutch disc abuse TM — Mechanical system
setting
15H0MW Hi clutch Slipping TM E03 Electrical system
15J0MW Lo clutch Slipping TM E03 Electrical system
15K0MW 1st clutch Slipping TM E03 Electrical system
15L0MW 2nd clutch Slipping TM E03 Electrical system
15M0MW 3rd clutch Slipping TM E03 Electrical system
Fill signal is ON when
15SBL1 R clutch solenoid TM E03 Electrical system
command current is OFF
15SBMA R clutch solenoid Malfunction TM E03 Electrical system
15SCL1 Hi clutch solenoid TM E03 Electrical system
15SCMA Hi clutch solenoid Malfunction TM E03 Electrical system
15SDL1 Lo clutch solenoid TM E03 Electrical system
15SDMA Lo clutch solenoid Malfunction TM E03 Electrical system
15SEL1 1st clutch solenoid TM E03 Electrical system
15SEMA 1st clutch solenoid Malfunction TM E03 Electrical system
15SFL1 2nd clutch solenoid TM E03 Electrical system
15SFMA 2nd clutch solenoid Malfunction TM E03 Electrical system
15SGL1 3rd clutch solenoid TM E03 Electrical system
15SGMA 3rd clutch solenoid Malfunction TM E03 Electrical system
15SJMA Lockup solenoid Malfunction TM E03 Electrical system
Inter axle differential lock
15SKMA Malfunction TM E01 Electrical system
pressure control valve
2F00KM Parking brake TM — Mechanical system
setting
2G42ZG Front accumulator Oil pressure too low BK E03 Mechanical system
2G43ZG Rear accumulator Oil pressure too low BK E03 Mechanical system
Engine overrun prevention
989A00 Prevention function activated MON E02 —
command signal
989D00 Rear section turnover alarm Prevention function activated MON — —
AA10NX Air cleaner Clogging MON E01 Mechanical system
AB00MA Alternator Malfunction MON E03 Mechanical system
B@BAZK Engine oil level Low too low TM E01 Mechanical system
B@BCNS Engine overheated Overheat ENG E02 Mechanical system
HM300-2R 19

B@BCZK Radiator coolant Low too low MON E01 Mechanical system
B@BFZK Fuel level Low too low MON — —
B@C6NS Front brake fluid Overheat MON E02 Mechanical system
B@C8NS Center brake oil Overheat MON E02 Mechanical system
B@CENS Torque converter Overheat TM E02 Mechanical system
B@HAZK Hydraulic tank oil Low too low TM E01 Mechanical system
B@JANS Steering oil Overheat TM E02 Mechanical system
CA111 Engine controller Internal abnormality ENG E03 Electrical system
Abnormal engine Ne and Bkup Abnormality occurred in both
CA115 ENG E03 Electrical system
sensors sensors at the same time
CA122 Charge pressure sensor Too high ENG E03 Electrical system
CA123 Charge pressure sensor Too low ENG E03 Electrical system
CA131 Throttle sensor Too high ENG E03 Electrical system
CA132 Throttle sensor Too low ENG E03 Electrical system
CA135 Oil pressure sensor Too high ENG E01 Electrical system
CA141 Oil pressure sensor Too low ENG E01 Electrical system
CA144 Water temperature sensor Too high ENG E01 Electrical system
CA145 Water temperature sensor Too low ENG E01 Electrical system
CA153 Charge temperature sensor Too high ENG E01 Electrical system
CA154 Charge temperature sensor Too low ENG E01 Electrical system
CA187 Sensor power source 2 Too low ENG E01 Electrical system
CA221 Atmospheric pressure sensor Too high ENG E01 Electrical system
CA222 Atmospheric pressure sensor Too low ENG E01 Electrical system
CA227 Sensor power source 2 Too high ENG E03 Electrical system
CA234 Engine overspeed Overspeed ENG E02 Mechanical system
CA238 Ne speed sensor Abnormal power supply ENG E03 Electrical system
CA263 Fuel temperature sensor Too high ENG E01 Electrical system
CA265 Fuel temperature sensor Too low ENG E01 Electrical system
CA271 PCV1 short circuit Short circuit ENG E03 Electrical system
CA272 PCV1 disconnection Disconnection ENG E03 Electrical system
CA273 PCV2 short circuit Short circuit ENG E03 Electrical system
CA274 PCV2 disconnection Disconnection ENG E03 Electrical system
CA322 Injector #1 system Disconnection and short circuit ENG E03 Electrical system
Abnormal engine controller data
CA342 Abnormal ENG E03 Electrical system
consistency
CA351 Injector drive circuit Abnormal ENG E03 Electrical system
CA352 Sensor power source 1 Too low ENG E03 Electrical system
CA386 Sensor power source 1 Too high ENG E03 Electrical system
CA431 Idle validation switch Abnormal ENG E01 Electrical system
CA432 Idle validation switch Abnormal procedure ENG E03 Electrical system
20 HM300-2R

CA441 Engine controller power supply Voltage too low ENG E03 Electrical system
Engine controller power supply
CA442 Too high ENG E03 Mechanical system
voltage
CA449 Common rail pressure high Abnormality 2 ENG E03 Electrical system
CA451 Common rail pressure sensor Too high ENG E03 Electrical system
CA452 Common rail pressure sensor Too low ENG E03 Electrical system
CA553 Common rail pressure high Abnormality 1 ENG E03 Electrical system
CA554 Common rail pressure sensor In range error ENG E03 Electrical system
Loss of pressure feed from supply
CA559 Abnormality 1 ENG E03 Electrical system
pump
CA689 Ne speed sensor Abnormal ENG E03 Electrical system
Abnormal Bkup speed sensor
CA731 ENG E03 Electrical system
phase
CA757 All data of engine controller Loss ENG E03 Electrical system
CA778 Bkup speed sensor Abnormal ENG E03 Electrical system
CA1633 KOMNET communication circuit Abnormal ENG E03 Electrical system
CA2185 Throttle sensor power supply Too high ENG E03 Electrical system
CA2186 Throttle sensor power supply Too low ENG E03 Electrical system
Loss of pressure feed from supply
CA2249 Abnormality 2 ENG E03 Electrical system
pump
CA2555 Intake air heater relay voltage Too low ENG E01 Electrical system
CA2556 Intake air heater relay voltage Too high ENG E01 Electrical system
DAF9KM Machine monitor connector MON E03 Electrical system
setting
CAN communication
DAFRKR Communication disabled MON E03 Electrical system
(machine monitor)
DAQ0KK Transmission controller Power supply voltage too low TM E03 Electrical system
Transmission controller non
DAQ0KT Abnormality in controller TM E01 Electrical system
volatile memory
Transmission controller solenoid
DAQ2KK Power supply voltage too low TM E03 Electrical system
power supply
DAQ9KQ Transmission controller Inconsistent model selection MON E03 Electrical system
COMMUNICATION LOST
DAQRKR Communication disabled MON E03 Electrical system
(transmission controller)
Transmission controller option
DAQRMA Malfunction MON E03 Electrical system
setting
Retarder controller non volatile
DB10KT Abnormality in controller BK E01 Electrical system
memory
Retarder controller solenoid
DB12KK Power supply voltage too low BK E03 Electrical system
power supply
Retarder controller direct battery
DB13KK Power supply voltage too low BK E03 Electrical system
power supply
Retarder controller model Inconsistent model selection
DB19KQ MON E03 Electrical system
selection signal signal
DB1QMA Retarder controller option setting Malfunction MON E03 Electrical system
CAN communication disabled
DB1RKR Communication disabled TM E03 Electrical system
(retarder controller)
CAN communication disabled
DB2RKR Communication disabled TM E03 Electrical system
(engine controller)
HM300-2R 21

DDTHKA Fill switch for Hi clutch Disconnection TM E03 Electrical system
DDTJKA Fill switch for Lo clutch Disconnection TM E03 Electrical system
DDTKKA Fill switch for 1st clutch Disconnection TM E03 Electrical system
DDTLKA Fill switch for 2nd clutch Disconnection TM E03 Electrical system
DDTMKA Fill switch for 3rd clutch Disconnection TM E03 Electrical system
DDTNKA Fill switch for R clutch Disconnection TM E03 Electrical system
DF10KA Gear shift lever Disconnection TM E03 Electrical system
DF10KB Gear shift lever Short-circuiting TM E03 Electrical system
Transmission oil temperature
DGF1KX Input signal out of range TM E03 Electrical system
sensor
Center brake oil temperature
DGR3KZ Disconnection or short circuit MON E01 Electrical system
sensor
Center brake oil temperature
DGR3L8 Inconsistent analog signal MON E01 Electrical system
sensor
Front brake oil temperature
DGR4KZ Disconnection or short circuit MON E01 Electrical system
sensor
Front brake oil temperature
DGR4L8 Inconsistent analog signal MON E01 Electrical system
sensor
DGR6KX Steering oil temperature sensor Input signal out of range TM E01 Electrical system
Torque converter oil temperature
DGT1KX Input signal out of range TM E01 Electrical system
sensor
Torque converter intermediate
DHT5KX Input signal out of range TM E01 Electrical system
pressure sensor
Torque converter oil pressure Inconsistent signals during a
DHT5L6 TM E01 Electrical system
sensor travel and stop
Front accumulator oil pressure
DHU2KX Input signal out of range BK E01 Electrical system
sensor
Rear accumulator oil pressure
DHU3KX Input signal out of range BK E01 Electrical system
sensor
DJF1KA Fuel level sensor system Disconnection MON E01 Electrical system
Inconsistent signals of
DK51L5 Retarder lever potentiometer BK E03 Electrical system
potentiometer and switch
DK52KX Hoist lever potentiometer failure 1 Input signal out of range TM E03 Electrical system
DK53L8 Hoist lever potentiometer failure 2 Input signal out of range TM E03 Electrical system
DK54KX Body positioner sensor Input signal out of range TM E03 Electrical system
DKH0KX Pitch angle sensor Input signal out of range TM E01 Electrical system
Transmission input shaft speed
DLF1KA Disconnection TM E03 Electrical system
sensor
Transmission input shaft speed
DLF1LC Inconsistent speed signal TM E03 Electrical system
sensor
Transmission intermediate shaft
DLF2KA Disconnection TM E03 Electrical system
speed sensor
Transmission intermediate shaft
DLF2LC Inconsistent speed signal TM E03 Electrical system
speed sensor
DLF4KA Differential speed sensor Disconnection TM E01 Electrical system
Transmission output shaft speed
DLT3KA Disconnection TM E03 Electrical system
sensor
DV00KB Alarm buzzer output Short-circuiting TM E01 Electrical system
DW72KZ Kick out solenoid output system Disconnection or short circuit TM E01 Electrical system
22 HM300-2R

Hoist selector valve output
DW73KZ Disconnection or short circuit TM E03 Electrical system
system
Rear wheels BCV command
DW78KZ Disconnection or short circuit BK E01 Electrical system
output
Front wheels BCV command
DW79KZ Disconnection or short circuit BK E01 Electrical system
output
Rear wheels proportional Loss of control
DX11K4 BK E03 Electrical system
pressure reducing valve (stuck in operated condition)
Rear wheels proportional pres-
DX11KA Disconnection BK E03 Electrical system
sure reducing valve output circuit
DX11KB Short-circuiting BK E03 Electrical system
Rear wheels proportional pres- Short-circuiting to power source
DX11KY BK E03 Electrical system
sure reducing valve output circuit line
DX11MA Malfunction BK E03 Mechanical system
sure reducing valve
Front wheels proportional pres- Loss of control
DX12K4 BK E03 Electrical system
sure reducing valve output circuit (stuck in operated condition)
Front wheels proportional pres-
DX12KA Disconnection BK E03 Electrical system
DX12KB Short-circuiting BK E03 Electrical system
Front wheels proportional pres- Short-circuiting to power source
DX12KY BK E03 Electrical system
sure reducing valve output circuit line
DX12MA Malfunction BK E03 Electrical system
sure reducing valve
DX13KA Hoist EPC valve output circuit Disconnection TM E03 Electrical system
DX13KB Hoist EPC valve output circuit Short-circuiting TM E03 Electrical system
Short-circuiting to power source
DX13KY Hoist EPC valve output circuit TM E03 Electrical system
line
DXH0KA Disconnection TM E01 Electrical system
DXH0KB Short-circuiting TM E01 Electrical system
Inter axle differential lock Short circuit to power source
DXH0KY TM E03 Electrical system
pressure control valve line
Lock up clutch solenoid output
DXH1KA Disconnection TM E03 Electrical system
circuit
Lock up clutch solenoid output
DXH1KB Short-circuiting TM E03 Electrical system
circuit
Lock up clutch solenoid output Short circuit to power source
DXH1KY TM E03 Electrical system
circuit line
DXH2KA Hi clutch solenoid output circuit Disconnection TM E03 Electrical system
DXH2KB Hi clutch solenoid output circuit Short-circuiting TM E03 Electrical system
Short circuit to power source
DXH2KY Hi clutch solenoid output circuit TM E03 Electrical system
line
DXH3KA Lo clutch solenoid output circuit Disconnection TM E03 Electrical system
DXH3KB Lo clutch solenoid output circuit Short-circuiting TM E03 Electrical system
DXH3KY Lo clutch solenoid output circuit TM E03 Electrical system
line
HM300-2R 23

DXH4KA 1st clutch solenoid output circuit Disconnection TM E03 Electrical system
DXH4KB 1st clutch solenoid output circuit Short-circuiting TM E03 Electrical system
DXH4KY 1st clutch solenoid output circuit TM E03 Electrical system
line
DXH5KA 2nd clutch solenoid output circuit Disconnection TM E03 Electrical system
DXH5KB 2nd clutch solenoid output circuit Short-circuiting TM E03 Electrical system
DXH5KY 2nd clutch solenoid output circuit TM E03 Electrical system
line
DXH6KA 3rd clutch solenoid output circuit Disconnection TM E03 Electrical system
DXH6KB 3rd clutch solenoid output circuit Short-circuiting TM E03 Electrical system
DXH6KY 3rd clutch solenoid output circuit TM E03 Electrical system
line
DXH7KA R clutch solenoid output circuit Disconnection TM E03 Electrical system
DXH7KB R clutch solenoid output circuit Short-circuiting TM E03 Electrical system
DXH7KY R clutch solenoid output circuit TM E03 Electrical system
line
a Failure code with ( )

This failure code is not recorded in the failure history for both electrical system and mechanical system.
a About the failure code table
Failure code table is written in alphabetical order and also starting from small numbers.
Symbols of the controller in the failure code table is as indicated below, and it indicates in which control-
ler system the failure has occurred.
ENG: Engine controller system
TM: Transmission controller system
BK: Retarder controller system
MON: Machine monitor system
24 HM300-2R
6. Operation information display function (Stopped at the upper limit of

9999999.9)
Display of fuel consumption amount 2] Travel distance [km or mile] since the
last reset is displayed on the bottom
line.
(Stops at the upper limit of
9999999.9)
3] Press the [U] button to delete data
and return to the previous screen.
Press the [ t ] button to cancel data
deletion and return to the previous
screen.
1) Press the [U] button from the operation

information screen. Then the display
shows fuel consumption per km (mile).
1] Fuel consumption per 1km (mile) [L/
km or L/mile] since the last reset is
displayed on the top line.
a The calculation is made based on the
above fuel consumption amount and
travel distance.
a Either “km“ or “mile“ is selected in
accordance with the odometer. 3) If the [<] button is pressed on the accumu-
(Stopped at the upper limit of lated fuel consumption screen in step 2),
9999999.9.) another accumulated fuel consumption
2] Average fuel consumption [L/h] since screen is displayed.
the last reset is displayed on the bot- 1] Accumulated fuel consumption [L]
tom line. since the last reset is displayed on
(Stopped at the upper limit of the top line.
9999999.9) (Stops at the upper limit of
3] Press the [U] button to delete data 9999999.9)
and return to the previous screen. 2] Elapsed time since the last reset is
Press the [ t ] button to cancel data displayed on the bottom line.
deletion. (Stops at the upper limit of
9999999.9)
3] Press the [U] button to delete data
and return to the previous screen.
Press the [ t ] button to cancel data
deletion and return to the previous
screen.
2) If the [<] button is pressed on the fuel con-

sumption screen in step 1), the accumu-
lated fuel consumption screen is
displayed.
1] Accumulated fuel consumption [L]
since the last reset is displayed on
the top line.
HM300-2R 25
4) If the [<] button is pressed on the reset a Corrective action with machine moni-
screen in step 1) – 3), the fuel control tor
screen is displayed. q Default: 0.0%
(The current set value is displayed on the q Accumulated fuel consumption [L] is
bottom line.) corrected with this setting within the
1] If the [U] button is pressed, the gain range of [-50.0 – +50.0%].
compensation value setting screen is
displayed. On acquisition of fuel consumption [L]
2] Put the cursor at the sign (+ or -). 1) The machine monitor calculates accumu-
3] Every time the [>] or [<] button is lated fuel consumption [L] based on
pressed once with the cursor at the instantaneous fuel consumption [L/h]
sign position, the sigh changes ("+" which is acquired from the engine control-
"-"). ler.
4] If the sign is confirmed by the [U] but- 2) Accumulated fuel consumption [L] should
ton, the cursor moves to the most sig- be corrected with the fuel adjustment func-
nificant digit. tion (FUEL ADJUST) in the service mode.
5] Every time the [>] or [<] button is 3) Instantaneous fuel consumption [L/h]
pressed once with the cursor at the which is acquired from the engine control-
most significant digit, the displayed ler should be corrected according to the
number 0 – 9 increases or decreases following formula.
(0 through 2 in the most significant a Compensation value
digit). [Instantaneous fuel consumption
6] When the right number is input, press acquired from engine controller] x
the [U] button to confirm it. [compensation value (a)] = [1.0]
7] The cursor moves to the one digit
lower position. Implement the same Procedure for switching to service mode and
procedure as 5] to input a number. screen display
8] Input a number in the least significant a When using the service mode, change the
digit and press the [U] button. screen by the following special operation.
a When the figure has been con- 1) Checking screen display
firmed, the display returns to the Check that the machine monitor is in the
previous screen. operator mode and the screen is display-
9] If the [t] button is pressed while a ing either of “service meter and integrated
number is input, the cursor returns to odometer“, “action code“ or “failure code“.
the sign's position with the number 2) Displaying initial screen for ID input
unchanged. If the[t] button is Press the following 2 buttons at the same
pressed once again, the display time for at least 5 seconds to display the
returns to the previous screen. initial screen for ID input (Fig. 1).
10] If the figure is not in the range q [t] button and [<] button
between -50.0 and +50.0 when the a If the buttons are held pressed for at
least significant digit is confirmed, the least 5 seconds, the whole screen will
cursor returns to the sign's position give no display, so check this condi-
with the number unchanged just like tion, then release the buttons.
when the [t] button is pressed.
26 HM300-2R
3) Input and confirmation of ID 5) Menu selection in service mode

Operate the buttons to input the ID (Fig. Press the [>] button or [<] button on the
2). menu screen and the menus of the ser-
a ID: 6491 vice mode are displayed endlessly in the
q [>] button: Number at cursor goes up following order (Fig. 4).
q [<] button: a The menu is displayed in the
Number at cursor goes down places marked with [*].
q [U] button: q [>] button: Goes on to next menu
Number at cursor is confirmed q [<] button: Goes back to previous
q [t] button: menu
Returns to initial screen (See Note) [1] ELECTRIC FAULT:
Note: When the cursor is at the left side, Electrical system failure history
the screen returns to the normal display function
screen (operator mode). [2] MACHINE FAULT:
If the cursor is not at the left side, Mechanical system failure history
the cursor returns to the left side. display function
a If the buttons are not operated on the [3] REAL-TIME MONITOR:
ID input screen for more than 60 sec- Vehicle data monitoring function
onds, the display returns automati- [4] CYLINDER CUT-OUT:
cally to the normal screen. Reduced cylinder mode
[5] TUNING: Adjustment function
[6] MAINTENANCE MONITOR:
Filter and oil replacement time
setting function
[7] INITIALIZE:
Initialize function (exclusive func-
tion for factory)
4) Displaying menu initial screen

After confirming all 4 digits of the ID, the
menu initial screen of the service mode is
displayed (Fig. 3).
a Once the ID has been input and con-
firmed, it remains effective until the
starting switch is turned OFF.
6) Completion of mode, function
When operating at any point in any func-
tion, it is possible to finish the mode or
function by using any of the following
methods.
1] When continuing operations in another
mode or function:
Press the [t] button and return to the
mode screen to be used or menu
screen to be used.
a Note that if the [t] button is
pressed on the YES/NO screen,
the function will be executed.
HM300-2R 27
a If you return to the normal screen 3) Displayed failure history data

(operator mode) by mistake, With the electrical system failure history
repeat the procedure from step display function, the following data can be
1) above (there is no need to displayed (Fig. 3).
input the ID again). 1. Record number (recorded up to a
2] When completing all operations: maximum of 20 items)
Turn the starting switch OFF. A: Failure code (4-digit location code +
2-digit symptom code)
7. Electrical system failure history display func- 2. Number of occurrences (number of
tion (ELECTRIC FAULT) occurrences of same code in the
The machine monitor retains the data for prob- past)
lems that occurred in the electrical system in 3. Elapsed time 1 (time elapsed on ser-
the past as failure codes. They can be dis- vice meter since first occurrence)
played as follows. 4. Elapsed time 2 (time elapsed on ser-
1) Menu selection vice meter since last occurrence)
Select the electrical system failure history a Failure codes for problems that are
display function on the menu screen of the still existing are shown on a flashing
service mode (Fig. 1). display.
a The total number of failure history a For details of the failure codes dis-
data items recorded in memory is displayed, see “Failure code table“ in
played in the [* *] portion. failure code display function.
a Note that with the failure history dis-
play function and failure code display
function for the electrical system, the
displayed data are partially different.
a If no trouble data are recorded, [0] is
displayed on the display portion for 1,
and [–] is displayed on the display
portion for A, 2, 3 and 4.
2) Failure history data display

With the menu selected, press the [ U ]
button and display the failure history data
recorded in memory (Fig. 2: example).
q [U] button: Runs menu
4) Switching failure history display

If the [>] button or [<] button is pressed
during the display of failure history, the
display switches to another failure history
data recorded.
q [>] button: Goes on to data for next
record number
q [<] button: Goes back to data for pre-
vious record number
28 HM300-2R
5) Deleting individual failure history data 3] Operate the buttons according to the
1] Display the failure history data to be explanation on the screen (Fig. 6).
deleted, then press the [ U ] button q [<] button: Selects YES
once to display the individual item q [>] button: Select NO
CLEAR screen (Fig. 4). q [t] button: Run
q [U] button: a The data for an existing problem
Display CLEAR screen (flas hing display) cannot be
2] Operate the buttons according to the deleted.
explanation on the screen (Fig. 4).
q [<] button: Selects YES
q [>] button: Select NO
q [t] button: Run
a The data for an existing problem
(flashing display) cannot be
deleted.
8. Mechanical system failure history display

function (MACHINE FAULT)
The machine monitor retains the data for prob-
lems that occurred in the mechanical system in
the past as failure codes. They can be dis-
played as follows.
1) Menu selection
Select the mechanical system failure his-
6) Deleting all failure history data tory display function on the menu screen
1] Display the failure history, then press of the service mode (Fig. 1).
the [>] button or [<] button to display a The total number of failure history
the ALL CLEAR menu screen (Fig. 5). data items recorded in memory is dis-
2] Press the [U] button once to display played in the [* *] portion.
the ALL CLEAR screen (Fig. 6).
q [U] button:
Runs ALL CLEAR menu
2) Failure history data display

button and display the failure history data
recorded in memory (Fig. 2: example).
HM300-2R 29
4) Switching failure history display

If the [>] button or [<] button is pressed
during the display of failure history, the
display switches to another failure history
data recorded.
q [>] button: Goes on to data for next
record number
q [<] button: Goes back to data for pre-
vious record number
5) Deleting failure history data (not permit-
ted)
a The failure history data for the
mechanical system cannot be
deleted.
3) Displayed failure history data
With the mechanical system failure history
9. Real-time monitoring function
display function, the following data can be
(REAL-TIME MONITOR)
displayed (Fig. 3).
The machine monitor can monitor the condition
1. Record number
of the machine in real time through the signals
A: Failure code (4-digit location code +
from the sensors installed to various parts of
2-digit symptom code)
the machine.
2. Number of occurrences (number of
In the real-time monitoring function, the follow-
occurrences of same code in the
ing 2 types of display can be shown.
past)
q 1 item independent display (for each con-
3. Elapsed time 1 (time elapsed on ser-
troller)
vice meter since first occurrence)
q 2 items simultaneous display (code input)
4. Elapsed time 2 (time elapsed on ser-
vice meter since last occurrence) 1) Menu selection
a Failure codes for problems that are Select the real-time monitoring function on
still existing are shown on a flashing the menu screen of the service mode (Fig.
display. 1).
a For details of the failure codes dis-
played, see “Failure code table“ in
failure code display function.
a Note that with the failure history dis-
play function and failure code display
function for the mechanical system,
the displayed data are partially differ-
ent.
a If no trouble data are recorded, [0] is
displayed on the display portion for 1,
and [–] is displayed on the display
portion for A, 2, 3 and 4.
2) Displaying sub menu

button and display the initial screen of the
sub menu (Fig. 2).
30 HM300-2R
3) Selecting sub menu 3] Press the [>] button or [<] button to

If the [>] button or [<] button is pressed on select the item to be monitored (Fig.
the sub menu screen, the sub menu dis- 5: example).
plays endlessly in the following order (Fig. q [>] button: Goes on to next item
3). q [<] button:
a The sub menus are displayed in the Goes back to previous item
[*] portion. a The monitored items are scroll-
q [>] button: Goes on to next menu displayed in the internally set
q [<] button: order.
Goes back to previous menu a If the button is kept pressed, the
[1] MONITOR PANEL: items scroll at high speed.
Machine monitor system a To hold or cancel monitoring data:
[2] TRANSMISSION: If the [U] button is pressed during
Transmission controller system monitoring, the monitor data is held
[3] ENGINE: and the [U] mark flashes. If the [U ]
Engine controller system button is pressed again, it becomes
[4] BRAKE: active again.
Retarder controller system
[5] 2ITEMS: 2-item display
5) Display data for 1 item individual monitor-

ing
4) Setting 1 item individual monitoring O n the 1 item indi vidual monitori ng
1] Select the controller system to be screen, the following data are displayed
monitored on the sub menu screen (Fig. 6).
(Fig. 4: example). A: Item display
2] With the sub menu selected, press B: Monitoring code (5-digit)
the [U] button and display the moni- 1: Monitoring data (including unit)
toring data initial screen. a For details, see “Monitoring code
q [U] button: Runs sub menu table“.
HM300-2R 31
4] When both of the monitoring codes

have been confirmed, the screen
switches to the 2 items display screen
(Fig. 9: example).
a To hold or cancel monitoring
data:
If the [U] button is pressed dur-
ing monitoring, the monitor data
is held and the [U] mark flashes.
If th e [ U ] b utt on i s pr e ss e d
again, it becomes active again.
6) Setting 2 items simultaneous monitoring

1] Select the 2 items display on the sub
menu screen (Fig. 6).
2] With the sub menu selected, press
the [U] button and display the moni-
toring code input screen (Fig. 7).
q [U] button: Runs sub menu
7) Display data for 2 items simultaneous

monitoring
On the 2 items simultaneous monitoring
screen, the following data are displayed
(Fig. 10).
A: Monitoring code 1
1: Monitoring data 1 (including unit)
B: Monitoring code 2
2: Monitoring data 2 (including unit)
a For details, see “Monitoring code
3] Operate each button and input the table“.
monitoring codes for the 2 monitoring
items directly.
q [>] button:
Number at cursor goes up
q [<] button:
q [U] button:
q [t] button:
Returns to code input screen
32 HM300-2R
Monitoring code table

MACHINE MONITOR [Machine monitor system]
Monitoring
No. Monitored item Item display Display range Unit
code
1 Engine speed END SPEED 01001 0 – 65535 rpm
Resistance of fuel level
2 FUEL SENSOR 04201 0 – 150 z
sensor
3 Voltage of fuel level sensor FUEL SENSOR 04200 0.00 – 5.00 V
4 Brake oil temperature, F BRAKE OIL TF 30201 0 – 160 °C
Voltage of brake oil
5 BRAKE OIL TF 30204 0.00 – 5.00 V
temperature sensor, F
6 Brake oil temperature, M BRAKE OIL TM 30203 0 – 160 °C
Voltage of brake oil
7 BRAKE OIL TM 30206 0.00 – 5.00 V
temperature sensor, M
8 Input voltage of rheostat RHEOSTAT 30300 0.00 – 5.00 V
Setting status of rotary
Status
9 switch SW1, SW2, SW3 30800 ON/OFF
display
(SW & SW2 & SW2)
Setting status of dip switch ON/OFF, Status
10 SW5-1 & SW5-2 30900
(SW5-1 & SW5-2) ON/OFF display
Setting status of dip switch 0 – F, 0 – 0 – F, Status
11 SW5-3 & SW5-4 30901
(SW5-3 & SW5-4) 0 display
12 SW6-1 & SW6-2 30902
13 SW6-3 & SW6-4 30903
10000000 (headlamp = on)
01000000 (sw = on)
00100000 (AISS SW = on)
00000000 (not in use) Status
14 Input signal D_IN _0-7 40900
00000000 (not in use) display
00000100 (sw = on)
00000010 (sw = on)
00000001 (sw = economy)
10000000 (always 1)
00000000 (monitor mode SW (t) = on
00100000 (monitor mode SW (>) = on
00010000 (monitor mode SW (<) = on Status
15 Input signal D_IN_8-15 40901
00001000 (right turning lamp = on) display
00000100 (left turning lamp = on)
00000010 (monitor mode SW (U U) = on
00000000 (not in use)
00000000 (not in use)
01000000 (filter normal = 1)
00100000 (filter normal = 1)
00010000 (filter normal = 1) Status
00001000 (oil level normal = 1) display
00000000 (not in use)
00000010 (coolant level normal = 1)
00000000 (not in use)
HM300-2R 33
MACHINE MONITOR [Machine monitor system]

Monitoring
code
10000000 (headlamp = on)
01000000 (seat belt = fastened)
00100000 (sw = on)
00001000 (sw = up) display
00000000 (not in use)
00000010 (sw = down)
00000001 (sw = down)
00000000 (not in use)
00000000 (not in use)
00000000 (always 0)
00000000 (not in use)
Status
18 Input signal D_IN_32-39 00000000 (not in use) 40904
display
00000000 (not in use)
00000000 (not in use)
00000000 (reserved for service OP7 =
open)
1000 (buzzer = on)
19 Input signal D_OUT_0-3 40925
0000 (not in use) display
0000 (not in use)
Status
20 Application version VERSION (APP) 20221 Numeral
display
Status
21 Data version VERSION (DATA) 20222 Numeral
display
Status
22 Software product number VERSION 20200 Numeral
display
34 HM300-2R
TRANSMISSION [Transmission controller system]

Monitoring
code
Transmission input shaft
1 T/M SPEED: IN 31200 0 – 32767 rpm
speed
Transmission intermediate T/M SPEED:
2 31300 0 – 32767 rpm
shaft speed MID
Transmission output shaft T/M SPEED:
3 31400 0 – 32767 rpm
speed OUT
Transmission differential Status
4 T/M DIFF: OUT 31402 0 – 65535
speed display
5 Alternator terminal R ALTERNATOR R 04301 ON [1 actuated] OFF [0] °C
Torque converter oil tempera-
6 T/C OIL TEMP 30100 0 – 160 V
ture
Input voltage of torque con-
7 T/C OIL TEMP 30101 0.00 – 5.00 °C
verter oil temperature sensor
8 Transmission oil temperature T/M OIL TEMP 32500 0 – 160 V
Input voltage of transmission
9 T/M OIL TEMP 32501 0.00 – 5.00 °C
oil temperature sensor
STRG OIL
10 Steering oil temperature 32701 0 – 160 V
TEMP
Input voltage of steering oil STRG OIL
11 32702 0.00 – 5.00 MPa
temperature sensor TEMP
12 Torque converter oil pressure T/C OIL PRESS 32600 0.00 – 5.00 V
Input voltage of torque con- Status
13 T/C OIL PRESS 32605 0.00 – 5.00
verter oil pressure sensor display
State of fill switch recognized for each
14 Clutch fill switch FILL HLR 1 2 3 38922 mA
clutch is outputted
Output command current for
15 ECMV H DIR 31600 0 – 1000 mA
Hi clutch solenoid
16 ECMV L DIR 31601 0 – 1000 mA
Lo clutch solenoid
17 ECMV 1 DIR 31602 0 – 1000 mA
1st clutch solenoid
18 ECMV 2 DIR 31603 0 – 1000 mA
2nd clutch solenoid
19 ECMV 3 DIR 31604 0 – 1000 mA
3rd clutch solenoid
20 ECMV R DIR 31606 0 – 1000 mA
R clutch solenoid
21 ECMV LU DIR 31609 0-1000 mA
lock-up clutch solenoid
22 transmission clutch differential ECMV D DIR 31607 0 – 1000 mA
lock solenoid
ANGLE
23 Pitch angle sensor 32900 -180 – +180 deg.
SENSOR
Input voltage of pitch angle ANGLE
24 32902 0.00 – 5.00 V
sensor SENSOR
Brake output current
25 BK OUTP DIR F 33807 0 – 1000 mA
(front wheel)
Brake output current
26 BK OUTP DIR R 33806 0 – 1000 mA
(rear wheel)
HM300-2R 35

Monitoring
code
THROTTLE
27 Throttle correction value 36000 -100 – 100 %
MOD
Input voltage of body
28 BODY POSITON 34603 0.00 – 5.00 V
positioner
29 Dump (hoist) lever position 1 DUMP LEVER 1 34506 0.00 – 5.00 V
30 Dump (hoist) lever position 2 DUMP LEVER 2 34507 0.00 – 5.00 V
Status
31 Body seating BODY SEATNG 34600 ON [1 seated] OFF [0]
display
Seating control command
32 S CNT DIR H 45100 0 – 1000 mA
(Hi)
Seating control command
33 S CNT DIR H 45101 0 – 1000 mA
(Lo)
Libration value in seated con-
34 S CAL A 45200 0.00 – 5.00 V
dition ( )
Cylinder stopper calibration
35 S CAL B 45300 0.00 – 5.00 V
value ( )
36 Seating control time (Hi) S CNT TIME H 45400 0.00 – 10.00 S
37 Hoist EPC output HOIT EPC RIR 45601 0 – 1000 mA
38 Seating control time (Lo) S CNT TIME L 45401 0.00 – 10.00 S
Lo clutch trigger compensa- TRIGGER Lo clutch trigger compensation value is Status
39 38900
tion value MOOD L displayed. display
Hi clutch trigger compensa- TRIGGER Hi clutch trigger compensation value is Status
40 38901
tion value MOOD H displayed display
1st clutch trigger compensa- TRIGGER 1st clutch trigger compensation value is Status
41 38902
tion value MOOD 1 displayed display
2nd clutch trigger compensa- TRIGGER 2nd clutch trigger compensation value is Status
42 38903
3rd clutch trigger compensa- TRIGGER 3rd clutch trigger compensation value is Status
43 38904
R clutch trigger compensa- TRIGGER R clutch trigger compensation value is Status
44 38906
tion value MOOD R displayed display
ON/OFF status of corresponding clutch is Status
45 Trigger initial learning flag TRIG HLR 1 2 3 38922
displayed with 1 or 0 display
46 Lo clutch fill time FIR TIME L 41800 0 – 2550 ms
47 Hi clutch fill time FIR TIME H 41801 0 – 2550 ms
48 1st clutch fill time FIR TIME 1 41802 0 – 2550 ms
49 2nd clutch fill time FIR TIME 2 41803 0 – 2550 ms
50 3rd clutch fill time FIR TIME 3 41804 0 – 2550 ms
51 R clutch fill time FIR TIME R 41806 0 – 2550 ms
THROT LIMIT
52 Throttle lower limit output 44201 0.0 – 100.0 %
LO
THROT LIMIT
53 Throttle upper limit output 44200 0.0 – 100.0 %
HI
36 HM300-2R

Monitoring
code
**0*****: Emergency steering is not actu-
ated (HM400)
Always 0 (HM300, HM350)
**1*****: Emergency steering is actuated
(HM400)
****1***: In cranking Status
54 Input signal D_IN_0-7 D-IN-0------7 40905
*****0**: Emergency steering is not actu- display
ated
*****1**: Emergency steering is actuated
******0*: Shift hold SW=OFF
******1*: Shift hold SW=ON
*******1: Gear shift lever N
*1******: L fill
**1*****: H fill
***1****: 1st fill
*****1**: 2nd fill
*****1**: 3rd fill
Status
55 Input signal D_IN_8-15 D-IN-8-----15 40906
display
Example
01010000: at F1
00001010: at R2
00000000: at N
00100100: at F6
10000000: Gear shift lever R2
01000000: Gear shift lever R1
00100000: Gear shift lever D
00010000: Gear shift lever 5 Status
00001000: Gear shift lever 4 display
00000100: Gear shift lever 3
0*******: TM oil filter is clogged
Status
57 Input signal D_IN_24-31 D-IN-24-----31 40908 ****0***: Engine oil level is falling
display
*****0**: Engine oil filter is clogged
*1**0*00: Hoist selector valve ON
Status
58 Input signal D_OUT_0-7 D-OUT-0------7 40949 ****0100: Hoist lever kick-out
display
ON
VERSION Status
59 Application version 20223 Numeral
(APP) display
VERSION Status
60 Data version 20224 Numeral
(DATA) display
Status
display
HM300-2R 37
BRAKE [Retarder controller system]

Monitoring
code
Status
1 Alternator R ALTERNATOR R 04302 ON [1 actuated] OFF [0]
display
2 Front ACC oil pressure ACC OIL PRE F 35500 0.00 – 99.99 MPa
Voltage of front ACC oil pres-
3 ACC OIL PRE F 35506 0.00 – 5.00 V
sure sensor
4 Rear ACC oil pressure ACC OIL PRE R 35501 0.00 – 99.99 MPa
Voltage of rear ACC oil pres-
5 ACC OIL PRE R 35507 0.00 – 5.00 V
sure sensor
Front wheel brake output cur-
6 BK OUTP DIR F 33807 0 – 1000 mA
rent
Rear wheel brake output cur-
7 BK OUTP DIR R 33806 0 – 1000 mA
rent
RETARD
8 Input voltage of retarder lever 33900 0.00 – 5.00 V
LEVER
10000000: (Not in use)
01000000: Brake pedal switch (ON: 1)
00100000: Front retarder switch (ON: 1)
00010000: Rear retarder switch (ON: 1)
00001000: Idle validation switch 1 Status
9 Input signal D_IN_0-7 D-IN--0------7 40932
(ON: 1) display
00000100: Idle validation switch 2
(ON: 1)
00000010: (Not in use)
00000001: (Not in use)
10000000: Front differential oil pressure
switch (ON: 1)
01000000: Rear differential oil pressure
switch (ON: 1)
00100000: (Not in use) Status
10 Input signal D_IN_8-15 D-IN--8-----15 40933
00010000: (Not in use) display
00001000: Parking brake switch (ON: 1)
00000100: (Not in use)
00000010: (Not in use)
00000001: (Not in use)
10000000: Starting switch C terminal sig-
nal (when engine start: 1)
01000000: (Not in use)
00100000: (Not in use)
Status
11 Input signal D_IN_16-23 D-IN-16-----23 40934 00010000: (Not in use)
display
00001000: (Not in use)
00000100: (Not in use)
00000010: (Not in use)
00000001: (Not in use)
10000000: (Not in use)
01000000: (Not in use)
00100000: (Not in use)
00000100: (Not in use)
00000010: (Not in use)
00000001: (Not in use)
38 HM300-2R
BRAKE [Retarder controller system]

Monitoring
code
10000000: (Not in use)
01000000: (Not in use)
00100000: (Not in use)
13 Input signal D_IN_32 D-IN-32-----39 40943
00000100: (Not in use)
00000010: (Not in use)
00000001: (Not in use)
10000000: Left and right differential out-
put (front) (when operating: 1)
01000000: Left and right differential out-
put (rear) (when operating: 1)
00100000: BVC output (front) (when
operating: 1) Status
14 Input signal D_OUT_0-7 D-OUT-0------7 40955
00010000: BVC output (rear) (when display
operating: 1)
00001000: (Not in use)
00000100: (Not in use)
00000010: (Not in use)
00000001: (Not in use)
10000000: (Not in use)
01000000: (Not in use)
00100000: (Not in use)
15 Input signal D_OUT_8-15 D-OUT-8-----15 40956
00000100: (Not in use)
00000010: (Not in use)
00000001: (Not in use)
10000000: (Not in use)
01000000: (Not in use)
00100000: (Not in use)
16 Input signal D_OUT_16-23 D-OUT-16----23 40957
00000100: (Not in use)
00000010: (Not in use)
00000001: (Not in use)
VERSION Status
17 Application version 20231 Numeral
(APP) display
VERSION Status
18 Data version 20232 Numeral
(DATA) display
Status
display
HM300-2R 39
ENGINE [Engine controller system]

Monitoring
code
1 Battery voltage POWER SUPPLY 3200 0.0 – 480 V
2 Engine speed ENG SPEED 1002 0 – 4000 rpm
3 Coolant temperature COOLANT TEMP 4104 -40 – 210 °C
4 Voltage of coolant temperature sensor COOLANT TEMP 4105 0.00 – 5.00 V
5 Engine oil pressure ENG OIL PRESS 37200 -99.9 – 999.9 kPa
6 Voltage of engine oil pressure sensor ENG OIL PRESS 37201 0.00 – 5.00 V
7 Engine oil temperature ENG OIL TEMP 42700 -40 – 210 °C
8 Voltage of engine oil temperature sensor ENG OIL TEMP 42702 0.00 – 5.00 V
9 Common rail pressure RAIL PRESS 36400 0 – 400 MPa
10 Voltage of common rail pressure sensor RAIL PRESS 36401 0.00 – 5.00 V
11 Atmospheric pressure AMBIENT PRESS 37400 -99.9 – 999.9 kPa
12 Voltage of atmospheric pressure sensor AMBIENT PRESS 37401 0.00 – 5.00 V
13 Intake air temperature INTAKE TEMP 18400 -50 – 200 °C
14 Voltage of intake air temperature sensor INTAKE TEMP 18401 0.00 – 5.00 V
15 Fuel temperature FUEL TEMP 04204 -40 – 210 °C
16 Voltage of fuel temperature sensor FUEL TEMP 04205 0.00 – 5.00 V
17 Boost temperature CHG TEMP 18500 -50 – 200 °C
18 Input voltage of boost temperature sensor CHG TEMP 18501 0.00 – 5.00 V
19 Boost pressure CHG PRESS-A 36500 -99.9 – 999.9 kPa
20 Input voltage of boost pressure sensor CHG PRESS-A 36501 0.00 – 5.00 V
21 Engine output torque OUTPUT TORQUE 18700 -24000 – 24000 Nm
22 Approximate torque TORQUE RATIO 36700 0 – 100 %
23 Final accelerator opening angle FINAL THROTTLE 31706 0 – 100 %
24 Instantaneous fuel consumption FUEL RATE 37300 0.0 – 999.9 L/H
Command for final injection amount
25 INJECT COMMAND 18600 0 – 1000 mg
(unit of weight)
26 Final injection timing INJECT TIMING 36300 -180 – 180 CA
27 Accelerator pedal opening angle THROTTLE POS 31701 0 – 100 %
28 Voltage of accelerator pedal sensor THROTTLE POS 31702 0.00 – 5.00 V
Status
29 Idle validation signal 1 IVS 1 18300 ON/OFF
display
Status
30 Idle validation signal 2 IVS 2 18301 ON/OFF
display
31 Controller inside temperature ECM IN TEMP 18900 -40 – 210 °C
Command for final common rail pressure
32 PRESS COMMAND 36200 0 – 400 MPa
PFM
33 PCV valve closing timing (from BTDC) PCV TIMING 17201 -180 – 180 CA
Status
34 Engine mode selection POWER MODE 17500 0–4
display
Upper 8 digits of Status
35 Selected model name (upper 8 digits) MACHINE ID (H) 00400
16 characters display
Lower 8 digits of Status
36 Selected model name (lower 8 digits) MACHINE ID (L) 00401
16 characters display
Numeral Status
37 BUILD version BUILD VER 20216
(8 characters) display
40 HM300-2R
ENGINE [Engine controller system]

Monitoring
code
Numeral Status
38 Calibration version CAL VER 20217
(8 characters) display
Status
39 Hardware S/N ECM S/N 20400 0 – 499999999
display
10. Reduced cylinder mode 2] With the menu selected, press the
(CYLINDER CUT-OUT) U ] button and display the cylinder
[U
As one method of troubleshooting for the selection screen (Fig. 2: example).
engine, the machine monitor has a reduced q U] button: Runs menu
[U
cylinder function that can set the desired cylin- a The cylinder No. and engine
der to the no injection condition. speed are displayed at the same
1) Starting engine time.
a Use this function while the engine is q A command for final injection
running, because a defective cylinder amount [mg] is displayed under
is determined depending on the the engine speed.
engine speed in the reduced cylinder
mode.
2) Menu selection
1] Select the reduced cylinder mode on
the menu screen of the service mode
(Fig. 1).
3) Setting cut-out cylinder

Operate each button to select the cylinder
to be cut out (Fig. 3: example).
q [>] button:
Selector cursor moves to the right.
q [<] button:
Selector cursor moves to the left.
q U] button: Cylinder is confirmed.
[U
q [t] button: Returns to menu screen
HM300-2R 41
a When the [U U] button is used to con-

firm the cut-out cylinder, communica-
tion is carried out between the
machine monitor and engine control-
ler. During this time, the cylinder No.
flashes. After completion of the com-
munication, the segment under the
cylinder No. becomes black to show
that the cylinder has been cut out.
a A single cylinder or multiple cylinders
can be cut out.
2] With the menu selected, press the

U] button and display the no injec-
[U
tion command screen, which is dis-
played until the cancel operation is
carried out.
4) Canceling cylinder cut-out

a Cancel the cylinder cut-out in the
same way as when setting the cut-out
(Fig. 4: example).
3] If the operation in step 1] is con-

ducted while the engine is running,
the following screen is displayed to
instruct to stop the engine.
a “STOP ENGINE“ flashes.
11. No injection cranking (NO INJECTION)

In order to crank without starting the engine,
the machine monitor has the function of no
injection cranking where the fuel injection for
all the cylinders is stopped.
a This setting must be done after stopping
the engine.
1) Menu selection
1] Select the no injection cranking mode
4] Canceling no injection cranking
on the menu screen of the service
a Operate the cancel button [t] for
mode.
cancellation.
42 HM300-2R
12. Filter and oil replacement time setting func- 3) Contents of filter and oil replacement time
tion (MAINTENANCE MONITOR) set item display
The machine monitor can set the maintenance If the maintenance items are selected, the
interval for filters and oil, which forms the basis following contents are displayed (Fig. 3).
for the filter and oil replacement time display. 1: Code (2 digits)
Also, it has the function to deactivate the set- A: Filter and oil replacement time set
ting. items
1) Menu selection 2: Remaining time to set replacement
Select the filter and oil replacement time time
setting function on the menu screen of the 3: Number of times of replacement up to
service mode (Fig. 1). present
2) Selecting filter and oil replacement time 4) Changing the interval

set items 1] With the set item selected, press the
1] With the menu selected, press the U ] button and display the interval
[U
U ] button and display the initial
[U input screen (Fig. 4: example).
screen of the set item (Fig. 2). q U] button:
[U
q U] button: Runs menu
[U Executes change function
2] Press the [>] button or [<] button to a The presently set interval is dis-
select the item to be set. played on the screen.
q [>] button: Goes on to next item
q [<] button:
Goes back to previous item
a The set items are displayed end-
lessly in the internal set order (for
details, see “Table of filter and oil
replacement time set items“.)
2] Operate the buttons to input the inter-

val (Fig. 4).
q [>] button:
Number at cursor goes up
q [<] button:
q U] button:
[U
q [t] button:
Returns to item selection screen
HM300-2R 43
a The time must always be input 5] Select YES/NO using the [<] and [>]
with 4 digits. For numbers of less buttons.
than 4 digits, input 0s at the The cursor (_) flashes at the selected
beginning. side, and by pressing the [t] button,
3] When all the interval times are con- the setting is executed in the case of
firmed, the change confirmation YES, or canceled in the case of NO.
screen is displayed, so operate the Then the display returns to the main-
buttons according to the screen dis- tenance item selection screen.
play (Fig. 5). a The cursor initially shows NO
q [<] button: Selects YES (not change) in order to prevent
q [>] button: Select NO reset by mistake.
q [t] button: Run 6] Set activation or deactivation of the
timer by each maintenance item.
6) Default value setting
1] Select YES or NO using the [<] and
[>] buttons on the above screen.
2] The cursor (_) flashes at the selected
side, and by pressing the [t] button,
the setting is executed in the case of
YES, or canceled in the case of NO.
Then the display returns to the main-
tenance monitor selection screen.
a The cursor initially shows NO
(not change) in order to prevent
reset by mistake.
5) Selecting deactivation/activation of timer
by each item
1] If the timer “by item“ is in the activated
condition, “(ON o OFF)“ is displayed
on the bottom line.
2] If the timer “by item“ is in the deacti-
vated condition, “(OFF o ON)“ is dis-
played on the bottom line.
3] Default is “(ON)“, where the timer
function is activated.
3] When default value setting is exe-

cuted
Targeted for all the items regardless
individual activation or deactivation
settings, the interval times which
have been changed, if any, are reset
to the default values.
a The timer remaining time is to be
[Default value – Elapsed time since
last replacement].
However, the number of resets is kept
4] When the [U U] button is pressed, intact with no incrementation.
“(OFF)“ is displayed on the top line if (The individual setting of activation
the timer “by item“ is set to be deacti- and deactivation is set to “activated“.)
vated, and “(ON)“ is displayed on the
top line if the timer “by item“is set to
be activated.
44 HM300-2R
7) Selecting deactivation or activation of 4] Select YES or NO with the [<] and [>]
timer for all items buttons.
1] Press the [U U] button on the screen The cursor (_) flashes at the selected
for selecting deactivation or activation side.
of the timer for all the items, and the a The cursor initially shows NO (not
display changes to the “timer deacti- change) in order to prevent reset by
vation for all the items“ screen. mistake.
a When activation for all items is exe-
cuted
When the [t] button is pressed, the
remaining interval times for all the
items become invalid regardless of
individual activation or deactivation
settings.The timer remaining time for
each item is reset to the initial interval
time.
However, the number of resets is kept
intact with no incrementation, and the
display returns to the maintenance
screen.
(The individual setting for each item is
2] If the deactivation for all the items is also set to “activated“.)
to be selected, press the [U U] button a When cancelled
on the screen in step 1] to display the The operation is cancelled and the
following screen, and select YES with display returns to the maintenance
the [>] and [<] buttons. monitor selection screen.
a When deactivation for all items is exe-

cuted
If the [t] button is pressed, the timer
function for all the items is deacti-
vated, and the display returns to the
maintenance monitor selection
screen.
The individual setting for each item is
also set to “deactivated“.
a When cancelled
The operation is cancelled and the
display returns to the maintenance
monitor selection screen.
3] If the activation for all the items is to
be selected, select the "all items ON"
screen with the [>] and [<] buttons
from the screen in step 1], and con-
U] button.
firm it with the [U
HM300-2R 45
Table of filter and oil replacement time set items

Replacement
No. Check item Code Display
time
1 Fuel pre-filter 41 P FUEL FILT 500
2 Engine oil 01 ENG OIL 500
3 Engine oil filter 02 ENG FILT 500
4 Transmission oil 12 TM OIL 1000
5 Transmission oil filter 13 TM FILT 1000
6 Fuel filter 03 FUEL FILT 1000
7 Corrosion resistor 06 CORR RES 1000
8 Brake oil 17 BK OIL 1000
9 Brake oil filter 14 BK OIL FIL 1000
10 Brake cooling oil filter 16 BK C FIL 1000
11 Hydraulic oil filter 04 HYD FILT 2000
12 Differential case oil 11 DIFF OIL 2000
13 Final drive oil 08 FNL OIL 2000
14 Hydraulic oil 10 HYD OIL 4000
46 HM300-2R
How to start operation of

KOMTRAX terminal 1
When the machine is delivered, KOMTRAX ter-
minal is installed:
a When the machine is delivered, KOMTRAX
terminal is installed (machine with the standard
equipment), implement the following proce-
dure.
1. Notification of model, model number and

serial number
Notify the model, model number and serial
number of the machine to the KOMTRAX oper- 3) Disconnect the inspecting connector 1
ations administrator. and maintain that state for 5 seconds.
4) Turn the starting switch ON and maintain
2. Registration of machine that state for 5 seconds.
The KOMTRAX operations administrator regis- 5) Disconnect the inspecting connector 2
ters the machine using a KOMTRAX client per- and maintain that state for 5 seconds.
sonal computer. 6) Connect the inspecting connector 1 again
a See “KOMTRAX administrator manual“ for and maintain that state for 5 seconds.
the procedure.
7) Connect the inspecting connector 2 again
a Above completes the necessary opera-
and maintain that state for 5 seconds.
tions.
8) Make sure that the KOMTRAX terminal's
In the case where KOMTRAX terminal is retrofit- indicator lamps are normally turned on.
ted on machine after shipment:
a Implement the following procedure in the case
where the KOMTRAX terminal is retrofitted
after shipment of the machine (retrofitted
machine)
3. Sign-up test on machine side

a Referencing “Preparation work for trouble-
shooting of electrical system“, confirm the
position of KOMTRAX terminal and the
inspecting connector (the inspecting con-
ne c to r i s pr o v i de d a t t he b ot to m o f
KOMTRAX terminal).
a Finish the operations of steps 4) to 7)
within 30 seconds.
1) Turn OFF the starting switch and then, af-
ter making sure 5 seconds have elapsed,
proceed to the next step.
2) Check visually that test connectors 1 and
2 are connected.
q Test connector 1: CHK1
q Test connector 2: CHK2
HM300-2R 47
a Move on to the next step if you can a If [GPS position data detection trou-
check that the display is [normal]. ble and reception trouble] is indi-
a If the display is [abnormal], start from cated, check if there is any
procedure 1) again. abnormality on the GPS antenna/
cable or communication antenna/
cable. If there is any abnormality,
repair it and start from procedure 1)
again.
a If [Network trouble] is indicated,
check the display of [LED-C4] refer-
ring to “Lamp display of KOMTRAX
terminal“. If the CAN is not recog-
nized, check the CAN harness of the
KOMTRAX terminal, and then if there
is any abnormality, repair it and start
from procedure 1) again.
9) Set the starting switch to START position

and maintain it in that state for 5 seconds.
Make sure the engine is not started.
a If the engine is started, repeat the
procedure from step 1).
10) Return the starting switch to ON position
and maintain that state for 5 seconds.
a Don't return it to OFF position.
11) Set the starting switch to START position
ag a i n a n d m a k e s ur e t h e e n gi n e i s
started.
12) Make sure that the KOMTRAX terminal's
indicator lamps are normally turned on.
Note: Though the third number in the dis-
play is “3“ in the diagram, either “2“
or “3“ is displayed in actual cases
( b o th i n n or ma l an d a b no r m a l
cases).
a Move on to the next step if you can
check that the display is [normal]. (It
takes from 90 seconds to 15 minutes
before the display turns normal.)
a If [GPS position data detection trou-
ble] is indicated, check if there is any
abnormality on the appearance of the
GPS antenna cable. If there is any
abnormality, repair it and start from
procedure 1) again.
a If [Reception trouble] is indicated,
check if there is any abnormality on
the appearance of the communication
antenna or cable. If there is any
abnormality, repair it then repeat from
procedure 1).
48 HM300-2R
13) Turn the starting switch OFF. 4. Application for the start of use
14) After 10 seconds, check that the 7 seg- a Application for the start of use should be
ments indicator is displaying normally. made only after the sign-up test is fin-
a If you can check that the display is ished.
[normal], that is the end of sign-up 1) Notify to the KOMTRAX operations admin-
test. istrator the following information concern-
a If the display shows [abnormal], ing the machine whose sign-up test on the
r ep eat fr om p ro ce dur e 1) a gai n machine side is completed.
because the sign-up test has not (1) Information on the machine whose
been completed successfully. sign-up test on the machine side is
completed (model, model number
and serial number).
(2) Part number and serial number of the
KOMTRAX terminal
(3) Reading of the service meter when
the KOMTRAX terminal is installed
(0.1h unit)
2) The KOMTRAX operations administrator

registers the machine using a KOMTRAX
client personal computer.
a See “KOMTRAX administrator man-
ual“ for the procedure.
a Above completes the necessary oper-
ations.
HM300-2R 49
Lamp display of KOMTRAX terminal 1
L ED f o r c o m mu n i ca t i o n CPU LED 7 segments and dot for CPU

module 6. LED-C1 (R signal and 12. 7 segments (number of
1. LED-A1 (Power indicator ACC signal) mails not yet sent)
lamp) 7. LED-C2 (Starting output 13. Dot (GPS positioning sta-
2. LED-A2 (Within corre- status) tus)
sponding area lamp) 8. LED-C3 (S-NET and C
3. LED-A3 (During corre- signal status)
spondence lamp) 9. LED-C4 (CAN status)
4. LED-A4 (Internal trans- 10. LED-C5 (downloading
mission lamp) and writing status)
5. LED-A5 (Internal recep- 11. LED-C6 (downloading
tion lamp) and writing status)
50 HM300-2R
In the KOMTRAX system, various information and processing details are displayed on the LEDs on the
upper surface of the KOMTRAX terminal. Therefore, if a detect is suspected in the system, perform the fol-
lowing checks.
q Check of antennas
q Check of terminal LED displays
Application for the start of use and sign-up test on the machine side should be completed in advance in order
to use KOMTRAX system.
On the machines for which these procedures have not been completed yet, all the communication module
LEDs are off. This is not a defect.
Check of antennas
a Before checking the LED displays, check that there is no abnormality around the communication
antenna and GPS antenna.
q The communication antenna should not be off or damaged.
q The communication antenna cable should not be broken and normally be connected to the KOMTRAX
terminal.
q The GPS antenna should not be off or damaged.
q The GPS antenna cable should not be broken and normally be connected to the KOMTRAX terminal.
Check of terminal LED displays

1. Contents of communication module LED displays
a LED displays should be checked with the starting switch ON.
No. LED Name, Function Display Contents of display

Power indicator ON
1 LED-A1 The LED is on when the electric power is normally supplied.
lamp OFF
Within corre- ON
The LED is on when the machine is within the corresponding area of the
2 LED-A2 sponding area
OFF KOMTRAX system.
lamp
During correspon- ON The LED is on when the KOMTRAX terminal is connected to the KOMTRAX
3 LED-A3
dence lamp OFF server. (The connection should be made only when it is necessary.)
Internal transmis- ON The LED is on when the CPU transmits data to the communication module.
4 LED-A4
sion lamp OFF (Transmission should be made only when it is necessary.)
Internal reception ON The LED is on when the CPU receives data from the communication mod-
5 LED-A5
lamp OFF ule. (Reception should be made only when it is necessary.)
HM300-2R 51
2. Meaning of CPU LED displays

a The LED displays should be checked with the starting switch ON, starting switch START, or with the
engine started.
No. LED Name, Function Display Contents of display

ON Starting switch ACC signal: ON, alternator R signal: ON
Fast
Starting switch ACC sig- Starting switch ACC signal: OFF, alternator R signal: ON
blinking
6 LED-C1 nal status and alternator
R signal status Slow
Starting switch ACC signal: ON, alternator R signal: OFF
blinking
OFF Starting switch ACC signal: OFF, alternator R signal: OFF
Engine control signal ON Engine control signal: ON
7 LED-C2
status OFF Engine control signal: OFF
ON S-NET: connected, starting switch C signal: OFF
Fast
S-NET connection sta- Starting switch C signal: ON
blinking
8 LED-C3 tus and starting switch
C signal status Slow
(Not used)
blinking
OFF S-NET: unconnected, starting switch C signal: OFF
ON CAN: active (fuel sensor: no communication)
Fast
CAN: active (fuel sensor: in communication)
blinking
9 LED-C4 CAN connection status
Slow
CAN: inactive (fuel sensor: in communication)
blinking
OFF CAN: inactive (fuel sensor: no communication)
Either one Downloading and writing status
10 LED-C5
Downloading and writ- is ON (special function for system administrator)
ing status Both are
11 LED-C6 Normal operation mode
OFF
* Type and time of blinking

Fast blinking: blinking on an approximately 1 second cycle
Slow blinking: blinking on an approximately 4 seconds cycle
3. Contents of 7-segment and dot displays for CPU

a LED displays should be checked with the starting switch ON.
No. Display section Name, Function Display Contents of display

Number of mails
12 7 segments 0–9 Number of unsent mails
not yet sent
GPS positioning has been completed.
ON
GPS positioning (Position has been recognized. Refer to [*].)
13 Dot
status GPS positioning has not been completed.
OFF
(Position has not been recognized. Refer to [*].)
* In a outdoor location within radio waves' penetration range, it sometimes takes more than a minute
from turning on of the starting switch to completion of the positioning.
Positioning is not available in a location where radio waves are extremely weak or unreachable.
52 HM300-2R
Pm Clinic check sheet
HM300-2R 53
54 HM300-2R
HM300-2R 55

© 2009 KOMATSU
All Rights Reserved
56 HM300-2R
SEN03422-00
HM300-2R

40 Troubleshooting 1
Failure code table and fuse locations
Failure code table ........................................................................................................................................... 2
Before troubleshooting by failure codes.......................................................................................................... 9
HM300-2R 1
SEN03422-00 40 Troubleshooting
Failure code table 1

Failure Applicable Action History Reference
code equipment code classification document No.
Mechanical
1500L0 Dual engagement TM E03
system
Mechanical
15B0NX Transmission oil filter Clogging TM E01
system
Operational error or incor- Mechanical
15F0KM R o F gear shift abuse 1 TM —
rect setting system
Mechanical
15F0MB R o F gear shift abuse 2 Functional deterioration TM —
system
15F7KM Forward clutch disc abuse TM —
rect setting system
Electrical
15G0MW Slipping R clutch Slipping TM E03
system
15G7KM Reverse clutch disc abuse TM —
rect setting system
Electrical
15H0MW Hi clutch Slipping TM E03
system
Electrical
15J0MW Lo clutch Slipping TM E03
system
Electrical
15K0MW 1st clutch Slipping TM E03
system
Electrical
15L0MW 2nd clutch Slipping TM E03
system
Electrical
15M0MW 3rd clutch Slipping TM E03
system
Fill signal is ON when Electrical
15SBL1 R clutch solenoid TM E03
command current is OFF. system Troubleshoot-
Electrical ing by failure
15SBMA R clutch solenoid Malfunction TM E03
system code, Part 1
Fill signal is ON when Electrical SEN03424-00
15SCL1 Hi clutch solenoid TM E03
command current is OFF. system
Electrical
15SCMA Hi clutch solenoid Malfunction TM E03
system
15SDL1 Lo clutch solenoid TM E03
Electrical
15SDMA Lo clutch solenoid Malfunction TM E03
system
15SEL1 1st clutch solenoid TM E03
Electrical
15SEMA 1st clutch solenoid Malfunction TM E03
system
15SFL1 2nd clutch solenoid TM E03
Electrical
15SFMA 2nd clutch solenoid Malfunction TM E03
system
15SGL1 3rd clutch solenoid TM E03
Electrical
15SGMA 3rd clutch solenoid Malfunction TM E03
system
Electrical
15SJMA Lockup solenoid Malfunction TM E03
system
Inter axle differential lock Electrical
15SKMA Malfunction TM E01
pressure control valve system
2F00KM Parking brake TM —
rect setting system
2 HM300-2R

Mechanical Troubleshoot-
2G42ZG Front accumulator Oil pressure reduction BK E03
system ing by failure
Mechanical code, Part 1
2G43ZG Rear accumulator Oil pressure reduction BK E03 SEN03424-00
system
Engine over run prevention Prevention function acti-
989A00 MON E02 —
command signal vated
Prevention function acti-
989D00 Rear section turnover alarm MON — —
vated
Mechanical
AA10NX Air cleaner Clogging MON E01
system
Mechanical
AB00MA Alternator Malfunction MON E03
system
Mechanical
B@BAZK Engine oil level Low level TM E01
system
Mechanical
B@BCNS Engine overheated Overheat ENG E02
system
Mechanical
B@BCZK Radiator coolant Low level MON E01
system
B@BFZK Fuel level Low level MON — —
Mechanical
B@C6NS Front brake fluid Overheat MON E02
system
Mechanical
B@C8NS Center brake oil Overheat MON E02
system
Mechanical
B@CENS Torque converter Overheat TM E02
system
Mechanical
B@HAZK Hydraulic tank oil Low level TM E01
system
Mechanical
B@JANS Steering oil Overheat TM E02
system Troubleshoot-
CA111 Engine controller Internal abnormality ENG E03 code, Part 2
system
SEN03425-00
Abnormality occurred in
Abnormal engine Ne and Bkup Electrical
CA115 both sensors at the same ENG E03
sensors system
time
Electrical
CA122 Charge pressure sensor Too high ENG E03
system
Electrical
CA123 Charge pressure sensor Too low ENG E03
system
Electrical
CA131 Throttle sensor Too high ENG E03
system
Electrical
CA132 Throttle sensor Too low ENG E03
system
Electrical
CA135 Oil pressure sensor Too high ENG E01
system
Electrical
CA141 Oil pressure sensor Too low ENG E01
system
Electrical
CA144 Water temperature sensor Too high ENG E01
system
Electrical
CA145 Water temperature sensor Too low ENG E01
system
Electrical
CA153 Charge temperature sensor Too high ENG E01
system
Electrical
CA154 Charge temperature sensor Too low ENG E01
system
Electrical
CA187 Sensor power supply 2 Too low ENG E01
system
HM300-2R 3

Electrical
CA221 Atmospheric pressure sensor Too high ENG E01
system
Electrical
CA222 Atmospheric pressure sensor Too low ENG E01
system
Electrical
CA227 Sensor power supply 2 Too high ENG E03
system
Mechanical
CA234 Engine overspeed Overspeed ENG E02
system
Electrical
CA238 Ne speed sensor Abnormal power supply ENG E03
system
Electrical
CA263 Fuel temperature sensor Too high ENG E01
system
Electrical
CA265 Fuel temperature sensor Too low ENG E01
system
Electrical
CA271 PCV1 short circuit Short circuit ENG E03
CA272 PCV1 disconnection Disconnection ENG E03
system code, Part 2
Electrical SEN03425-00
CA273 PCV2 short circuit Short circuit ENG E03
system
Electrical
CA274 PCV2 disconnection Disconnection ENG E03
system
Disconnection and short Electrical
CA322 Injector #1 system ENG E03
circuit system
circuit system
circuit system
circuit system
circuit system
circuit system
Abnormal engine controller data Electrical
CA342 Abnormal ENG E03
consistency system
Electrical
CA351 Injector drive circuit Abnormal ENG E03
system
Electrical
CA352 Sensor power supply 1 Too low ENG E03
system
Electrical
CA386 Sensor power supply 1 Too high ENG E03
system
Electrical
CA431 Idle validation switch Abnormal ENG E01
CA432 Idle validation switch Abnormal procedure ENG E03
system code, Part 3
Electrical SEN03426-00
CA441 Engine controller power supply Voltage too low ENG E03
system
Engine controller power supply Mechanical
CA442 Too high ENG E03
voltage system
Electrical
CA449 Common rail pressure high Abnormality 2 ENG E03
system
Electrical
CA451 Common rail pressure sensor Too high ENG E03
system
Electrical
CA452 Common rail pressure sensor Too low ENG E03
system
4 HM300-2R

Electrical
CA553 Common rail pressure high Abnormality 1 ENG E03
system
Electrical
CA554 Common rail pressure sensor In range error ENG E03
system
Loss of pressure feed from Electrical
CA559 Abnormality 1 ENG E03
supply pump system
Electrical
CA689 Ne speed sensor Abnormal ENG E03
system
Abnormal Bkup speed sensor Electrical
CA731 ENG E03
phase system
Electrical
CA757 All data of engine controller Loss ENG E03
system
Electrical
CA778 Bkup speed sensor Abnormal ENG E03
system
Electrical
CA1633 KOMNET communication circuit Abnormal ENG E03
system
Electrical
CA2185 Throttle sensor power supply Too high ENG E03
system
Electrical
CA2186 Throttle sensor power supply Too low ENG E03
system
Loss of pressure feed from Electrical
CA2249 Abnormality 2 ENG E03
supply pump system
Electrical
CA2555 Intake air heater relay voltage Too low ENG E01
system
Electrical
CA2556 Intake air heater relay voltage Too high ENG E01
system
Operational error or incor- Electrical Troubleshoot-
DAF9KM Machine monitor connector MON E03
rect setting system ing by failure
CAN communication Electrical code, Part 3
DAFRKR Communication disabled MON E03 SEN03426-00
(machine monitor) system
Power supply voltage too Electrical
DAQ0KK Transmission controller TM E03
low system
Transmission controller non Electrical
DAQ0KT Abnormality in controller TM E01
volatile memory system
Transmission controller solenoid Power supply voltage too Electrical
DAQ2KK TM E03
power supply low system
Inconsistent model selec- Electrical
DAQ9KQ Transmission controller MON E03
tion system
COMMUNICATION LOST Electrical
DAQRKR Communication disabled MON E03
(transmission controller) system
Transmission controller option Electrical
DAQRMA Malfunction MON E03
setting system
Retarder controller non volatile Electrical
DB10KT Abnormality in controller BK E01
memory system
Retarder controller solenoid Power supply voltage too Electrical
DB12KK BK E03
Retarder controller direct battery Power supply voltage too Electrical
DB13KK BK E03
Retarder controller model Model select signal Electrical
DB19KQ MON E03
selection signal inconsistency system
Electrical
DB1QMA Retarder controller option setting Malfunction MON E03
system
CAN communication disabled Electrical
DB1RKR Communication disabled TM E03
(retarder controller) system
CAN communication disabled Electrical
DB2RKR Communication disabled TM E03
(engine controller) system
HM300-2R 5

Electrical
DDTHKA Fill switch for Hi clutch Disconnection TM E03
system
Electrical
DDTJKA Fill switch for Lo clutch Disconnection TM E03
system
Electrical
DDTKKA Fill switch for 1st clutch Disconnection TM E03
system
Electrical Troubleshoot-
DDTLKA Fill switch for 2nd clutch Disconnection TM E03
system ing by failure
Electrical code, Part 3
DDTMKA Fill switch for 3rd clutch Disconnection TM E03 SEN03426-00
system
Electrical
DDTNKA Fill switch for R clutch Disconnection TM E03
system
Electrical
DF10KA Gear shift lever Disconnection TM E03
system
Electrical
DF10KB Gear shift lever Short-circuiting TM E03
system
Transmission oil temperature Electrical
DGF1KX Input signal out of range TM E03
sensor system
Center brake oil temperature Disconnection or short cir- Electrical
DGR3KZ MON E01
sensor cuit system
Center brake oil temperature Electrical
DGR3L8 Inconsistent analog signal MON E01
sensor system
Front brake oil temperature Disconnection or short cir- Electrical
DGR4KZ MON E01
sensor cuit system
Front brake oil temperature Electrical
DGR4L8 Inconsistent analog signal MON E01
sensor system
Electrical
DGR6KX Steering oil temperature sensor Input signal out of range TM E01
system
Torque converter oil temperature Electrical
DGT1KX Input signal out of range TM E01
sensor system
Torque converter intermediate Electrical
DHT5KX Input signal out of range TM E01
pressure sensor system
Torque converter oil pressure Inconsistent signals dur- Electrical
DHT5L6 TM E01
sensor ing a travel and stop system
Front accumulator oil pressure Electrical Troubleshoot-
DHU2KX Input signal out of range BK E01 ing by failure
sensor system
code, Part 4
Rear accumulator oil pressure Electrical SEN03427-00
DHU3KX Input signal out of range BK E01
sensor system
Electrical
DJF1KA Fuel level sensor system Disconnection MON E01
system
Inconsistent signals of Electrical
DK51L5 Retarder lever potentiometer BK E03
potentiometer and switch system
Hoist lever potentiometer failure Electrical
DK52KX Input signal out of range TM E03
1 system
Hoist lever potentiometer failure Electrical
DK53L8 Input signal out of range TM E03
2 system
Electrical
DK54KX Body positioner sensor Input signal out of range TM E03
system
Electrical
DKH0KX Pitch angle sensor Input signal out of range TM E01
system
Transmission input shaft speed Electrical
DLF1KA Disconnection TM E03
sensor system
Transmission input shaft speed Electrical
DLF1LC Inconsistent speed signal TM E03
sensor system
Transmission intermediate shaft Electrical
DLF2KA Disconnection TM E03
speed sensor system
6 HM300-2R

Transmission intermediate shaft Electrical
DLF2LC Inconsistent speed signal TM E03
speed sensor system
Electrical
DLF4KA Differential speed sensor Disconnection TM E01
system
Transmission output shaft speed Electrical
DLT3KA Disconnection TM E03
sensor system
Electrical
DV00KB Alarm buzzer output Short-circuiting TM E01
system
Disconnection or short cir- Electrical
DW72KZ Kick out solenoid output system TM E01
cuit system
Hoist selector valve output sys- Disconnection or short cir- Electrical
DW73KZ TM E03
tem cuit system
Rear wheels BCV command Disconnection or short cir- Electrical
DW78KZ BK E01
output cuit system
Front wheels BCV command Disconnection or short cir- Electrical
DW79KZ BK E01
output cuit system Troubleshoot-
Loss of control ing by failure
Rear wheels proportional Electrical code, Part 4
DX11K4 (stuck in operated condi- BK E03
pressure reducing valve system SEN03427-00
tion)
Rear wheels proportional pres- Electrical
DX11KA Disconnection BK E03
sure reducing valve output circuit system
Rear wheels proportional pres- Electrical
DX11KB Short-circuiting BK E03
Rear wheels proportional pres- Short-circuiting to power Electrical
DX11KY BK E03
sure reducing valve output circuit source line system
Rear wheels proportional pres- Mechanical
DX11MA Malfunction BK E03
sure reducing valve system
Loss of control
Front wheels proportional pres- Electrical
DX12K4 (stuck in operated condi- BK E03
tion)
DX12KA Disconnection BK E03
DX12KB Short-circuiting BK E03
Front wheels proportional pres- Short-circuiting to power Electrical
DX12KY BK E03
sure reducing valve output circuit source line system
DX12MA Malfunction BK E03
sure reducing valve system
Electrical
DX13KA Hoist EPC valve output circuit Disconnection TM E03
system
Electrical
DX13KB Hoist EPC valve output circuit Short-circuiting TM E03
system
Short-circuiting to power Electrical
DX13KY Hoist EPC valve output circuit TM E03
source line system Troubleshoot-
Inter axle differential lock pres- Electrical ing by failure
DXH0KA Disconnection TM E01
sure control valve system code, Part 5
Inter axle differential lock pres- Electrical SEN03428-00
DXH0KB Short-circuiting TM E01
sure control valve system
Inter axle differential lock pres- Short circuit to power Electrical
DXH0KY TM E03
sure control valve source line system
Lockup clutch solenoid output Electrical
DXH1KA Disconnection TM E03
circuit system
Lockup clutch solenoid output Electrical
DXH1KB Short-circuiting TM E03
circuit system
Lockup clutch solenoid output Short circuit to power Electrical
DXH1KY TM E03
circuit source line system
HM300-2R 7

Electrical
DXH2KA Hi clutch solenoid output circuit Disconnection TM E03
system
Electrical
DXH2KB Hi clutch solenoid output circuit Short-circuiting TM E03
system
Short circuit to power Electrical
DXH2KY Hi clutch solenoid output circuit TM E03
source line system
Electrical
DXH3KA Lo clutch solenoid output circuit Disconnection TM E03
system
Electrical
DXH3KB Lo clutch solenoid output circuit Short-circuiting TM E03
system
DXH3KY Lo clutch solenoid output circuit TM E03
source line system
Electrical
DXH4KA 1st clutch solenoid output circuit Disconnection TM E03
system
Electrical
DXH4KB 1st clutch solenoid output circuit Short-circuiting TM E03
system
Short circuit to power Electrical Troubleshoot-
DXH4KY 1st clutch solenoid output circuit TM E03
source line system ing by failure
Electrical code, Part 5
DXH5KA 2nd clutch solenoid output circuit Disconnection TM E03 SEN03428-00
system
Electrical
DXH5KB 2nd clutch solenoid output circuit Short-circuiting TM E03
system
DXH5KY 2nd clutch solenoid output circuit TM E03
source line system
Electrical
DXH6KA 3rd clutch solenoid output circuit Disconnection TM E03
system
Electrical
DXH6KB 3rd clutch solenoid output circuit Short-circuiting TM E03
system
DXH6KY 3rd clutch solenoid output circuit TM E03
source line system
Electrical
DXH7KA R clutch solenoid output circuit Disconnection TM E03
system
Electrical
DXH7KB R clutch solenoid output circuit Short-circuiting TM E03
system
DXH7KY R clutch solenoid output circuit TM E03
source line system
8 HM300-2R
Before troubleshooting by failure codes 1

Wiring table for circuit breaker and slow blow fuse
a This wiring table shows apparatuses to which electric power is supplied through the circuit breakers or
slow blow fuses. (The switched power supply supplies power when the starting switch is ON, and the
constant power supply supplies power when the starting switch is OFF.)
a When proceeding to a troubleshooting by failure code, first inspect the circuit breaker to check if the
power source is supplied properly.
Type of
Breaker name Content Destinations of electric power distribution
power supply
• Fuse (BT3) (inlet terminal No.)
80 A
80A (3), (5), (7), (9), (11), (13), (15), (17), (19), (21), (23),
(Terminals No. 65, 64)
(25), (27)
Power source of switch (1), (3), (13), (15), (17), (19)
(Terminal M of • Fuse (BT2) (inlet terminal No.)
battery relay) 80 A (11), (13)
80A
(Terminals No. 62, 63) • Fuse (BT3) (inlet terminal No.)
(1)
(1), (3), (5), (7), (9), (13), (15), (17), (19)
30 A • Fuse (BT3) (inlet terminal No.)
30A
(Terminals No. 81, 83) (29)
Constant power source
(Terminal B of • Fuse (BT2) (inlet terminal No.)
battery relay) 30 A (15), (17), (19), (21), (23), (25), (27), (29)
30A
(Terminals No. 82, 84) • Fuse (BT4) (inlet terminal No.)
(11)
Power source of switch
(Terminal M of Slow blow fuse 120A • Engine intake air heater relay
battery relay)
HM300-2R 9
Connection table of fuse box

a This wiring table shows apparatuses to which electric power is supplied through the fuse box. (The
switched power supply supplies power when the starting switch is ON, and the constant power supply
supplies power when the starting switch is OFF.)
a When proceeding to a troubleshooting by failure code, first inspect the fuse box to check if the power
source is supplied properly.
a Fuse numbers are indicated in the order of the fuse outlet No. o inlet No.
Type of Fuse
Fuse No. Destinations of electric power distribution
power supply capacity
(4) – (3) 20A Air conditioner
(6) – (5) 10A Car heater
(10) – (9) 10A Machine monitor
(12) – (11) 10A Retarder controller
(14) – (13) 10A Transmission controller
(Terminal M of
battery relay) Emergency steering
BT3 (16) – (15) 10A
(Circuit breaker) Parking brake relay
(80 A)
(18) – (17) 20A Power window (rear)
(20) – (19) 20A Power window (left)
(22) – (21) —
(24) – (23) —
(26) – (25) —
(28) – (27) 30A Rear heater
(2) – (1) 20A Main lamp
(4) – (3) 10A Turning lamp
(14) – (13) 10A Stop lamp
BT1
(16) – (15) 20A Backup lamp, buzzer
(18) – (17) 20A Working lamp (F)
(20) – (19) 20A Spare
(12) – (11) 20A Front wiper
Power source of switch BT2
(14) – (13) 20A Rear wiper
(Terminal M of
battery relay) BT3 (2) – (1) 20A Fog lamp
(Circuit breaker) (2) – (1) 10A Room lamp
(80 A)
(4) – (3) 10A Radio
(6) – (5) 10A Revolving warning lamp
(8) – (7) 20A Side lamp
BT4 (10) – (9) 10A Auto preheater
(14) – (13) 10A Tachograph
(16) – (15) 10A Cigarette lighter
(18) – (17) 10A Air suspension seat
(Terminal B of
battery relay) BT3 (30) – (29) 30A Engine controller
30 A
10 HM300-2R
Type of Fuse
Fuse No. Destinations of electric power distribution
power supply capacity
Machine monitor
(16) – (15) 10A
KOMTRAX
Constant power source (20) – (19) 20A Terminal B of starting switch
(Terminal B of BT2 (22) – (21) 10A Transmission controller
battery relay)
30 A (24) – (23) 20A Hazard lamp
(Terminals No. 82, 84) (26) – (25) 10A Emergency steering
(28) – (27) 10A Room lamp
(30) – (29) 20A Spare
BT4 (12) – (11) 10A Horn
(6) – (5) 20A Head lamp (Hi)
(8) – (7) 20A Head lamp (Lo)
BT1
(10) – (9) 10A Small lamp (right)
(12) – (11) 10A Small lamp (left)
Fuse in a circuit (2) – (1) 5A Starting switch ACC – engine controller
(4) – (3) 10A Starting switch ACC – KOMTRAX
BT2 (6) – (5) 10A Starting switch ACC – machine monitor
(8) – (7) 10A Starting switch BRP/B
(10) – (9) 10A Starting switch BR – backup monitor
HM300-2R 11

© 2007 KOMATSU
All Rights Reserved
12 HM300-2R
SEN03423-01
HM300-2R

General information on troubleshooting
Points to remember when troubleshooting ..................................................................................................... 2
Sequence of events in troubleshooting........................................................................................................... 3
Checks before troubleshooting ....................................................................................................................... 4
Classification and procedures for troubleshooting .......................................................................................... 5
Information in troubleshooting table................................................................................................................ 6
Connection table for connector pin numbers .................................................................................................. 8
T-branch box and T- branch adapter table .................................................................................................... 44
HM300-2R 1
Points to remember when troubleshooting 1

k Stop the machine in a level ground, and check that the lock pin, blocks, and parking brake are
securely fitted.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals,
and do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not 4) Check the stroke of the control valve
hurry to disassemble the components. spool.
If components are disassembled immediately 5) Other maintenance items can be checked
any failure occurs: externally, so check any item that is con-
q Parts that have no connection with the fail- sidered to be necessary.
ure or other unnecessary parts will be dis-
4. Confirming failure
assembled.
q Confirm the extent of the failure yourself,
q It will become impossible to find the cause
and judge whether to handle it as a real
of the failure.
failure or as a problem with the method of
It will also cause a waste of manhours, parts,
operation, etc.
or oil or grease, and at the same time, will also
a When operating the machine to reen-
lose the confidence of the user or operator.
act the troubleshooting symptoms, do
For this reason, when carrying out trouble-
not carry out any investigation or
shooting, it is necessary to carry out thorough
measurement that may make the
prior investigation and to carry out trouble-
problem worse.
shooting in accordance with the fixed proce-
dure. 5. Troubleshooting
q Use the results of the investigation and
2. Points to ask user or operator
inspection in Items 2 – 4 to narrow down
1) Have any other problems occurred apart
the causes of failure, then use the trouble-
from the problem that has been reported?
shooting flowchart to locate the position of
2) Was there anything strange about the
the failure exactly.
machine before the failure occurred?
a The basic procedure for troubleshoot-
3) Did the failure occur suddenly, or were
ing is as follows.
there problems with the machine condition
1) Start from the simple points.
before this?
2) Start from the most likely points.
4) Under what conditions did the failure
3) Investigate other related parts or
occur?
information.
5) Had any repairs been carried out before
the failure? 6. Measures to remove root cause of failure
When were these repairs carried out? q Even if the failure is repaired, if the root
6) Has the same kind of failure occurred cause of the failure is not repaired, the
before? same failure will occur again.
To prevent this, always investigate why
3. Check before troubleshooting
the problem occurred. Then, remove the
1) Check the oil level
root cause.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
2 HM300-2R
Sequence of events in troubleshooting 1
HM300-2R 3
Checks before troubleshooting 1
Check item Judgement value Remedy

1. Check fuel level and type — Add fuel
2. Check for impurities in fuel — Clean, drain
3. Check hydraulic oil level — Add oil
4. Check hydraulic oil strainer — Clean, drain
5. Check power train oil level — Add oil
Lubricating 6. Check engine oil level (engine oil pan level) and
— Add oil
oil, coolant type
7. Check coolant level — Add coolant
8. Check dust indicator for clogging — Clean or replace
9. Check power train oil filter — Replace
10. Check hydraulic oil filter — Replace
11. Check final drive oil level — Add oil
1. Check for looseness and corrosion of battery
— Retighten or replace
cable terminals
2. Check for looseness and corrosion of alternator
Electrical — Retighten or replace
harness terminals
equipment
3. Check for looseness and corrosion of starting
— Retighten or replace
motor harness terminals
4. Check operation of instruments — Repair or replace
Hydraulic 1. Check for abnormal noise and smell — Repair
and 2. Check for oil leakage — Repair
mechanical
equipment 3. Carry out air bleeding — Bleed air
1. Check battery voltage (engine stopped) 20 – 26 V Replace
2. Check battery electrolyte level — Refill or replace
3. Check for discoloration, burnout of wiring, and
— Replace
peeling of harness coating
4. Check for missing wiring clamps and a slack of
— Repair
wire
Electrical 5. Check for water leaking on wiring
equipment Disconnect connector
(pay particularly careful attention to water leaking —
and dry
on connectors or terminals)
6. Check for blown or corroded fuse — Replace
7. Check alternator voltage (engine running at half After running for several
Replace
throttle or above) minutes: 27.5 – 29.5 V
8. Check operating noise of battery relay (when
— Replace
turning the starting switch ON or OFF)
4 HM300-2R
Classification and procedures for troubleshooting 1

Classification for troubleshooting
Type Contents
Display of code Troubleshooting by failure code
E mode Troubleshooting for electrical system
H mode Troubleshooting for hydraulic and mechanical system
S mode Troubleshooting for engine
Procedure for troubleshooting

If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according
to the following procedure, and then go to the corresponding troubleshooting section.
1. Procedure for troubleshooting to be taken when action code and failure code are displayed on
machine monitor:
If a action code and a failure code are displayed on the machine monitor, carry out the troubleshooting
for the corresponding "Display of code" according to the displayed failure code.
2. When electrical system failure code or mechanical system failure code is recorded in fault his-
tory:
If a action code and a failure code are not displayed on the machine monitor, check for a mechanical
system failure code and an electrical system failure code with the fault history function of the machine
monitor.
If a failure code is recorded, carry out troubleshooting for the corresponding "Display of code" accord-
ing to that code.
a If an electrical system failure code is recorded, delete all the codes and reproduce them, and then
see if the trouble is still detected.
a A failure code of the mechanical system cannot be deleted.
a If a trouble is displayed in the air conditioner fault history or heater fault history by the fault history
function, carry out the corresponding troubleshooting in "E mode".
3. When action code or failure code is not displayed and no failure code is recorded in fault
history:
If a action code or a failure code is not displayed on the machine monitor and no failure code is recorded
in the fault history, a trouble that the machine cannot find out by itself may have occurred in the electrical
system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of "Phenomena looking like troubles and troubleshooting Nos.", and then carry out trouble-
shooting corresponding to that phenomenon in the "E mode", "H mode", or "S mode".
HM300-2R 5
Information in troubleshooting table 1

a The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before carrying out troubleshooting, understand that information fully.
Action code Failure code
Display on Trouble Trouble name displayed in fault history of machine monitor
Display on machine
machine moni-
monitor
tor
Contents of
Contents of trouble detected by machine monitor or controller
trouble
Action of
Action taken by machine monitor or controller to protect system or devices when they detect
machine moni-
trouble
tor or controller
Problem that
Problem that appears on machine as result of action taken by machine monitor or controller
appears on
(shown above)
machine
Related infor-
Information related to detected trouble or troubleshooting
mation
Cause Standard value in normal state/Remarks on troubleshooting
<Contents of description>
• Standard value in normal state to judge possible causes
• Remarks on judgment
1
<Troubles in wiring harness>
• Disconnection
Connector is connected defectively or wiring harness is
broken.
• Ground fault
Wiring harness which is not connected to chassis ground
circuit is in contact with chassis ground circuit.
• Hot short
Wiring harness which is not connected to power source (24
2 V) circuit is in contact with power source (24 V) circuit.
• Short circuit
Independent wiring harnesses are in contact with each
Possible causes other abnormally.
and standard Possible causes of trouble
value in normal (Given numbers are refer-
<Precautions for troubleshooting>
state ence numbers, which do not
(1) Method of indicating connector No. and handling of T-
indicate priority)
adapter
Insert or connect T-adapter as explained below for trouble-
shooting, unless otherwise specified.
3 • If connector No. has no marks of "male" and "female",
disconnect connector and insert T-adapters in both male
side and female side.
• If connector No. has marks of "male" and "female", dis-
connect connector and connect T-adapter to only male
side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester as
explained below for troubleshooting, unless otherwise
specified.
4 • Connect positive (+) lead to pin No. or wiring harness
entered on front side.
• Connect negative (–) lead to pin No. or harness entered
on rear side.
6 HM300-2R
Related circuit diagram
This drawing is a part of the electric circuit diagram related

to troubleshooting.
• Connector No.: Indicates (Model – Number of pins) and
(Color).
• "Connector No. and pin No." from each branching/merg-
ing point: Shows the ends of branch or source of merging
within the parts of the same wiring harness.
• Arrow (i o): Roughly shows the location on the machine.
HM300-2R 7
Connection table for connector pin numbers (Rev. 2009.04)
a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
8 HM300-2R
HM300-2R 9
10 HM300-2R
HM300-2R 11
12 HM300-2R
HM300-2R 13
14 HM300-2R
HM300-2R 15
16 HM300-2R
HM300-2R 17
18 HM300-2R
HM300-2R 19
20 HM300-2R
HM300-2R 21
22 HM300-2R
HM300-2R 23
24 HM300-2R
HM300-2R 25
26 HM300-2R
HM300-2R 27
28 HM300-2R
HM300-2R 29
30 HM300-2R
HM300-2R 31
32 HM300-2R
HM300-2R 33
34 HM300-2R
HM300-2R 35
36 HM300-2R
HM300-2R 37
38 HM300-2R
HM300-2R 39
40 HM300-2R
HM300-2R 41
42 HM300-2R
HM300-2R 43
T-branch box and T- branch adapter table 1

(Rev. 2009.03)
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
44 HM300-2R
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 — q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 — q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
HM300-2R 45
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 — q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190* 3 1,2,3L q q
Commonrail pressure
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 — q
799-601-4280* Box for controller (PUMP) 121 — q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for
799-601-9890 3, — q
DT2 – 4 and DTM2
4,
“*” Shows not T-adapter but socket.
46 HM300-2R
HM300-2R 47

© 2009 KOMATSU
All Rights Reserved
48 HM300-2R
SEN03424-00
HM300-2R

Troubleshooting by failure code
(Display of code), Part 1
Failure code [1500L0] (Dual engagement) ..................................................................................................... 3
Failure code [15B0NX] (Transmission oil filter: Clogged) ............................................................................... 4
Failure code [15F0KM] (R o F shifting abuse 1: Operational error or incorrect setting) ................................ 6
Failure code [15F0MB] (R o F shifting abuse 2: Functional deterioration) .................................................... 6
Failure code [15F7KM] (forward clutch disc abuse)........................................................................................ 7
Failure code [15G0MW] (R clutch: Slipping)................................................................................................... 8
Failure code [15G7KM] (reverse clutch disc abuse) ..................................................................................... 10
Failure code [15H0MW] (Hi clutch: Slipping) .................................................................................................11
Failure code [15J0MW] (Lo clutch: Slipping) ................................................................................................ 14
Failure code [15K0MW] (1st clutch: Slipping) ............................................................................................... 16
Failure code [15L0MW] (2nd clutch: Slipping) .............................................................................................. 18
Failure code [15M0MW] (3rd clutch: Slipping) .............................................................................................. 20
Failure code [15SBL1] (R clutch solenoid: Fill signal is ON when command current is OFF.)...................... 22
Failure code [15SBMA] (R clutch solenoid: Malfunction).............................................................................. 26
HM300-2R 1
Failure code [15SCL1] (Hi clutch solenoid: Fill signal is ON when command current is OFF.)..................... 28
Failure code [15SCMA] (Hi clutch solenoid: Malfunction) ............................................................................. 32
Failure code [15SDL1] (Lo clutch solenoid: Fill signal is ON when command current is OFF.) .................... 34
Failure code [15SDMA] (Lo clutch solenoid: Malfunction) ............................................................................ 36
Failure code [15SEL1] (1st clutch solenoid: Fill signal is ON when command current is OFF) .................... 40
Failure code [15SEMA] (1st clutch solenoid: Malfunction)............................................................................ 44
Failure code [15SFL1] (2nd clutch solenoid: Fill signal is ON when command current is OFF.)................... 46
Failure code [15SFMA] (2nd clutch solenoid: Malfunction)........................................................................... 50
Failure code [15SGL1] (3rd clutch solenoid: Fill signal is ON when command current is OFF.)................... 52
Failure code [15SGMA] (3rd clutch solenoid: Malfunction) ........................................................................... 56
Failure code [15SJMA] (Lockup clutch solenoid: Malfunction)...................................................................... 58
Failure code [15SKMA] (Inter-axle differential lockup pressure control valve: Malfunction) ......................... 60
Failure code [2F00KM] (Parking brake: Error in operation or setting)........................................................... 62
Failure code [2G42ZG] (Front accumulator: Oil pressure too low) ............................................................... 64
Failure code [2G43ZG] (Rear accumulator: Oil pressure too low) ................................................................ 64
2 HM300-2R
Failure code [1500L0] (Dual engagement) 1
Action code Failure code Dual engagement:

Trouble
E03 1500L0 (Transmission controller system)
Contents of
• Fill switch signals have been inputted from 2 clutches that do not form a normal combination.
trouble
Action of • Suddenly shifts to Neutral while traveling, and cannot move off again.
controller • Even after the repair, does not resume to normal unless starting switch is once turned OFF.
Problem that
appears on • The gear speed is shifted to Neutral.
machine
Related infor-
• Other problem (clutch pressure control valve system failure code [15S*L1]) occurs at same time.
mation

Possible causes Clutch pressure control valve
and standard 1 system failure code (15S*L1) Troubleshooting by the active failure code.
value in normal has occurred
state Defective transmission
2 Troubleshooting by the active failure code.
controller
HM300-2R 3
Failure code [15B0NX] (Transmission oil filter: Clogged) 1
Action code Failure code Transmission oil filter: Clogged

Trouble
E01 15B0NX (Transmission controller system)
Contents of • When the torque converter oil temperature is above 50°C, the signal circuit of the transmission
trouble clogging sensor has become OPEN (disconnected from the ground).
Action of
• Takes no particular action.
controller
Problem that
appears on • If the machine is operated in as-is condition, a dirt may get into the transmission circuit.
machine
• Check that the condition has returned to normal after taking corrective measures, and then
Related infor-
implement initial learning procedure for the transmission controller referring to “Setting and adjusting
mation
various equipments“ in “Testing and adjusting“.

1 Clogged transmission filter Clean or replace
a Prepare with starting switch OFF and troubleshooting with start-
ing switch still OFF.
Defective transmission filter Resis-
2 Filter is normal Max. 1 z
clogging sensor Between T03 (male) tance
(1) – (2) Resis-
Clogging filter Min. 1 Mz
tance
Possible causes
and standard a Prepare with starting switch OFF and troubleshooting with start-
value in normal Disconnection in wiring ing switch still OFF.
state harness Wiring harness between ATC2 (female) (37) Resis-
3 Max. 1 z
(Disconnection or defective – T03 (female) (1) tance
contact) Wiring harness between ATC1 (female) (21) Resis-
Max. 1 z
– T03 (female) (2) tance
ing switch ON.
Defective transmission con-
4 Between ATC2 Filter is normal Voltage Max. 1V
troller
(female) (37) – body
ground Clogging filter Voltage 20 – 30 V
4 HM300-2R
Circuit diagram related
HM300-2R 5
Failure code [15F0KM]

(R o F shifting abuse 1: Operational error or incorrect setting) 1
Action code Failure code R o F shifting abuse 1: Operational error or incorrect setting
Trouble
— 15F0KM (Transmission controller system)
Contents of • When output shaft speed is 200 – 300 rpm (about 5 – 7 km/h), gear shifting from reverse to forward
trouble has been detected.
Action of
controller
Problem that
• If the machine is operated in as-is condition, the machine may be damaged.
appears on
machine • Only recorded in failure history.
Related infor-
• Output shaft speed can be checked by monitoring function (code: 31400).
mation
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal A forward-reverse shifting should be performed when the machine
1 Abuse
state is stationary.
Failure code [15F0MB]

(R o F shifting abuse 2: Functional deterioration) 1
Action
Failure code R o F shifting abuse 2: Operational error or incorrect setting
code Trouble
(Transmission controller system)
— 15F0MB
Contents of • When output shaft speed is above 300 rpm (about 7 km/h), gear shifting from reverse to forward has
trouble been detected.
Action of
controller
Problem that
• If the machine is operated in as-is condition, the machine may be damaged.
appears on
Related infor-
• Output shaft speed can be checked by monitoring function (code: 31400).
mation

and standard
1 Abuse
6 HM300-2R
Failure code [15F7KM] (forward clutch disc abuse) 1
Action code Failure code Transmission forward clutch disc abuse

Trouble
— 15F7KM (Transmission controller system)
Contents of • When the engine speed is above 1,800 rpm, gear shifting from neutral or reverse to forward has
Action of
controller
Problem that
• Repeated abnormal operations may cause machine damage.
appears on
Related infor-
mation

and standard
1 Abuse
HM300-2R 7
Failure code [15G0MW] (R clutch: Slipping) 1
Action code Failure code R clutch: Slipping

(R command holding pressure, R clutch fill switch ON, slipping
Trouble
E03 15G0MW detected)
Contents of
• During an output to R clutch ECMV, a slip of R clutch has been detected.
trouble
• Shifts up and holds the gear speed depending on the gear speed before failure as mentioned in
Action of
Table 1.
controller
• Turns lockup to OFF.
Problem that
appears on • Once the gear shift lever is set to neutral, the machine can not move off in any gear speeds.
machine
• Electric current of output to ECMV can be checked by monitoring function (code: 31606)
Related infor-
mation • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for R
clutch or pressure control valve.

Resis-
1 Defective R clutch ECMV Between CN8 (male) (1) – (2) 5 – 15 z
tance
Resis-
Between CN8 (male) (1), (2) – body ground Min. 1 Mz
tance
Possible causes ing switch still OFF.
and standard Disconnection in wiring
value in normal harness Wiring harness between ATC3 (female) (25) Resis-
2 Max. 1 z
state (Disconnection or defective – CN8 (female) (1) tance
Max. 1 z
– CN8 (female) (2) tance
Defective speed sensor
3 • Troubleshooting by failure code DL**KA, DL**LC
detection
Defective transmission ing switch still OFF.
4
controller Wiring harness between ATC3 (female) (25) Resis-
5 – 15 z
– (23) tance
8 HM300-2R
HM300-2R 9
Failure code [15G7KM] (reverse clutch disc abuse) 1
Action code Failure code Transmission reverse clutch disc abuse

Trouble
— 15G7KM (Transmission controller system)
Contents of • When the engine speed is above 1,800 rpm, gear shifting from neutral or forward to reverse has
Action of
controller
Problem that
• Repeated abnormal operations may cause machine damage.
appears on
Related infor-
mation

and standard
1 Abuse
10 HM300-2R
Failure code [15H0MW] (Hi clutch: Slipping) 1
Action code Failure code Hi clutch: Slipping

(Hi command holding pressure, Hi clutch fill switch ON, slipping
Trouble
E03 15H0MW detected)
• During an output to the Hi clutch ECMV, an abnormality exists in the value calculated from the
Contents of
signals of transmission input shaft speed sensor, transmission intermediate shaft speed sensor
trouble
and transmission output shaft speed sensor.
Action of
Table 1.
controller
Problem that
machine
Related infor-
mation • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for Hi

Resis-
1 Defective Hi clutch ECMV Between CN10 (male) (1) – (2) 5 – 15 z
tance
Resis-
tance
2 Max. 1 z
Max. 1 z
detection
4
5 – 15 z
– (13) tance
HM300-2R 11
Table 1
Trouble clutch
Previous [Command ON] Controller reaction ON or OFF state of
range (Slip , short to GND or (Alternative clutch) lockup clutch
signal lost)
3rd 3rd OFF Neutral OFF
F6
High High OFF Neutral OFF
F5
Low Low 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
High High 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Low Low 2H F4 OFF
1st 1st 2L F3 OFF
F2
High High 2L F3 OFF
1st 1st 2L F3 OFF
F1
Low Low 1H F2 OFF
R3
Reverse Reverse OFF Neutral OFF
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
12 HM300-2R
HM300-2R 13
Failure code [15J0MW] (Lo clutch: Slipping) 1
Action code Failure code Lo clutch: Slipping

(Lo command holding pressure, Lo clutch fill switch ON, slipping
Trouble
E03 15J0MW detected)
• During an output to the Lo clutch ECMV, an abnormality exists in the value calculated from the
Contents of
trouble
Action of
Table 1.
controller
Problem that
machine
Related infor-
mation • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for Lo

Resis-
1 Defective Lo clutch ECMV Between CN6 (male) (1) – (2) 5 – 15 z
tance
Resis-
tance
2 Max. 1 z
Max. 1 z
detection
4
5 – 15 z
– (3) tance
14 HM300-2R
Table 1
Trouble clutch
signal lost)
F6
F5
Low Low 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
High High 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Low Low 2H F4 OFF
1st 1st 2L F3 OFF
F2
High High 2L F3 OFF
1st 1st 2L F3 OFF
F1
Low Low 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM300-2R 15
Failure code [15K0MW] (1st clutch: Slipping) 1
Action code Failure code 1st clutch: Slipping

(1st command holding pressure, 1st clutch fill switch ON, slipping
Trouble
E03 15K0MW detected)
• During an output to the 1st clutch ECMV, an abnormality exists in the value calculated from the
Contents of
trouble
Action of
Table 1.
controller
Problem that
machine
Related infor-
mation • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for 1st

Resis-
1 Defective 1st clutch ECMV Between CN12 (male) (1) – (2) 5 – 15 z
tance
Resis-
tance
2 Max. 1 z
Max. 1 z
detection
4
5 – 15 z
– ATC3 (female) (13) tance
16 HM300-2R
Table 1
Trouble clutch
signal lost)
F6
F5
Low Low 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
High High 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Low Low 2H F4 OFF
1st 1st 2L F3 OFF
F2
High High 2L F3 OFF
1st 1st 2L F3 OFF
F1
Low Low 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM300-2R 17
Failure code [15L0MW] (2nd clutch: Slipping) 1
Action code Failure code 2nd clutch: Slipping

(2nd command holding pressure, 2nd clutch fill switch ON, slipping
Trouble
E03 15L0MW detected)
• During an output to the 2nd clutch ECMV, an abnormality exists in the value calculated from the
Contents of
trouble
Action of
Table 1.
controller
Problem that
machine
Related infor-
mation • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for 2nd

Resis-
1 Defective 2nd clutch ECMV Between CN14 (male) (1) – (2) 5 – 15 z
tance
Between CN14 (male) (1), (2) and body Resis-
Min. 1 Mz
ground tance
value in normal harness Wiring harness between ATC3 (female) (5) – Resis-
2 Max. 1 z
state (Disconnection or defective CN14 (female) (1) tance
contact) Wiring harness between ATC3 (female) (3) – Resis-
Max. 1 z
CN14 (female) (2) tance
detection
4
controller Wiring harness between ATC3 (female) (5) – Resis-
5 – 15 z
ATC3 (female) (3) tance
18 HM300-2R
Table 1
Trouble clutch
signal lost)
F6
F5
Low Low 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
High High 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Low Low 2H F4 OFF
1st 1st 2L F3 OFF
F2
High High 2L F3 OFF
1st 1st 2L F3 OFF
F1
Low Low 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM300-2R 19
Failure code [15M0MW] (3rd clutch: Slipping) 1
Action code Failure code 3rd clutch: Slipping

(3rd command holding pressure, 3rd clutch fill switch ON, slipping
Trouble
E03 15M0MW detected)
• During an output to the 3rd clutch ECMV, an abnormality exists in the value calculated from the
Contents of
trouble
Action of • Shifts up and holds the gear speed depending on the gear speed before failure as mentioned in
controller Table 1.
Problem that
machine
Related infor-
mation • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for 3rd

Resis-
1 Defective 3rd clutch ECMV Between CN16 (male) (1) – (2) 5 – 15 z
tance
Resis-
tance
2 Max. 1 z
Max. 1 z
detection
4
5 – 15 z
20 HM300-2R
Table 1
Trouble clutch
signal lost)
F6
F5
Low Low 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
High High 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Low Low 2H F4 OFF
1st 1st 2L F3 OFF
F2
High High 2L F3 OFF
1st 1st 2L F3 OFF
F1
Low Low 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM300-2R 21
Failure code [15SBL1] (R clutch solenoid: Fill signal is ON when

command current is OFF.) 1
Action code Failure code R clutch solenoid: Fill signal is ON when command current is OFF.
Trouble
E03 15SBL1 (Transmission controller system)
Contents of • Even when output to the R clutch ECMV is turned OFF, the signal from the fill switch stays ON and
trouble the clutch is not released.
Action of
Table 2.
controller
Problem that
machine
Related infor-
mation

Defective for R clutch fill When Resis-
1 Min. 1 Mz
switch Between CN9 (male) (1) – body released tance
ground When Resis-
Max. 1 z
engaged tance
Possible causes a Prepare with starting switch OFF and troubleshooting with start-
and standard ing switch still OFF.
value in normal Defective harness grounding
2
state (Contact with ground circuit) Between ground and wiring harness Resis-
between ATC3 (female) (29) – CN9 (female) Min. 1 Mz
tance
(1)
Defective transmission When Resis-
3 Min. 1 Mz
controller Between ATC3 (female) (29) – released tance
body ground When Resis-
Max. 1 z
engaged tance
22 HM300-2R
Table 2
Trouble clutch
Previous Controller reaction ON or OFF state of
[Command ON]
range (Alternative clutch) lockup clutch
(Fill SW ON)
2nd OFF Neutral OFF
3rd 1st OFF Neutral OFF
F6
High Reverse OFF Neutral OFF
Low OFF Neutral OFF
2nd OFF Neutral OFF
F5
Low Reverse OFF Neutral OFF
High 3H F6 OFF
3rd 3L F5 OFF
2nd 1st OFF Neutral OFF
F4
Low 3L F5 OFF
3rd 3L F5 OFF
F3
High 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Low 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
High 1H F2 OFF
2nd OFF Neutral OFF
R3
Reverse High OFF Neutral OFF
Low OFF Neutral OFF
3rd 3R R3 OFF
R2
Low OFF Neutral OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Low OFF Neutral OFF
N Any None No reaction —
HM300-2R 23
24 HM300-2R
HM300-2R 25
Failure code [15SBMA] (R clutch solenoid: Malfunction) 1
Action code Failure code R clutch solenoid: Malfunction

(R command holding pressure, R clutch fill switch OFF, slipping
Trouble
E03 15SBMA detected)
• The signal from the fill switch stays OFF during an output to the R clutch ECMV and an abnormality
Contents of
exists in the value calculated from the signals of transmission input shaft speed sensor, transmission
trouble
intermediate shaft speed sensor and transmission output shaft speed sensor.
Action of
Table 1.
controller
Problem that
machine
Related infor-
mation • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for R

Resis-
tance
Resis-
tance
2 Max. 1 z
Max. 1 z
detection
4
5 – 15 z
26 HM300-2R
Table 1
Trouble clutch
signal lost)
F6
F5
Low Low 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
High High 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Low Low 2H F4 OFF
1st 1st 2L F3 OFF
F2
High High 2L F3 OFF
1st 1st 2L F3 OFF
F1
Low Low 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM300-2R 27
Failure code [15SCL1] (Hi clutch solenoid: Fill signal is ON when

Action code Failure code Hi clutch solenoid: Fill signal is ON when command signal is OFF.
Trouble
E03 15SCL1 (Transmission controller system)
Contents of • Even when output to the Hi clutch ECMV is turned OFF, the signal from the fill switch stays ON and
trouble the clutch is not released.
Action of
Table 2.
controller
Problem that
machine
Related infor-
mation

When Resis-
1 Defective Hi clutch fill switch Min. 1 Mz
Between CN11 (male) (1) – body released tance
ground When Resis-
Max. 1 z
engaged tance
2
between ATC3 (female) (30) – CN11 Min. 1 Mz
tance
(female) (1)
3 Min. 1 Mz
Max. 1 z
engaged tance
28 HM300-2R
Table 2
Trouble clutch
[Command ON]
(Fill SW ON)
2nd OFF Neutral OFF
F6
Low OFF Neutral OFF
2nd OFF Neutral OFF
F5
High 3H F6 OFF
3rd 3L F5 OFF
F4
Low 3L F5 OFF
3rd 3L F5 OFF
F3
High 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Low 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
High 1H F2 OFF
2nd OFF Neutral OFF
R3
Low OFF Neutral OFF
3rd 3R R3 OFF
R2
Low OFF Neutral OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Low OFF Neutral OFF
HM300-2R 29
30 HM300-2R
HM300-2R 31
Failure code [15SCMA] (Hi clutch solenoid: Malfunction) 1
Action code Failure code Hi clutch solenoid: Malfunction

(Hi command holding pressure, Hi clutch fill switch OFF, slipping
Trouble
E03 15SCMA detected)
• The signal from the fill switch stays OFF during an output to the Hi clutch ECMV and an abnormality
Contents of
trouble
Action of
Table 1.
controller
Problem that
machine
Related infor-
mation • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for Hi

Resis-
tance
Resis-
tance
2 Max. 1 z
Max. 1 z
detection
4
5 – 15 z
32 HM300-2R
Table 1
Trouble clutch
signal lost)
F6
F5
Low Low 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
High High 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Low Low 2H F4 OFF
1st 1st 2L F3 OFF
F2
High High 2L F3 OFF
1st 1st 2L F3 OFF
F1
Low Low 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM300-2R 33
Failure code [15SDL1] (Lo clutch solenoid: Fill signal is ON when

Action code Failure code Lo clutch solenoid: Fill signal is ON when command current is OFF.
Trouble
E03 15SDL1 (Transmission controller system)
Contents of • Even when output to the Lo clutch ECMV is turned “OFF“, the signal from the fill switch stays “ON“
trouble and the clutch is not released.
Action of • Shifts up and holds the gear speed as shown in Table 1 depending on the gear speed before failure.
controller • Turns lockup to OFF.
Problem that
machine
Related infor-
mation

When Resis-
1 Defective Lo clutch fill switch Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
2
tance
(1)
3 Min. 1 Mz
Max. 1 z
engaged tance
34 HM300-2R
Table 1
Trouble clutch
signal lost)
F6
F5
Low Low 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
High High 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Low Low 2H F4 OFF
1st 1st 2L F3 OFF
F2
High High 2L F3 OFF
1st 1st 2L F3 OFF
F1
Low Low 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM300-2R 35
Failure code [15SDMA] (Lo clutch solenoid: Malfunction) 1
Action code Failure code Lo clutch solenoid: Malfunction

(Lo command holding pressure, Lo clutch fill switch OFF, slipping
Trouble
E03 15SDMA detected)
• The signal from the fill switch stays OFF during an output to the Lo clutch ECMV and an abnormality
Contents of
trouble
Problem that
machine
Related infor-
mation • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for Lo

Resis-
tance
Resis-
tance
2 Max. 1 z
Max. 1 z
detection
4
5 – 15 z
36 HM300-2R
Table 2
Trouble clutch
[Command ON]
(Fill SW ON)
2nd OFF Neutral OFF
F6
Low OFF Neutral OFF
2nd OFF Neutral OFF
F5
High 3H F6 OFF
3rd 3L F5 OFF
F4
Low 3L F5 OFF
3rd 3L F5 OFF
F3
High 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Low 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
High 1H F2 OFF
2nd OFF Neutral OFF
R3
Low OFF Neutral OFF
3rd 3R R3 OFF
R2
Low OFF Neutral OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Low OFF Neutral OFF
HM300-2R 37
38 HM300-2R
HM300-2R 39
Failure code [15SEL1] (1st clutch solenoid: Fill signal is ON when

command current is OFF) 1
Action code Failure code 1st clutch solenoid: Fill signal is ON when command current is OFF
Trouble
E03 15SEL1 (Transmission controller system)
Contents of • Even when output to the 1st clutch ECMV is turned “OFF“, the signal from the fill switch stays “ON“
Problem that
machine
Related infor-
mation

When Resis-
1 Defective 1st clutch fill switch Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
2
tance
(female) (1)
3 Min. 1 Mz
Max. 1 z
engaged tance
40 HM300-2R
Table 2
Trouble clutch
[Command ON]
(Fill SW ON)
2nd OFF Neutral OFF
F6
Low OFF Neutral OFF
2nd OFF Neutral OFF
F5
High 3H F6 OFF
3rd 3L F5 OFF
F4
Low 3L F5 OFF
3rd 3L F5 OFF
F3
High 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Low 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
High 1H F2 OFF
2nd OFF Neutral OFF
R3
Low OFF Neutral OFF
3rd 3R R3 OFF
R2
Low OFF Neutral OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Low OFF Neutral OFF
HM300-2R 41
42 HM300-2R
HM300-2R 43
Failure code [15SEMA] (1st clutch solenoid: Malfunction) 1
Action code Failure code 1st clutch solenoid: Malfunction

(1st command holding pressure, 1st clutch fill switch OFF, slipping
Trouble
E03 15SEMA detected)
• The signal from the fill switch stays OFF during an output to the 1st clutch ECMV and an abnormality
Contents of
trouble
Problem that
machine
Related infor-
mation • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for 1st

Resis-
tance
Resis-
tance
value in normal harness Wiring harness between ACT2 (female) (36) Resis-
2 Max. 1 z
Max. 1 z
detection
4
5 – 15 z
44 HM300-2R
Table 1
Trouble clutch
signal lost)
F6
F5
Low Low 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
High High 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Low Low 2H F4 OFF
1st 1st 2L F3 OFF
F2
High High 2L F3 OFF
1st 1st 2L F3 OFF
F1
Low Low 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM300-2R 45
Failure code [15SFL1] (2nd clutch solenoid: Fill signal is ON when

Action code Failure code 2nd clutch solenoid: Fill signal is ON when command current is OFF.
Trouble
E03 15SFL1 (Transmission controller system)
Contents of • Even when output to the 2nd clutch ECMV is turned “OFF“, the signal from the fill switch stays “ON“
Problem that
machine
Related infor-
mation

Defective fill switch for 2nd When Resis-
1 Min. 1 Mz
clutch Between CN15 (male) (1) – body released tance
ground When Resis-
Max. 1 z
engaged tance
2
tance
(1)
3 Min. 1 Mz
Max. 1 z
engaged tance
46 HM300-2R
Table 2
Trouble clutch
[Command ON]
(Fill SW ON)
2nd OFF Neutral OFF
F6
Low OFF Neutral OFF
2nd OFF Neutral OFF
F5
High 3H F6 OFF
3rd 3L F5 OFF
F4
Low 3L F5 OFF
3rd 3L F5 OFF
F3
High 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Low 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
High 1H F2 OFF
2nd OFF Neutral OFF
R3
Low OFF Neutral OFF
3rd 3R R3 OFF
R2
Low OFF Neutral OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Low OFF Neutral OFF
HM300-2R 47
48 HM300-2R
HM300-2R 49
Failure code [15SFMA] (2nd clutch solenoid: Malfunction) 1
Action code Failure code 2nd clutch solenoid: Malfunction

(2nd command holding pressure, 2nd clutch fill switch OFF, slipping
Trouble
E03 15SFMA detected)
• The signal from the fill switch stays OFF during an output to the 2nd clutch ECMV and an abnormal-
Contents of
ity exists in the value calculated from the signals of transmission input shaft speed sensor, transmis-
trouble
sion intermediate shaft speed sensor and transmission output shaft speed sensor.
Problem that
machine
Related infor-
mation • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for 2nd

Resis-
tance
Resis-
tance
2 Max. 1 z
Max. 1 z
detection
4
controller Wiring harness between ACT3 (female) (5) – Resis-
5 – 15 z
ACT3 (female) (3) tance
50 HM300-2R
Table 1
Trouble clutch
signal lost)
F6
F5
Low Low 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
High High 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Low Low 2H F4 OFF
1st 1st 2L F3 OFF
F2
High High 2L F3 OFF
1st 1st 2L F3 OFF
F1
Low Low 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM300-2R 51
Failure code [15SGL1] (3rd clutch solenoid: Fill signal is ON when

Action code Failure code 3rd clutch solenoid: Fill signal is ON when command current is OFF.
Trouble
E03 15SGL1 (Transmission controller system)
Contents of • Even when output to the 3rd clutch ECMV is turned “OFF“, the signal from the fill switch stays “ON“
Problem that
machine
Related infor-
mation

Defective 3rd clutch fill When Resis-
1 Min. 1 Mz
switch Between CN17 (male) (1) – body released tance
ground When Resis-
Max. 1 z
engaged tance
2
tance
(female) (1)
3 Min. 1 Mz
Max. 1 z
engaged tance
52 HM300-2R
Table 2
Trouble clutch
[Command ON]
(Fill SW ON)
2nd OFF Neutral OFF
F6
Low OFF Neutral OFF
2nd OFF Neutral OFF
F5
High 3H F6 OFF
3rd 3L F5 OFF
F4
Low 3L F5 OFF
3rd 3L F5 OFF
F3
High 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Low 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
High 1H F2 OFF
2nd OFF Neutral OFF
R3
Low OFF Neutral OFF
3rd 3R R3 OFF
R2
Low OFF Neutral OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Low OFF Neutral OFF
HM300-2R 53
54 HM300-2R
HM300-2R 55
Failure code [15SGMA] (3rd clutch solenoid: Malfunction) 1
Action code Failure code 3rd clutch solenoid: Malfunction

(3rd command holding pressure, 3rd clutch fill switch OFF, slipping
Trouble
E03 15SGMA detected)
• The signal from the fill switch stays OFF during an output to the 3rd clutch ECMV and an abnormality
Contents of
trouble
Problem that
machine
Related infor-
mation • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for 3rd

Resis-
tance
Resis-
tance
2 Max. 1 z
Max. 1 z
detection
4
5 – 15 z
56 HM300-2R
Table 1
Trouble clutch
signal lost)
F6
F5
Low Low 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
High High 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Low Low 2H F4 OFF
1st 1st 2L F3 OFF
F2
High High 2L F3 OFF
1st 1st 2L F3 OFF
F1
Low Low 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM300-2R 57
Failure code [15SJMA] (Lockup clutch solenoid: Malfunction) 1
Action code Failure code Lockup clutch solenoid: Malfunction

(Lockup command holding pressure, lockup clutch fill switch OFF,
Trouble
E03 15SJMA slipping detected)
• During an output to the lockup clutch solenoid, an abnormality exists in the value calculated from the
Contents of
signals of engine speed sensor, transmission intermediated shaft speed sensor, and transmission
trouble
output shaft speed sensor.
Action of • Holds gear speed during traveling and turns lockup to OFF.
controller • Holds neutral when gear shift lever is set to “N“.
Problem that
• Lockup is released and gear shift is disabled.
appears on
machine • If gear shift lever is shifted to “N“, machine does not start unless it is stopped.
Related infor-
mation • If the electrical system is normal, check for a failure in the hydraulic or mechanical system for lockup

Defective lockup clutch Resis-
1 Between CN18 (male) (1) – (2) 5 – 15 z
solenoid tance
Resis-
Between CN18 (male) (1), (2) – ground Min. 1 Mz
tance
2 Max. 1 z
Max. 1 z
detection
4
5 – 15 z
ATC3 (female) (23) tance
58 HM300-2R
HM300-2R 59
Failure code [15SKMA] (Inter-axle differential lockup pressure control

valve: Malfunction) 1
Action code Failure code Inter-axle differential lockup pressure control valve: Malfunction
Trouble (Failure of pressure control valve)
E01 15SKMA (Transmission controller system)
Contents of • Whereas there is output to differential lockup clutch pressure control valve, clutch does not engage
trouble or clutch slips.
• Turns inter-axle differential lockup command OFF.
Action of
controller • Even though the symptom of failure disappears, it does not return to normal unless once turning
starting switch OFF.
Problem that
appears on • Inter-axle differential lockup does not operate.
machine
Related infor- • Output current to inter-axle differential lockup pressure control valve can be checked by monitoring
mation function (code: 31607).

Defective differential lockup Resis-
1 Between CN20 (male) (1) – (2) 7 – 14 z
pressure control valve tance
Resis-
tance
Possible causes
and standard
Disconnection in wiring ing switch still OFF.
value in normal
state harness Wiring harness between ACT3 (female) (35) Resis-
2 Max. 1 z
(Disconnection or defective – CN20 (female) (1) tance
contact of connectors) Wiring harness between ACT3 (female) (23) Resis-
Max. 1 z
3
controller Resis-
Between ATC3 (female) (35) – (23) 4 – 14 z
tance
60 HM300-2R
HM300-2R 61
Failure code [2F00KM] (Parking brake: Error in operation or setting) 1

Action code Failure code Parking brake: Error in operation or setting
Trouble (Dragging of parking brake)
— 2F00KM (Retarder controller system)
Contents of • When output shaft speed is more than 200 rpm (approx. 5 km/h), parking brake or emergency brake
trouble has been activated.
Action of
controller
Problem that • When oil pressure of accumulator is decreased (ACC switch is turned to OPEN), parking brake
appears on cannot be released.
machine • If the machine is operated in as-is condition, the machine may be damaged.
Related infor-
mation

• Turn parking brake switch to “Release“ position and then travel.
Error in operation of parking
1 • Stop machine completely, turn emergency brake switch to
brake switch
“Release“ position and then travel.
Does the problem The problem is
Relay (R02) is normal
resolve by replacing resolved.
parking brake relay The problem is not Relay (R02) is
(R02)? resolved. defective
Defective parking brake relay Resis- 200 – 400
2 Between R02 (male) (1) – (2)
(R02) tance z
a Prepare with starting switch OFF, disconnect connector R02, and
troubleshooting with starting switch ON.
Applying 24V Resis-
Min. 1 Mz
Between R02 (male) between (1) – (2) tance
(3) – (6) Voltage not applied Resis-
Max. 1 z
between (1) – (2) tance
Defective parking brake oil Turn parking brake Resis-
3 Min. 1 Mz
Possible causes pressure switch Between B17 (male) switch to “Release“ tance
and standard (1) – (2) Turn parking brake Resis-
value in normal Max. 1 z
switch to “Park“ tance
state
Error in operation of
emergency brake
4
(Operate emergency brake • Do not operate emergency brake unless it is necessary.
while traveling)
Disconnection in wiring Wiring harness between R02 (female) (2), Resis-
Max. 1 z
harness (6) – machine body tance
5
(Disconnection or defective Wiring harness between fuse BT3 (16) – B17 Resis-
contact) Max. 1 z
(female) (1) tance
Wiring harness between R02 (female) (1) – Resis-
Max. 1 z
B17 (female) (2) tance
Defective harness grounding ing switch still OFF.
6
(Contact with ground circuit) Between ground and wiring harness between Resis-
Min. 1 Mz
BRC3 (female) (9) – R02 (female) (3) tance
ing switch ON.
Turn parking brake
7 Defective retarder controller Voltage Max. 1V
Between BRC3 (9) switch to “Release“
and ground Turn parking brake
Voltage 20 – 30 V
switch to “Park“
62 HM300-2R
HM300-2R 63
Failure code [2G42ZG] (Front accumulator: Oil pressure too low) 1
Action code Failure code Front accumulator: Oil pressure too low
Trouble
E03 2G42ZG (Retarder controller system)
Contents of • When engine is running (continuously for more than 30 seconds), signal from front accumulator oil
trouble pressure sensor became below 6.9 MPa {70 kg/cm²} (Voltage is below 1.56 V)
Action of
controller
Problem that
appears on • If machine is kept operated in such a condition, front brake may become ineffective.
machine
Related infor- • Input signal of accumulator pressure can be checked in monitoring function (code: 35500 and
mation 35506).

Possible causes • Front accumulator (brake) oil pressure is normal.
Front accumulator
and standard 1 a If oil pressure is not normal, carry out troubleshooting for
(brake) oil pressure too low
value in normal hydraulic and mechanical systems.
state
• If front accumulator (brake) oil pressure is normal, the retarder
2 Defective retarder controller
controller is defective.
Failure code [2G43ZG] (Rear accumulator: Oil pressure too low) 1
Action code Failure code Rear accumulator: Oil pressure too low
Trouble
E03 2G43ZG (Retarder controller system)
Contents of • When engine is running (continuously for more than 30 seconds), signal from rear accumulator oil
trouble pressure sensor became below 6.9 MPa {70 kg/cm²} (Voltage is below 1.56 V)
Action of
controller
Problem that
appears on • If machine is kept operated in such a condition, rear brake may become ineffective.
machine
Related infor- • Input signal of accumulator pressure can be checked in monitoring function (code: 35501 and
mation 35507).

Possible causes • Rear accumulator (brake) oil pressure is normal.
Rear accumulator
and standard 1 a If oil pressure is not normal, carry out troubleshooting for
(brake) oil pressure too low
value in normal hydraulic and mechanical systems.
state
• If rear accumulator (brake) oil pressure is normal, there is a
defect in retarder controller.
64 HM300-2R
HM300-2R 65

© 2007 KOMATSU
All Rights Reserved
66 HM300-2R
SEN03425-00
HM300-2R

Failure code [989A00] (Engine over run prevention command signal: Operating) ......................................... 3
Failure code [989D00] (Rear section tipping over alarm: Alarm is activated.) ................................................ 3
Failure code [AA10NX] (Air cleaner element: Clogged).................................................................................. 4
Failure code [AB00MA] (Alternator: Malfunction)............................................................................................ 6
Failure code [B@BAZK] (Engine oil : Level too low)....................................................................................... 7
Failure code [B@BCNS] (Eng overheat) ........................................................................................................ 8
Failure code [B@BCZK] (Radiator coolant: Level too low) ............................................................................. 9
Failure code [B@BFZK] (Fuel level: Level too low) ...................................................................................... 10
Failure code [B@C6NS] (Front brake oil: Overheat) .....................................................................................11
Failure code [B@C8NS] (Center brake oil: Overheat) ...................................................................................11
Failure code [B@CENS] (Torque converter: Overheat) ................................................................................ 12
Failure code [B@HAZK] (Hydraulic tank oil: Level too low).......................................................................... 13
Failure code [B@JANS] (Steering oil: Overheat) .......................................................................................... 14
Failure code [CA111] (Abnormality in engine controller) ............................................................................... 15
HM300-2R 1
Failure code [CA115] (Abnormal engine Ne and Bkup sensors)................................................................... 16

Failure code [CA122] (Charge pressure sensor too high)............................................................................. 18
Failure code [CA123] (Charge pressure sensor too low) .............................................................................. 20
Failure code [CA131] (Throttle sensor tool high) .......................................................................................... 22
Failure code [CA132] (Throttle sensor tool low)............................................................................................ 24
Failure code [CA135] (Oil pressure sensor too high) .................................................................................... 26
Failure code [CA141] (Oil pressure sensor too low) ..................................................................................... 28
Failure code [CA144] (Coolant temperature sensor too high)....................................................................... 30
Failure code [CA145] (Coolant temperature sensor too low) ........................................................................ 32
Failure code [CA153] (Charge temperature sensor too high) ....................................................................... 34
Failure code [CA154] (Charge temperature sensor too low)......................................................................... 36
Failure code [CA187] (Sensor power source 2 too low)................................................................................ 36
Failure code [CA221] (Atmospheric sensor too high) ................................................................................... 38
Failure code [CA222] (Atmospheric sensor too low)..................................................................................... 40
Failure code [CA227] (Sensor power source 2 too high) .............................................................................. 42
Failure code [CA234] (Engine over speed) ................................................................................................... 44
Failure code [CA238] (Abnormal power source for Ne speed sensor).......................................................... 46
Failure code [CA263] (Fuel temperature sensor too high) ............................................................................ 48
Failure code [CA265] (Fuel temperature sensor too low) ............................................................................. 50
Failure code [CA271] (PCV1 short circuit) .................................................................................................... 51
Failure code [CA272] (PCV1 disconnection)................................................................................................. 52
Failure code [CA273] (PCV2 short circuit) .................................................................................................... 53
Failure code [CA274] (PCV2 disconnection)................................................................................................. 54
Failure code [CA322] (Injector No. 1 system disconnection or short circuit)................................................. 56
2 HM300-2R
Failure code [989A00] (Engine over run prevention command signal:

Operating) 1
Action code Failure code Engine over run prevention signal: Operating
Trouble
E02 989A00 (Machine monitor system)
Contents of • When gear speed is set at the position other than neutral, transmission input shaft speed signal
trouble exceeds the input shaft speed which is set for each gear speed to prevent over run.
Action of
• Send out command signal to retarder controller and activate brake.
machine monitor
Problem that
appears on • Brake becomes activated and travel speed lowers.
machine
Related infor-
• Input shaft speed can be checked in monitoring function (code: 31200).
mation

Possible causes a If the machine is traveling with transmission input shaft speed
1 Engine over run
and standard signal at more than 2,600 rpm, engine is over running.
value in normal
• If the machine is not traveling with transmission input shaft speed
state Defective transmission
2 signal at more than 2,600 rpm, there is defect in transmission
controller
controller.
Failure code [989D00] (Rear section tipping over alarm: Alarm is

activated.) 1
Action code Failure code Rear section tipping over alarm: Alarm is activated.
Trouble (Lift operation when machine is inclined)
— 989D00 (Machine monitor system)
Contents of
• Body is lifted when machine is inclined.
trouble
Action of • Inclination caution lamp
controller • Turns on centralized warning lamp and sounds alarm buzzer.
Problem that
appears on • If body is lifted in such condition, machine body may tip over.
machine
Related infor-
• Input signal from pitch angle sensor can be checked with monitoring function (code: 32900, 32902).
mation

and standard
value in normal 1 Error in operation Do not lift body when machine is inclined for more than 15°.
state
HM300-2R 3
Failure code [AA10NX] (Air cleaner element: Clogged) 1
Action code Failure code Air cleaner element: Clogged

Trouble
E01 AA10NX (Machine monitor system)
Contents of
trouble • Air cleaner element clogging signal circuit becomes “OPEN“ (disconnected with GND).
Action of
machine monitor • Takes no particular action.
Problem that
appears on • If machine is operated in such a condition, air intake performance may be deteriorated.
machine
Related infor-
mation

Dust indicator is not indicated in
Air cleaner is normal.
1 Clogged air cleaner red.
Dust indicator is indicated in red. Clogged air cleaner
Relay
The problem is not
(R03)
Does the problem resolve by resolved.
is normal
replacing dust indicator relay
(R03)? Defective
The problem is
relay
resolved.
(R03)
Defective dust indicator relay a Prepare with starting switch OFF and troubleshooting with start-
2 ing switch still OFF.
(R32)
Resis- 200 – 400
Between R03 (male) (1) – (2)
tance z
Applying 24V Resis-
Min. 1 Mz
Between R03 (male) between (1) – (2) tance
Possible causes
and standard (5) – (6) Voltage not applied Resis-
Max. 1 z
value in normal between (1) – (2) tance
state a Prepare with starting switch OFF and troubleshooting with start-
Defective air cleaner Resis-
3 Air cleaner is normal. Max. 1 z
clogging sensor Between M11 (male) tance
(1) – (2) Resis-
Clogged air cleaner Min. 1 Mz
tance
harness Wiring harness between DPC2B (female) (6) Resis-
4 Max. 1 z
(Disconnection or defective – R03 (female) (6) tance
contact) Wiring harness between DPC2B (female) (2) Resis-
Max. 1 z
– R03 (female) (5) tance
5 Defective harness grounding
Min. 1 Mz
M11 (female) (1) tance
ing switch ON.
6 Defective machine monitor
Between DPC2B (2) Air cleaner is normal. Voltage 20 – 30 V
– (6) Clogged air cleaner Voltage Max. 1V
4 HM300-2R
HM300-2R 5
Failure code [AB00MA] (Alternator: Malfunction) 1
Action code Failure code Alternator: Malfunction

Trouble (Failure of battery charge circuit)
E03 AB00MA (Transmission controller system)
Contents of
• Electricity generation signal is not input from alternator while engine is running.
trouble
Action of
controller
Problem that
• If machine is operated in such a condition, power supply voltage may drop and machine may not be
appears on
able to travel.
machine
Related infor-
• It can be checked with monitoring function (code: 04301).
mation

ing switch ON.
27.6 –
1 Defective alternator Between alternator R – E Voltage
29.5 V
a If deteriorated battery is used or in a cold region, voltage may not
rise for a while after engine is started.
ing switch ON.
Possible causes
Between ATC1 (15) – ground Voltage 20 – 30 V
value in normal harness a If deteriorated battery is used or in a cold region, voltage may not
state 2 rise for a while after engine is started.
(Disconnection or defective
contact) If no problem is found in above 1 and no voltage is supplied
between ATC1 (15) and ground, there is disconnection and
defective contact of wiring harness between alternator terminal R
and ATC1 (female) (5).
ing switch ON.
Defective transmission
3 Between ACT1 (15) – ground Voltage 20 – 30 V
controller
a If deteriorated battery is used or in a cold region, voltage may not
rise for a while after engine is started.
6 HM300-2R
Failure code [B@BAZK] (Engine oil : Level too low) 1
Action code Failure code Engine oil: Level too low

Trouble
E01 B@BAZK (Transmission controller system)
Contents of
• Engine oil level switch circuit has become “OPEN“ (disconnected with GND).
trouble
Action of
• Turn on the maintenance caution lamp.
controller
Problem that
appears on • If machine is operated in such a condition, engine may be seized.
machine
Related infor-
mation

• Engine oil level is normal.
1 Engine oil level is too low. a If engine oil level is too low, check for an oil leakage around
engine before refilling.
Defective engine oil level Engine oil level is Resis-
2 Max. 1 z
switch Between OL (male) normal tance
Possible causes (1) and ground Engine oil level is too Resis-
Min. 1 Mz
and standard low. tance
value in normal
Disconnection in wiring a Prepare with starting switch OFF and troubleshooting with start-
state
harness ing switch still OFF.
3
(Disconnection or defective Wiring harness between ATC2 (female) (13) Resis-
contact) Max. 1 z
– OL (female) (1) tance
ing switch ON.
Defective transmission Engine oil level is
4 Voltage Max. 1V
controller Between ATC2 (13) – normal
ground Engine oil level is too
Voltage 20 – 30 V
low.
HM300-2R 7
Failure code [B@BCNS] (Eng overheat) 1
Action code Failure code Eng overheat

Trouble
E02 B@BCNS (Engine controller system)
Contents of • While engine was running, engine coolant temperature sensor signal circuit detected that engine
trouble coolant was overheated.
Action of
• Displays engine coolant temperature monitor red on machine monitor.
controller
Problem that
appears on • If machine is used as it is, engine may be seized.
machine
• Engine coolant temperature sensor signal is input to engine controller and then transmitted to
machine monitor through communication system.
Related
• Engine coolant temperature can be checked with monitoring function.
information
(Code: 04107 Coolant Temperature)
• Method of reproducing failure code: Start engine.

Possible causes Overheated engine coolant Check engine coolant for overheating. If it is overheated, remove
1
and standard (When system is normal) cause.
value in normal If cause 1 is not detected, engine coolant temperature sensor may
state Defective engine coolant
2 be defective. Carry out troubleshooting for failure codes [CA144]
temperature sensor system
and [CA145].
8 HM300-2R
Failure code [B@BCZK] (Radiator coolant: Level too low) 1
Action code Failure code Radiator coolant: Level too low

Trouble
E01 B@BCZK (Machine monitor system)
Contents of
• Radiator level switch circuit has become “OPEN“ (disconnected with GND).
trouble
Action of
machine monitor
Problem that
appears on • If machine is operated in such a condition, engine may overheat.
machine
Related infor-
mation

• Radiator coolant level is normal.
Radiator coolant level is too
1 a If radiator coolant level is too low, check for a coolant leakage
low.
around engine and radiator before refilling.
Defective radiator coolant Radiator level is Resis-
2 Max. 1 z
level switch Between M01 (male) normal tance
(1) – (2) Resis-
Possible causes Radiator level too low Min. 1 Mz
tance
and standard
value in normal a Prepare with starting switch OFF and troubleshooting with start-
state Disconnection in wiring ing switch still OFF.
3 Max. 1 z
(Disconnection or defective – FL01 (female) (1) tance
contact) Wiring harness between DPC2B (female) (6) Resis-
Max. 1 z
and ground tance
ing switch ON.
4 Defective machine monitor Radiator level is
Between DPC2B (4) Voltage Max. 1V
normal
– (6)
Radiator level too low Voltage 20 – 30 V
HM300-2R 9
Failure code [B@BFZK] (Fuel level: Level too low) 1
Action code Failure code Fuel level: Level too low

Trouble
— B@BFZK (Machine monitor system)
Contents of
• Fuel level sensor signal (resistance becomes above 70 z) is indicating the level is too low.
trouble
Action of • Does not detect an excessively low fuel level when DJF1KA is detected.
controller • Turns on the fuel level caution lamp.
Problem that
appears on • No particular influence
machine
Related infor- • When fuel level is below the low level, fill the fuel. If indication goes off, it means “fuel shortage“.
mation • Signal from fuel level sensor can be checked with monitoring function (code: 04200 and 04201).

Resis-
1 Defective fuel level sensor Fuel level: at Full Max. 12 z
Between M06 (male) tance
Possible causes (1) – (2) Resis- 74 – 100
and standard Fuel level: at Empty
tance z
value in normal
Resis-
2 Defective machine monitor Fuel level: at Full Max. 12 z
Between DPC3B tance
(female) (3) – 6) Resis- 74 – 100
Fuel level: at Empty
tance z
10 HM300-2R
Failure code [B@C6NS] (Front brake oil: Overheat) 1
Action code Failure code Front brake oil: Overheat

Trouble
E02 B@C6NS (Machine monitor system)
Contents of
• Overheat (120°C) was detected in front brake cooling oil.
trouble
Action of • Turns on brake oil temperature caution lamp.
Problem that
appears on • If the machine is operated in such a condition, the front brake may be damaged.
machine
Related infor-
• Brake oil temperature can be checked with monitoring function (code: 30201).
mation

Front brake oil is overheated.
Investigate the cause and irregular condition of brake, and carry out
1 (When the system is
Possible causes the repair.
operating normally)
and standard
value in normal If no problem is found in cause 1, the front brake oil temperature
state sensor system can be suspected to be defective. Carry out the
Defective front brake oil
2 troubleshooting of failure code [DGR4KZ].
temperature sensor
• If brake cooling oil is not overheated, machine monitor is
defective.
Failure code [B@C8NS] (Center brake oil: Overheat) 1
Action code Failure code Center brake oil: Overheat

Trouble (Brake cooling oil is overheated)
E02 B@C8NS (Machine monitor system)
Contents of
• Center brake cooling oil is overheated.
trouble
Action of
controller
Problem that
appears on • If the machine is operated in such a condition, center brake may be damaged.
machine
Related infor- • This failure code is indicated when the trouble is less likely due to a failure of electrical system.
mation • Center brake oil temperature can be checked with monitoring function (code: 30203 and 30206).

Possible causes Center brake oil is Since the overheat of the center brake oil can be suspected, if there
1
and standard overheated. is an overheat, repair the cause of the failure.
value in normal If no problem is found in cause 1, it is suspected that center brake
state Defective center brake oil
2 oil temperature sensor system is defective. Carry out troubleshoot-
temperature sensor
ing of [Failure code DGR3KZ].
HM300-2R 11
Failure code [B@CENS] (Torque converter: Overheat) 1
Action code Failure code Torque converter: Overheat

Trouble
E02 B@CENS (Transmission controller system)
Contents of
• Overheat (above 120°C) of torque converter has been detected.
trouble
Action of • Turns on the caution lamp of torque converter oil temperature.
Problem that
appears on • If machine is operated in such a condition, torque converter may be damaged.
machine
Related infor-
• Torque converter oil temperature can be checked with monitoring function (code: 30100).
mation

Torque converter is
a Investigate the cause and irregular condition of torque converter,
1 overheated (When system is
transmission, and machine, and repair the trouble.
normal)
Defective torque converter Torque converter
2 oil temperature sensor CN23 (male) Resistance
oil temperature
(Internal short circuit)
Possible causes Between (1) – (2) 50 – 3.5 kz
25 – 100°C
and standard Between (1) – ground Min. 1 Mz
state ing switch still OFF.
Defective harness grounding
3
(Contact with ground circuit) Between ground and wiring harness Resis-
between CN23 (female) (1) – ATC1 (female) Min. 1 Mz
tance
(9)
4 Torque converter
controller ATC1 (female) Resistance
oil temperature
Between (9) – (21) 25 – 100°C 50 – 3.5 kz
12 HM300-2R
Failure code [B@HAZK] (Hydraulic tank oil: Level too low) 1
Controller
Action code Failure code Hydraulic tank oil: Level too low
code Trouble
(Machine monitor system)
E01 B@HAZK MON
Contents of
• The hydraulic oil level switch signal has become “OPEN“ (disconnected with GND).
trouble
• No particular action
Action of
• Turn on the maintenance caution lamp.
machine monitor
• Detect failure when engine is stopped and starting switch terminal C signal is OFF.
Problem that
appears on • If machine is operated in such a condition, hydraulic oil may overheat.
machine
Related infor-
mation

• Hydraulic oil level is normal.
1 Hydraulic oil level too low a If hydraulic oil level is too low, check for an oil leakage around
hydraulic pump and hydraulic piping before refilling.
Defective hydraulic oil level Hydraulic oil level Resis-
2 Max. 1 z
switch Between M02 (male) is normal tance
Possible causes (1) and ground Hydraulic oil level Resis-
Min. 1 Mz
and standard too low tance
value in normal
state
3
(Disconnection or defective Wiring harness between DPC2B (female) (3) Resis-
contact) Max. 1 z
– M02 (female) (1) tance
ing switch ON.
Hydraulic oil level
4 Defective machine monitor Between DPC2B Voltage Max. 1V
is normal
(female) (3) and
ground Hydraulic oil level
Voltage 20 – 30 V
too low
HM300-2R 13
Failure code [B@JANS] (Steering oil: Overheat) 1
Action code Failure code Steering oil: Overheat

Trouble
E02 B@JANS (Transmission controller system)
Contents of • Voltage of steering temperature sensor circuit has become below 1.61 V (oil temperature is above
trouble 120°C).
• No particular action
Action of
• Turn on steering oil temperature caution lamp.
controller
• Turns on centralized warning lamp and sounds alarm buzzer.
Problem that
appears on • If machine is operated in such a condition, it may cause an oil leakage.
machine
Related infor-
• Steering oil temperature can be checked with monitoring function (code: 32701 and 32702).
mation

Steering oil temperature is
overheated. Since the overheat of the steering oil can be suspected, if there is
Possible causes 1
(When the system is operat- an overheat, repair the cause of the failure.
and standard
ing normally)
value in normal
state If no problem is found in cause 1, the steering oil temperature
Defective steering oil sensor system can be suspected to be defective. Carry out the
2
temperature sensor troubleshooting of [Steering oil temperature does not indicate
correctly] in E mode.
14 HM300-2R
Failure code [CA111] (Abnormality in engine controller) 1
Action code Failure code Abnormality in engine controller

Trouble
E03 CA111 (Engine controller system)
Contents of
• Abnormality has occurred in engine controller.
trouble
Action of
controller
Problem that
• Though the engine can operate normally, it may stall during the operation and may not start when the
appears on
engine is stopped.
machine
Related infor-
mation

Since a fuse or circuit breaker of equipped machine side can be
suspected to be defective, directly check them.
1 Defective fuse
(If fuse is blown, or circuit breaker is shut off, it is highly possible
that a defective grounding, etc. has occurred in the circuit.)
harness Wiring harness between J3P (female) (3), (4) Resis-
2 Max. 1 z
(Disconnection or defective – battery (+) tance
Possible causes contact of connectors) Wiring harness between J3P (female) (1), (2) Resis-
and standard Max. 1 z
– ground tance
value in normal
state
Defective harness grounding Between ground and wiring harness Resis-
3 Min. 1 Mz
(Contact with ground circuit) between J3P (female) (3), (4) – battery (+) tance
Between ground and wiring harness Resis-
Min. 1 Mz
between J3P (female) (1), (2) – ground tance
ing switch ON.
4 Defective engine controller
J3P Voltage
Between (3) – (1) 20 – 30 V
HM300-2R 15
Failure code [CA115] (Abnormal engine Ne and Bkup sensors) 1
Action code Failure code Abnormal engine Ne and Bkup speed sensors
Trouble
Contents of • Abnormality has occurred at the same time in Ne speed sensor circuit and Bkup speed sensor
trouble circuit.
Action of
controller
Problem that
• Engine does not start (during engine stop).
appears on
machine • Engine stops (during engine running).
Related infor-
mation

Defective Ne speed sensor
1 Carry out troubleshooting of the failure code [CA689].
circuit
Defective Bkup speed sensor
2 Carry out troubleshooting of failure code [CA778].
circuit
Since a mounting section of Ne speed sensor can be suspected to
Defective Ne speed sensor
Possible causes 3 be defective, directly check the mounting section. (Defective
mounting section
and standard installation of sensor itself, internal defect of flywheel, etc.)
value in normal Since a mounting section of Bkup speed sensor can be suspected
state Bkup speed sensor mounting
4 to be defective, directly check the mounting section. (Defective
section
installation of sensor itself, internal defect of supply pump, etc.)
Defective connection of sensor The defective (wrong) connections of Ne speed sensor and Bkup
5
(wrong connection) speed sensor can be suspected. Directly check them.
Engine controller can be suspected to be defective if no problem
6 Defective engine controller is found in causes 1 – 5 (since this is an internal defect, it cannot
be diagnosed).
16 HM300-2R
HM300-2R 17
Failure code [CA122] (Charge pressure sensor too high) 1

Action code Failure code Charge pressure sensor too high
Trouble
Contents of
trouble • Excessively high voltage has occurred in charge pressure sensor circuit.
Action of
controller • Operate with a fixed charge pressure (400 kPa {4.1 kg/cm²}).
Problem that
appears on • Acceleration performance of engine deteriorates.
machine
Related infor-
mation

Defective sensor power If failure code [CA187] or [CA227] is displayed, carry out
1
source circuit troubleshooting for it first.
Prepare with starting switch OFF and troubleshooting with starting
switch ON or with engine started.
PIM Voltage
Defective charge pressure
2 sensor Between (1) – (3) Power source 4.75 – 5.25 V
(internal defect) Since voltage of sensor is measured with the harness connected,
troubleshooting the harness and the controller if the voltage is
abnormal, and then make judgment after it is determined that there
is no other cause of the abnormality.
Disconnection in wiring Wiring harness between ENG (female) (37) Resis-
Max. 1 z
harness – PIM (female) (1) tance
3
(Disconnection or defective Wiring harness between ENG (female) (44) Resis-
contact of connectors) Max. 1 z
– PIM (female) (2) tance
Wiring harness between ENG (female) (47) Resis-
Max. 1 z
– PIM (female) (3) tance
Possible causes
and standard Between ground and wiring harness
Resis-
value in normal between ENG (female) (37) – PIM (female) Min. 1 Mz
tance
state (1)
4
between ENG (female) (44) – PIM (female) Min. 1 Mz
tance
(2)
Between ground and wiring harness
Resis-
between ENG (female) (47) – PIM (female) Min. 1 Mz
tance
(3)
Between wiring harness from ENG (female)
Resis-
(37) – PIM (female) (1) and wiring harness Min. 1 Mz
tance
from ENG (female) (44) – PIM (female) (2)
Harness short
5 Between wiring harness from ENG (female)
(Harness internal short) Resis-
tance
Resis-
tance
a Prepare with starting switch OFF, and troubleshooting with start-
ing switch ON or with engine started.
ENG Voltage
Between (37) – (47) Power source 4.75 – 5.25 V
18 HM300-2R
HM300-2R 19
Failure code [CA123] (Charge pressure sensor too low) 1
Action code Failure code Charge pressure sensor too low

Trouble
Contents of
• Excessively low voltage has occurred in charge pressure sensor circuit.
trouble
Action of
• Operate with a fixed charge pressure (400 kPa {4.1 kg/cm²}).
controller
Problem that
appears on • Acceleration performance of engine deteriorates.
machine
Related infor-
mation

and standard
value in normal Carry out troubleshooting of failure code [CA122].
state
20 HM300-2R
HM300-2R 21
Failure code [CA131] (Throttle sensor tool high) 1
Action code Failure code Throttle sensor tool high

Trouble
Contents of
• Signal voltage of throttle sensor has become above 4.5 V.
trouble
Action of • Sets the throttle to low idle position when pedal is released and sets to a medium speed position
when pedal is depressed according to idle validation switch.
controller
• Turns on a warning lamp and sounds an alarm buzzer.
Problem that
appears on • Even if the accelerator pedal is depressed, the engine speed does not increase above medium
speed.
machine
Related infor-
mation

1
ing switch ON.
AS1 Accelerator pedal Voltage
At any position
Between (1) – (3) 4.75 – 5.25 V
(power source)
Defective accelerator pedal (13 ± 2 % of power
2 When released
(internal defect) source)
Between (2) – (3)
(77 ± 2 % of power
When depressed
source)
Since voltage of sensor is measured with the harness connected,
Disconnection in wiring Wiring harness between J2P (female) (22) – Resis-
Possible causes Max. 1 z
harness AS1 (female) (1) tance
and standard 3
(Disconnection or defective Wiring harness between J2P (female) (9) – Resis-
value in normal contact of connectors) Max. 1 z
AS1 (female) (2) tance
state
Wiring harness between J2P (female) (23) – Resis-
Max. 1 z
Between ground and wiring harness between Resis-
Min. 1 Mz
Defective harness grounding J2P (female) (22) – AS1 (female) (1) tance
4
Min. 1 Mz
between J2P (female) (9) – AS1 (female) (2) tance
Min. 1 Mz
J2P (female) (23) – AS1 (female) (3) tance
ing switch ON.
J2P Accelerator pedal Voltage
At any position
Between (22) – (23) 4.75 – 5.25 V
5 Defective engine controller (power source)
(13 ± 2 % of power
When released
source)
Between (9) – (23)
(77 ± 2 % of power
When depressed
source)
22 HM300-2R
HM300-2R 23
Failure code [CA132] (Throttle sensor tool low) 1
Action code Failure code Throttle sensor too low

Trouble
Contents of
• Excessively low voltage has occurred in throttle sensor circuit.
trouble
Action of
• Establishes the throttle opening and controls using signals other than throttle sensor signal.
controller
Problem that
appears on
machine
Related infor-
mation

and standard
state
24 HM300-2R
HM300-2R 25
Failure code [CA135] (Oil pressure sensor too high) 1
Action code Failure code Oil pressure sensor too high

Trouble
Contents of
• Excessively high voltage has occurred in oil pressure sensor circuit.
trouble
Action of
• Operates with oil pressure at default value (250 kPa {2.55 kg/cm²})
controller
Problem that
appears on
machine
Related infor-
mation

1
Prepare with starting switch OFF and troubleshooting with starting
switch ON or with engine started.
POIL Voltage
Defective oil pressure sensor Between (1) – (2) Power source 4.75 – 5.25 V
2
(internal defect)
Max. 1 z
harness – POIL (female) (1) tance
3
– POIL (female) (2) tance
Max. 1 z
– POIL (female) (3) tance
value in normal Between ground and wiring harness between Resis-
state Min. 1 Mz
Defective harness grounding ENG (female) (37) – POIL (female) (1) tance
4
Min. 1 Mz
ENG (female) (47) – POIL (female) (2) tance
Min. 1 Mz
ENG (female) (13) – POIL (female) (3) tance
Resis-
(37) – POIL (female) (1) and wiring harness Min. 1 Mz
tance
from ENG (female) (47) – POIL (female) (2)
Harness short
tance
Resis-
tance
ENG Voltage
Between (37) – (47) Power source 4.75 – 5.25 V
26 HM300-2R
HM300-2R 27
Failure code [CA141] (Oil pressure sensor too low) 1
Action code Failure code Oil pressure sensor too low

Trouble
Contents of
• Excessively low voltage has occurred in oil pressure sensor circuit.
trouble
Action of
• Operates with oil pressure at default value (250 kPa {2.5 kg/cm²})
controller
Problem that
appears on
machine
Related infor-
mation

and standard
state
28 HM300-2R
HM300-2R 29
Failure code [CA144] (Coolant temperature sensor too high) 1
Action code Failure code Coolant temperature sensor too high

Trouble
Contents of
• Excessively high voltage has occurred in coolant temperature sensor circuit.
trouble
Action of
• Operates with a fixed coolant temperature (90°C).
controller
Problem that
appears on • Startability of engine lowers at low temperature.
machine
Related infor-
mation

Defective coolant ing switch still OFF.
1 temperature sensor
TWTR (male) Coolant temperature Resistance
(internal defect)
Between (A) – (B) 10 – 100°C 0.6 – 20 kz
harness Wiring harness between ENG (female) (15) Resis-
2 Max. 1 z
Possible causes (Disconnection or defective – TWTR (female) (A) tance
and standard contact of connectors) Wiring harness between ENG (female) (38) Resis-
– TWTR (female) (B) tance
state
3
between ENG (female) (15) – TWTR Min. 1 Mz
tance
(female) (A)
ENG (female) Coolant temperature Resistance
Between (15) – (38) 10 – 100°C 0.6 – 20 kz
30 HM300-2R
HM300-2R 31
Failure code [CA145] (Coolant temperature sensor too low) 1
Action code Failure code Coolant temperature sensor too low

Trouble
Contents of
• Excessively low voltage has occurred in coolant temperature sensor circuit.
trouble
Action of
• Operates with a fixed coolant temperature (90°C).
controller
Problem that
machine
Related infor-
mation

and standard
state
32 HM300-2R
HM300-2R 33
Failure code [CA153] (Charge temperature sensor too high) 1
Action code Failure code Charge temperature sensor too high

Trouble
Contents of
• Excessively high voltage has occurred in charge temperature sensor circuit.
trouble
Action of
• Operates with a fixed charge temperature (intake air temperature) (70°C).
controller
Problem that
machine
Related infor-
mation

Defective charge Intake air tempera-
1 temperature sensor TIM (male) Resistance
ture
(internal defect)
Between (A) – (B) 10 – 100°C 0.5 – 20 kz
Between (A) – ground Any condition Min. 1 Mz
Possible causes harness Wiring harness between ENG (female) (23) Resis-
2 Max. 1 z
and standard (Disconnection or defective – TIM (female) (A) tance
value in normal contact of connectors) Wiring harness between ENG (female) (47) Resis-
state Max. 1 z
– TIM (female) (B) tance
3
Min. 1 Mz
ENG (female) (23) – TIM (female) (A) tance
4 Defective engine controller Intake air tempera-
ENG (female) Resistance
ture
Between (23) – (47) 10 – 100°C 0.5 – 20 kz
34 HM300-2R
HM300-2R 35
Failure code [CA154] (Charge temperature sensor too low) 1
Action code Failure code Charge temperature sensor too low

Trouble
Contents of
• Excessively low voltage has occurred in charge temperature sensor circuit.
trouble
Action of
• Operates with a fixed charge temperature (intake air temperature) (70°C).
controller
Problem that
machine
Related infor-
mation

and standard
state
Failure code [CA187] (Sensor power source 2 too low) 1
Action code Failure code Sensor power source 2 too low

Trouble
Contents of
• Excessively low voltage has occurred in sensor power source 2 (5 V) circuit.
trouble
• Operates using Ne speed sensor signal instead of Bkup speed sensor signal.
• Operate oil pressure sensor with oil pressure at default value (250 kPa {25 kg/cm²})
• Operates with atmospheric pressure sensor value defaulted to (52.44 kPa {0.5 kg/cm²})
Action of • Operates with charge pressure sensor at fixed value (400 kPa {4.1 kg/cm²}).
controller • Operates with EGR inlet pressure sensor value defaulted to (102 kPa {1.0 kg/cm²}) and runs by
limiting output.
• Restricts the EGR valve lift sensor output and closes EGR valve and bypass valve.
• Restricts the bypass valve lift sensor output and closes EGR valve and bypass valve.
Problem that
appears on • Output decreases.
machine
Related infor-
mation

and standard
state
36 HM300-2R
HM300-2R 37
Failure code [CA221] (Atmospheric sensor too high) 1

Action code Failure code Atmospheric pressure sensor too high
Trouble
Contents of
• Excessively high voltage has occurred in atmospheric pressure sensor circuit.
trouble
Action of
• Operates with atmospheric pressure value defaulted to (52.44 kPa {0.51 kg/cm²}).
controller
Problem that
machine
Related infor-
mation

Defective sensor power If failure code [CA187] or [CA227] is displayed, carry out trouble-
1
source circuit shooting for it first.
ing switch ON.
PAMB Voltage
Defective atmospheric Between (1) – (3) Power source 4.75 – 5.25 V
2 pressure sensor Between (2) – (3) Signal
(internal defect)
Max. 1 z
harness – PAMB (female) (1) tance
3
(Disconnection or defective Wiring harness between ENG (female) (3) – Resis-
PAMB (female) (2) tance
Max. 1 z
– PAMB (female) (3) tance
state Min. 1 Mz
Defective harness grounding ENG (female) (37) – PAMB (female) (1) tance
4
Min. 1 Mz
ENG (female) (3) – PAMB (female) (2) tance
Min. 1 Mz
ENG (female) (38) – PAMB (female) (3) tance
Resis-
(37) – PAMB (female) (1) and wiring harness Min. 1 Mz
tance
from ENG (female) (3) – PAMB (female) (2)
Harness short
tance
Resis-
tance
6 Defective engine controller ENG Voltage
Between (37) – (38) 4.75 – 5.25 V
Between (3) – (38)
38 HM300-2R
HM300-2R 39
Failure code [CA222] (Atmospheric sensor too low) 1
Action code Failure code Atmospheric pressure sensor too low

Trouble
Contents of
• Excessively low voltage has occurred in atmospheric pressure sensor circuit.
trouble
Action of
• Operates with atmospheric pressure value defaulted to (52.44 kPa {0.51 kg/cm²}).
controller
Problem that
machine
Related infor-
mation

and standard
state
40 HM300-2R
HM300-2R 41
Failure code [CA227] (Sensor power source 2 too high) 1

Action code Failure code Sensor power source 2 too high
Trouble
Contents of
• Excessively high voltage has occurred in sensor power source 2 (5 V) circuit.
trouble
• Operates using Ne speed sensor signal instead of Bkup speed sensor signal.
Action of • Operate oil pressure sensor with oil pressure at default value (250 kPa {2.55 kg/cm²})
controller • Operates with atmospheric pressure sensor value defaulted to (52.44 kPa {0.53 kg/cm²})
• Operates with charge pressure sensor at fixed value (400 kPa {4.08 kg/cm²}).
Problem that
machine
Related infor-
mation

Check the codes that are displayed at the same time. If any other
1 Defective related circuits
codes are displayed, carry out troubleshooting for those codes.
ing switch ON.
Bkup speed sensor G connector
Disconnect the
Defective sensor (internal devices on the right Oil pressure sensor POIL connector
2
defect) one at a time. Atmospheric
If the code disap- PAMB connector
pressure sensor
pears, that device is
Charge pressure
internally defective. PIM connector
sensor
3 Max. 1 z
(Disconnection or defective – each sensor (female) tance
Possible causes contact of connectors)
and standard Wiring harness between ENG (female) (47) Resis-
Max. 1 z
value in normal – each sensor (female) tance
Defective harness grounding Between ground and wiring harness between Resis-
4 Min. 1 Mz
(Contact with ground circuit) ENG (female) (37) – each sensor (female) tance
Min. 1 Mz
ENG (female) (47) – each sensor (female) tance
Harness short Between wiring harness from ENG (female)
5
(Harness internal short) (37) – each sensor (female) and wiring Resis-
Min. 1 Mz
harness from ENG (female) (47) – each tance
sensor (female)
ing switch ON.
ENG Voltage
Between (37) – (47) 4.75 – 5.25 V
42 HM300-2R
HM300-2R 43
Failure code [CA234] (Engine over speed) 1
Action code Failure code Engine overspeed

Trouble
Contents of
• Engine speed has exceeded the normal operating range.
trouble
Action of
• Limits fuel injection rate until the speed drops within operating range.
controller
Problem that
appears on • Engine speed fluctuates.
machine
Related infor-
mation

Check the failure codes that are displayed at the same time.
1 Defective related circuits If any other codes are displayed, carry out troubleshooting for those
Possible causes codes.
and standard The improper usage of equipped machine can be suspected.
value in normal 2 Improper usage Instruct the proper
state usage.
Engine controller can be suspected to be defective if no problem is
3 Defective engine controller found in causes 1 – 2 (since this is an internal defect, it cannot be
diagnosed).
44 HM300-2R
HM300-2R 45
Failure code [CA238] (Abnormal power source for Ne speed sensor) 1
Action code Failure code Abnormal power source for Ne speed sensor
Trouble
Contents of
• An abnormality has occurred in Ne speed sensor power supply (5 V) circuit.
trouble
Action of
• Controls using Bkup speed sensor signal.
controller
Problem that
• Engine stops during operation (when Bkup speed sensor is defective at the same time).
appears on
machine • Engine cannot be started while stopping (when Bkup speed sensor is defective at the same time).
Related infor-
mation

Disconnect a device
Defective Ne speed sensor shown on the right.
1
(internal defect) If the failure code
Ne speed sensor NE connector
disappears, that
device is internally
defective.
2 Max. 1 z
(Disconnection or defective – NE (female) (1) tance
contact of connectors) Wiring harness between ENG (female) (48) Resis-
– NE (female) (2) tance
and standard
3 Min. 1 Mz
(Contact with ground circuit) ENG (female) (16) – NE (female) (1) tance
Min. 1 Mz
ENG (female) (48) – NE (female) (2) tance
Harness short
(16) – NE (female) (1) and wiring harness Min. 1 Mz
tance
from ENG (female) (48) – NE (female) (2)
ing switch ON.
ENG Voltage
Between (16) – (48) 4.75 – 5.25 V
46 HM300-2R
HM300-2R 47
Failure code [CA263] (Fuel temperature sensor too high) 1
Action code Failure code Fuel temperature sensor too high

Trouble
Contents of
• Excessively high voltage has occurred in fuel temperature sensor circuit.
trouble
• Uses coolant temperature sensor instead of fuel temperature sensor for correction of injection rate.
Action of
Fixes fuel temperature (95°C) and continues operation, if coolant temperature sensor is also defec-
controller
tive.
Problem that
appears on
machine
Related infor-
mation

TFUEL (male) Fuel temperature Resistance
Defective fuel temperature 0°C 30 – 37 kz
1 sensor
25°C 9.3 – 10.7 kz
(internal defect)
Between (A) – (B) 50°C 3.2 – 3.8 kz
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
2 Max. 1 z
Possible causes (Disconnection or defective – TFUEL (female) (A) tance
and standard contact of connectors) Wiring harness between ENG (female) (47) Resis-
– TFUEL (female) (B) tance
state
Defective harness grounding Resis-
3 between ENG (female) (30) – TFUEL Min. 1 Mz
(Contact with ground circuit) tance
(female) (A)
ENG (female) Fuel temperature Resistance
0°C 30 – 37 kz
25°C 9.3 – 10.7 kz
Between (30) – (47) 50°C 3.2 – 3.8 kz
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
48 HM300-2R
HM300-2R 49
Failure code [CA265] (Fuel temperature sensor too low) 1
Action code Failure code Fuel temperature sensor too low

Trouble
Contents of
• Excessively low voltage has occurred in fuel temperature sensor circuit.
trouble
• Uses coolant temperature sensor instead of fuel temperature sensor for correction of injection rate.
Action of
Fixes fuel temperature (95°C) and continues operation, if coolant temperature sensor is also defec-
controller
tive.
Problem that
appears on
machine
Related infor-
mation

and standard
state
50 HM300-2R
Failure code [CA271] (PCV1 short circuit) 1
Action code Failure code PCV1 short circuit

Trouble
Contents of
• Short circuit has occurred in supply pump PCV1 circuit.
trouble
Action of
controller
Problem that
appears on
machine
• Method of reproducing failure code: Turn the starting switch ON.
Related infor-
mation • While engine is running normally, pulse voltage of about 24 V is applied to PCV (1). This pulse volt-
age cannot be measured with circuit tester.

Defective supply pump
1 PCV1 PCV1 (male) Resistance
(internal short circuit) Between (1) – (2) 2.3 – 5.3 z
Between (1), (2) – ground Min. 1 Mz
2 Min. 1 Mz
(Contact with ground circuit) ENG (female) (4) – PCV1 (female) (1) tance
Possible causes
and standard Min. 1 Mz
ENG (female) (5) – PCV1 (female) (2) tance
value in normal
ing switch ON.
Hot short of wiring harness Between ground and wiring harness between
3 Voltage Max. 1 V
(a contact with 24 V circuit) ENG (female) (4) – PCV1 (female) (1)
Between ground and wiring harness between
Voltage Max. 1 V
ENG (female) (5) – PCV1 (female) (2)
4 Defective engine controller ENG (female) Resistance
Between (4) – (5) 2.3 – 5.3 z
HM300-2R 51
Failure code [CA272] (PCV1 disconnection) 1
Action code Failure code PCV1 disconnection

Trouble
Contents of
• Disconnection has occurred in supply pump PCV1 circuit.
trouble
Action of
controller
Problem that
appears on
machine
• Method of reproducing failure code: Turn the starting switch ON.
Related infor-
mation • While engine is running normally, pulse voltage of about 24 V is applied to PCV (1). This pulse volt-
age cannot be measured with circuit tester.

(internal disconnection) Between (1) – (2) 2.3 – 5.3 z
harness Wiring harness between ENG (female) (4) – Resis-
2 Max. 1 z
(Disconnection or defective PCV1 (female) (1) tance
Possible causes contact of connectors) Wiring harness between ENG (female) (5) – Resis-
PCV1 (female) (2) tance
value in normal
3 Min. 1 Mz
Min. 1 Mz
Between (4) – (5) 2.3 – 5.3 z
52 HM300-2R
Failure code [CA273] (PCV2 short circuit) 1
Action code Failure code PCV2 short circuit

Trouble
Contents of
• Short circuit has occurred in supply pump PCV2 circuit.
trouble
Action of
controller
Problem that
appears on
machine
Related infor- • While engine is running normally, pulse voltage of about 24 V is applied to PCV (2). This pulse volt-
mation age cannot be measured with circuit tester.

(internal short circuit) Between (1) – (2) 2.3 – 5.3 z
2 Min. 1 Mz
Possible causes
value in normal
ing switch ON.
Hot short of wiring harness Between ground and wiring harness between
3 Voltage Max. 1 V
(a contact with 24 V circuit) ENG (female) (9) – PCV2 (female) (1)
Voltage Max. 1 V
ENG (female) (10) – PCV2 (female) (2)
Between (9) – (10) 2.3 – 5.3 z
HM300-2R 53
Failure code [CA274] (PCV2 disconnection) 1
Action code Failure code PCV2 disconnection

Trouble
Contents of
• Disconnection has occurred in supply pump PCV2 circuit.
trouble
Action of
controller
Problem that
appears on
machine
Related infor- • While engine is running normally, pulse voltage of about 24 V is applied to PCV (2). This pulse volt-
mation age cannot be measured with circuit tester.

Defective supply pump ing switch still OFF.
1 PCV2
PCV2 (male) Resistance
(internal disconnection)
Between (1) – (2) 2.3 – 5.3 z
harness Wiring harness between ENG (female) (9) – Resis-
2 Max. 1 z
(Disconnection or defective PCV2 (female) (1) tance
and standard – PCV2 (female) (2) tance
3 Min. 1 Mz
Min. 1 Mz
Between (9) – (10) 2.3 – 5.3 z
54 HM300-2R
HM300-2R 55
Failure code [CA322] (Injector No. 1 system disconnection or short

circuit) 1
Action code Failure code Injector No. 1 system disconnection or short circuit
Trouble
Contents of
• A disconnection or short has occurred in injector No. 1 circuit.
trouble
Action of
controller
Problem that
• Output decreases.
appears on
machine • Speed is not stable.

Related infor-
mation • While engine is running normally, pulse voltage of about 65 V is applied to positive (+) side of injec-
tor. This pulse voltage cannot be measured with circuit tester.

Defective injector No. 1 Injector No.1 (terminal) Resistance
1
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
(Disconnection or defective – CN1(1) – injector No.1 (1) (terminal) tance
Max. 1 z
– CN1 (2) – injector No.1 (2) (terminal) tance
Possible causes
value in normal ing switch still OFF.
state Between ground and wiring harness between
Resis-
Defective harness grounding ENG (female) (45) – CN1 (1) – injector No.1 Min. 1 Mz
3 tance
(Contact with ground circuit) (1) (terminal)
Resis-
ENG (female) (53) – CN1 (2) – injector No.1 Min. 1 Mz
tance
(2) (terminal)
Defective another cylinder If multiple failure codes are displayed for infector malfunction, carry
4
injector or wiring harness out troubleshooting for them, too.
Between (45) – (53) 0.4 – 1.1 z
56 HM300-2R
HM300-2R 57

circuit) 1
Trouble
Contents of
trouble
Action of
controller
Problem that
appears on

Related infor-

1
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
(Disconnection or defective – CN5 (1) – injector No.5 (1) (terminal) tance
Max. 1 z
Possible causes
Resis-
3 tance
Resis-
tance
(2) (terminal)
4
Between (46) – (60) 0.4 – 1.1 z
58 HM300-2R
HM300-2R 59

circuit) 1
Trouble
Contents of
trouble
Action of
controller
Problem that
appears on

Related infor-

1
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
Max. 1 z
Possible causes
Resis-
3 tance
Resis-
tance
(2) (terminal)
4
Between (55) – (52) 0.4 – 1.1 z
60 HM300-2R
HM300-2R 61

circuit) 1
Trouble
Contents of
trouble
Action of
controller
Problem that
appears on

Related infor-

1
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
Max. 1 z
Possible causes
Resis-
3 tance
Resis-
tance
(2) (terminal)
4
Between (57) – (59) 0.4 – 1.1 z
62 HM300-2R
HM300-2R 63

circuit) 1
Trouble
Contents of
trouble
Action of
controller
Problem that
appears on

Related infor-

1
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
Max. 1 z
Possible causes
Resis-
3 tance
Resis-
tance
(2) (terminal)
4
Between (54) – (51) 0.4 – 1.1 z
64 HM300-2R
HM300-2R 65

circuit) 1
Trouble
Contents of
trouble
Action of
controller
Problem that
appears on

Related infor-

1
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
Disconnection in wiring har- ing switch still OFF.
ness Wiring harness between ENG (female) (56) Resis-
2 Max. 1 z
Max. 1 z
Possible causes
Resis-
3 tance
Resis-
tance
(2) (terminal)
4
Between (56) – (58) 0.4 – 1.1 z
66 HM300-2R
HM300-2R 67

© 2007 KOMATSU
All Rights Reserved
68 HM300-2R
SEN03426-00
HM300-2R

Failure code [CA342] (Abnormal engine controller data consistency) ............................................................ 3
Failure code [CA351] (Abnormal injector drive circuit).................................................................................... 4
Failure code [CA352] (Sensor power source 1 too low) ................................................................................. 5
Failure code [CA386] (Sensor power source 1 too high) ................................................................................ 6
Failure code [CA431] Idle validation switch error............................................................................................ 8
Failure code [CA432] (Abnormal process with idle validation switch)........................................................... 12
Failure code [CA441] (Power source voltage too low) .................................................................................. 13
Failure code [CA442] (Power source voltage too high) ................................................................................ 13
Failure code [CA449] (Common rail pressure too high 2)............................................................................. 14
Failure code [CA451] (Common rail pressure sensor too high) .................................................................... 16
Failure code [CA452] (Common rail pressure sensor too low) ..................................................................... 18
Failure code [CA553] (Common rail pressure too high 1)............................................................................. 18
Failure code [CA554] (In-range error of common rail pressure sensor) ....................................................... 19
Failure code [CA559] (Loss of pressure feed from supply pump 1).............................................................. 20
HM300-2R 1
Failure code [CA689] (Abnormal engine Ne speed sensor).......................................................................... 24

Failure code [CA731] (Abnormal engine Bkup speed sensor phase) ........................................................... 26
Failure code [CA757] (Loss of all engine controller data) ............................................................................. 26
Failure code [CA778] (Abnormal engine Bkup speed sensor) ...................................................................... 28
Failure code [CA1633] (Abnormal KOMNET) ............................................................................................... 30
Failure code [CA2185] (Throttle sensor power source too high)................................................................... 32
Failure code [CA2186] (Throttle sensor power source too low) .................................................................... 34
Failure code [CA2249] (Loss of pressure feed from supply pump 2)............................................................ 34
Failure code [CA2555] (Disconnection in intake air heater relay) ................................................................. 35
Failure code [CA2556] (Intake air heater relay short circuit) ......................................................................... 36
Failure code [DAF9KM] (Machine monitor connector: Error in operation or setting) .................................... 38
Failure code [DAFRKR] (Abnormal CAN communication (machine monitor): Abnormal communication) ... 40
Failure code [DAQ0KK] (Transmission controller: Power source voltage too low) ....................................... 42
Failure code [DAQ0KT] (Transmission nonvolatile memory: Abnormality in controller)................................ 44
Failure code [DAQ2KK] (Transmission controller solenoid power source: Voltage too low) ......................... 45
Failure code [DAQRKR] (COMMUNICATION LOST: Defective communication) ......................................... 46
Failure code [DAQRMA] (Transmission controller option setting: Malfunction) ............................................ 48
Failure code [DB10KT] (Retarder controller nonvolatile memory: Abnormality in controller) ........................ 48
Failure code [DB12KK] (Retarder controller solenoid power source: Power source voltage too low)........... 49
Failure code [DB13KK] (Retarder controller battery direct power source: Power source voltage too low) ... 50
Failure code [DB19KQ] (Retarder controller model select signal: Inconsistent model selection signal) ....... 51
Failure code [DB1QMA] (Retarder controller option setting: Malfunction) .................................................... 51
Failure code [DB1RKR] (CAN communication (retarder controller): Communication disabled) ................... 52
Failure code [DB2RKR] (CAN communication (engine controller): Communication disabled) ..................... 54
Failure code [DDTHKA] (Fill switch for Hi clutch: Disconnection) ................................................................. 56
Failure code [DDTJKA] (Fill switch for Lo clutch: Disconnection ) ................................................................ 58
Failure code [DDTKKA] (Fill switch for 1st clutch: Disconnection)................................................................ 60
Failure code [DDTLKA] (Fill switch for 2nd clutch: Disconnection) ............................................................... 61
Failure code [DDTMKA] (Fill switch for 3rd clutch: Disconnection)............................................................... 62
Failure code [DDTNKA] (Fill switch for R clutch: Disconnection).................................................................. 63
Failure code [DF10KA] (Gear shift lever: Disconnection) ............................................................................. 64
Failure code [DF10KB] (Gear shift lever: Short circuit) ................................................................................. 67
2 HM300-2R
Failure code [CA342] (Abnormal engine controller data consistency) 1
Action code Failure code Abnormal engine controller data consistency

Trouble
Contents of
• Abnormal data consistency has occurred in engine controller.
trouble
Action of
controller
Problem that
appears on
engine is stopped.
machine
Related infor-
mation

and standard
value in normal Carry out troubleshooting of [CA111].
state
HM300-2R 3
Failure code [CA351] (Abnormal injector drive circuit) 1
Action code Failure code Abnormal injector drive circuit

Trouble
Contents of
• Abnormality has occurred in injector drive circuit.
trouble
Action of
• Operates with limited output.(Limits common rail pressure.)
controller
Problem that
machine
Related infor-
mation

Check the failure codes (codes for injector system trouble) that are
1 Defective related circuits displayed at the same time. If any other codes are displayed, carry
out troubleshooting for those codes.
Since a defect of the fuse or circuit breaker can be suspected,
Defective fuse BT3 (30 – 29) directly check it.
2
or defective circuit breaker (If fuse is blown, or circuit breaker is shut off, it is highly possible
that a defective grounding, etc. has occurred in the circuit.)
harness Wiring harness between J3P (female) (3) – Resis-
Possible causes 3 Max. 1 z
(Disconnection or defective Battery (+) tance
and standard
contact of connectors) Wiring harness between J3P (female) (1) – Resis-
state ground tance
Defective harness grounding Between ground and wiring harness Resis-
4 Min. 1 Mz
(Contact with ground circuit) between J3P (female) (3) – Battery (+) tance
Min. 1 Mz
ground tance
ing switch ON.
J3P Voltage
Between (3) – (1) 20 – 30 V
4 HM300-2R
Failure code [CA352] (Sensor power source 1 too low) 1
Action code Failure code Sensor power source 1 too low

Trouble
Contents of
• Excessively low voltage has occurred in sensor power source 1 (5 V) circuit.
trouble
Action of
• Common rail pressure sensor functions with limited output. (Limits common rail pressure.)
controller
Problem that
machine
Related infor-
mation

and standard
state
HM300-2R 5
Failure code [CA386] (Sensor power source 1 too high) 1
Action code Failure code Sensor power source 1 too high

Trouble
Contents of
• Excessively high voltage has occurred in sensor power source 1 (5 V) circuit.
trouble
Action of
• Common rail pressure sensor functions with limited output. (Limits common rail pressure.)
controller
Problem that
machine
Related infor-
mation

codes.
ing switch ON.
Defective sensor (internal Disconnect a device

2 shown on the right.
defect) Common rail
If the failure code dis- PFUEL connector
pressure sensor
appears, that device
is internally defective.
3 Max. 1 z
(Disconnection or defective – PFUEL (female) (1) tance
Possible causes contact of connectors) Wiring harness between ENG (female) (47) Resis-
– PFUEL (female) (3) tance
value in normal
state
4 Min. 1 Mz
(Contact with ground circuit) ENG (female) (33) – PFUEL (female) (1) tance
Min. 1 Mz
ENG (female) (47) – PFUEL (female) (3) tance
Harness short Between wiring harness from ENG (female)
5
(Harness internal short) (33) – PFUEL (female) (1) and wiring Resis-
Min. 1 Mz
harness from ENG (female) (47) – PFUEL tance
(female) (3)
ing switch ON.
ENG Voltage
Between (33) – (47) 4.75 – 5.25 V
6 HM300-2R
HM300-2R 7
Failure code [CA431] Idle validation switch error 1

Action code Failure code Idle validation switch error
Trouble
Contents of
• Both of signals 1 and 2 of idle validation switch are open or there is trouble in ground circuit.
trouble
Action of
• Operates normally according to throttle sensor (E01 Testing and maintenance)
controller
Problem that
appears on • None in particular.
machine
• The input state (ON/OFF) from the idle validation switch 1 can be checked with the monitoring func-
Related tion (Monitoring code: ENGINE 18300 (1: ON / 0: OFF)).
information • The input state (ON/OFF) from the idle validation switch 2 can be checked with the monitoring func-
tion (Monitoring code: ENGINE 18301 (1: ON / 0: OFF)).

a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
AS1 Signal name Voltage
Between (5) – (4) Signal 1
Defective accelerator pedal See Fig. 1
1 Between (6) – (4) Signal 2
(Internal defect)
Between AS2 (1) – (2) Voltage 5V
Sensor voltage is measured with wiring harness connected.
Accordingly, if voltage is abnormal, check wiring harness and con-
troller, too, for another cause of trouble, and then judge.
a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.
Max. 1 z
Disconnection in wiring har- Wiring harness between J2P (female) (11) – Resis-
Max. 1 z
ness (Disconnection in wiring AS1 (female) (5) tance
2
or defective contact in con- Wiring harness between J2P (female) (1) – Resis-
nector) Max. 1 z
Possible causes AS1 (female) (6) tance
and standard Wiring harness between ATC1 (female) (4) Resis-
– AS2 (female) (2) tance
state
Wiring harness between ATC3 (female) (34) Resis-
Max. 1 z
– AS2 (female) (1) tance
Between wiring harness J2P (female) (32) – Resis-
Ground fault in wiring har- Min. 1 Mz
AS1 (female) (4) and ground tance
3 ness (Short circuit with GND
circuit) Between wiring harness J2P (female) (11) – Resis-
Min. 1 Mz
Between wiring harness J2P (female) (1) – Resis-
Min. 1 Mz
Between wiring harness J2P (female) (32) –
Voltage Max. 1 V
Hot short (Short circuit with AS1 (female) (4) and ground
4
24V circuit) in wiring harness Between wiring harness J2P (female) (11) –
Voltage Max. 1 V
AS1 (female) (5) and ground
Between wiring harness J2P (female) (1) –
Voltage Max. 1 V
AS1 (female) (6) and ground
8 HM300-2R

5 Defective engine controller J2P Signal name Voltage
Possible causes Between (11) – (32) Signal 1
and standard See Fig. 1
Between (1) – (32) Signal 2
value in normal
state 1) Starting switch OFF.
2) Disconnect AS2.
Defective transmission con- 3) Disconnect ATC3 and ATC1.
6 4) Connect T-blanch to ATC3 and ATC1.
troller
5) Turn starting switch ON and carry out troubleshooting.
Between ATC3 (34) and ATC1 (4) Voltage 5V
HM300-2R 9
Fig. 1
Pedal: Stroke of accelerator pedal

Output voltage: Output voltage (%)
Sig1: Signal voltage of throttle sensor
Sig2: Signal voltage of idle validation switch 1
Sig3: Signal voltage of idle validation switch 2
Lo: Switch circuit is closed
Hi: Switch circuit is open
Switch gap: Overlap between signals of switch 1
and switch 2
10 HM300-2R
HM300-2R 11
Failure code [CA432] (Abnormal process with idle validation switch) 1
Action code Failure code Abnormal process with idle validation

Trouble
Contents of • Throttle potentiometer signal of accelerator pedal is inconsistent with idle validation switch signal 1
trouble and 2.
• Turns on a warning lamp and sounds an alarm buzzer.
Action of
controller • Fixes throttle at low idle or fixes engine speed at idle when the pedal is released and at a medium
speed when the pedal is depressed.
Problem that
• Even if accelerator pedal is depressed, the engine speed stays at low idle or does not increase
appears on
above medium speed.
machine
Related infor-
mation

and standard
state
12 HM300-2R
Failure code [CA441] (Power source voltage too low) 1
Action code Failure code Power source voltage too low

Trouble
Contents of
• Excessively low voltage has occurred in power source voltage circuit.
trouble
Action of
controller
Problem that
appears on
engine is stopped.
machine
Related infor-
mation

and standard
state
Failure code [CA442] (Power source voltage too high) 1
Action code Failure code Power source voltage too high

Trouble
Contents of
• Excessively high voltage has occurred in power source voltage circuit.
trouble
Action of
controller
Problem that
appears on
engine is stopped.
machine
Related infor-
mation

and standard
state
HM300-2R 13
Failure code [CA449] (Common rail pressure too high 2) 1
Action code Failure code Common rail pressure too high 2

Trouble
Contents of
• Excessively high pressure (level 2) has been detected with common rail pressure sensor circuit.
trouble
Action of
controller
Problem that
machine
Related infor-
mation

and standard
state
14 HM300-2R
HM300-2R 15
Failure code [CA451] (Common rail pressure sensor too high) 1

Action code Failure code Common rail pressure sensor too high
Trouble
Contents of
trouble • Excessively high voltage has occurred in common rail pressure sensor circuit.
Action of
controller • Operates with limited output.(Limits common rail pressure.)
Problem that
machine
Related infor-
mation

1
ing switch ON.
PFUEL Voltage
Defective common rail Between (1) – (3) Power source 4.75 – 5.25 V
2 pressure sensor Between (2) – (3) Signal 0.25 – 4.6 V
(internal defect)
Max. 1 z
harness – PFUEL (female) (1) tance
3
Max. 1 z
state Min. 1 Mz
Defective harness grounding ENG (female) (33) – PFUEL (female) (1) tance
4
Min. 1 Mz
Min. 1 Mz
Resis-
(33) – PFUEL (female) (1) and wiring harness Min. 1 Mz
tance
from ENG (female) (25) – PFUEL (female) (2)
Harness short
tance
Resis-
tance
ing switch ON.
6 Defective engine controller ENG Voltage
Between (33) – (47) 4.75 – 5.25 V
Between (25) – (47) 0.25 – 4.6 V
16 HM300-2R
HM300-2R 17
Failure code [CA452] (Common rail pressure sensor too low) 1
Action code Failure code Common rail pressure sensor too low
Trouble
Contents of
• Excessively low voltage has occurred in common rail pressure sensor circuit.
trouble
Action of
controller
Problem that
machine
Related infor-
mation

and standard
state
Failure code [CA553] (Common rail pressure too high 1) 1
Action code Failure code Common rail pressure too high 1

Trouble
Contents of
trouble • Excessively high pressure (level 1) has been detected with common rail pressure sensor circuit.
Action of
controller • Takes no particular action.
Problem that
machine
Related infor-
mation

codes.
Since the use of improper fuel can be suspected, check the fuel.
2 Improper fuel has been used.
(Viscosity is too high)
Since an electrical defect of common
Possible causes Defective electrical system of
3 rail pressure sensor is suspected, carry out troubleshooting for the
and standard common rail pressure sensor
following code. [CA451]
value in normal
state Defective mechanical system
Since a mechanical defect of common rail pressure sensor is sus-
4 of common rail pressure sen-
pected, directly check the sensor.
sor
Since a damage of spring, wear of seat or sticking of ball is sus-
5 Defective overflow valve
pected, directly check them.
6 Clogged over flow piping Since an over flow piping is suspected to be clogged, directly check it.
Since a mechanical defect of pressure limiter is suspected, directly
7 Defective pressure limiter
check the limiter.
18 HM300-2R
Failure code [CA554] (In-range error of common rail pressure sensor) 1
Action code Failure code In-range error in common rail pressure sensor
Trouble
Contents of
• In-range error has occurred in common rail pressure sensor circuit.
trouble
Action of
controller
Problem that
machine
Related infor-
mation

and standard
state
HM300-2R 19
Failure code [CA559] (Loss of pressure feed from supply pump 1) 1
Action code Failure code Loss of pressure feed from supply pump 1
Trouble
Contents of
• Loss of pressure feed (level 1) from supply pump has occurred.
trouble
Action of
• Limits common rail pressure.
controller
Problem that
machine
Related infor-
mation

codes.
2 Improper fuel has been used. Since the use of improper fuel is suspected, directly check the fuel.
a See “Note 1“ for the contents of diagnosis. See Testing and
adjusting “Testing fuel pressure“ for the pressure inspection of the
Defective low pressure fuel low pressure circuit.
3
circuit device
Fuel low pressure circuit Min. 0.15 MPa
pressure {Min. 1.5 kg/cm²}
4 Clogged filter or strainer a See “Note 2“ for the contents of diagnosis.
Defective electrical system of Since an electrical defect of supply pump PCV is suspected, carry
5 supply pump PCV out troubleshooting for the following codes.
[CA271], [CA272], [CA273], and [CA274]
Possible causes Defective common rail Since a defect of common rail pressure sensor is suspected, check
6
and standard pressure sensor for a damage in harnesses.
value in normal a As for testing an amount of pressure limiter leak, see testing and
state adjusting “Testing fuel return and leak amount“.
7 Defective pressure limiter
Pressure limiter leak amount Max. 10 cc/min (at 1,600 rpm)
a As for the test relating to return (spill) limit amount of injector, see
testing and adjusting “Testing fuel return and leak amount“.
Speed under the conditions
Injector return (spill)
which is equivalent to rated
limit amount
operation
8 Defective injector 1,600 rpm 960 cc/min
1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
Supply pump can be suspected to be defective if no problem is
9 Defective supply pump
found in causes 1 – 8.
<How to use the check sheet>

Carry out the above diagnosis as well as record the results for the contents of diagnosis using the attached
“Check sheet for loss of pressure feed“.
20 HM300-2R
Note 1: When low-pressure circuit is defective, check the following:

1) Fuel level
2) Clogged hydraulic tank breather
3) Stuck or worn feed pump, clogged filter
4) Leaked or clogged low-pressure fuel pipe
5) Bypass valve malfunction, defective assembly of other parts (See Fig.1.)
6) Clogged fuel filter
7) Fuel in oil pan (fuel leakage in head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Follow the procedure below to check, clean, and replace filter and strainer.
1) Gauze filter: Disassemble this filter for checking. If clogged, clean it.
2) Gauze filter upstream strainer: Clean upstream strainer if gauze filter is clogged.
3) Fuel filter: If failure is not remedied after steps 1) and 2) above were executed, replace fuel filter.
HM300-2R 21
Check sheet for no-pressure feed
Machine model Working No.

Model serial No. Checked on / /
Engine Service meter h
Engine serial No. Worker name
A. Visual check Good Bad

1 Fuel leakage to outside
2 Clogged fuel tank breather
B. Check with machine monitor (Abnormality record, monitoring, cylinder cut-out operation) Good Bad
3 Checking failure code / / / /
Checking monitoring information
Standard value
Measured
Code Display item Check conditions Unit (Reference Good Bad
value
value)
Low idle rpm 1,930 ± 50
*1 Engine Speed High idle rpm 1,000 ± 25
Rating or equivalent rpm 1,850
Low idle % 0
*2 Throttle speed
High idle % 100
Injection rate
*3 Rating or equivalent mm³ — — —
command
4
Common rail
*4 Rating or equivalent MPa
pressure command
Common rail fuel
*5 Rating or equivalent MPa
pressure
Low idle CA — — —
Injection timing
*6 High idle CA — — —
command
Rating or equivalent CA — — —
*7 Boost Pressure Rating or equivalent kPa — — —
Engine coolant
*8 Low idle °C — — —
temperature (High)
*9 Fuel temperature Low idle °C — — —
Checking cylinder cut-out operation (Engine speed)
Standard value
Func- Measured
Cut-out cylinder Check conditions Unit (Reference Good Bad
tion value
value)
Cylinder 1 Low idle rpm — — —
5 Cylinder 2 Low idle rpm — — —
*10
22 HM300-2R
Standard value
C. Checking fuel circuit Measured
Check conditions Unit (Reference Good Bad
pressure value
value)
Pressure in fuel MPa Min. 0.15
6 High idle
low-pressure circuit {kg/cm²} {Min. 1.5}
D. Checking strainer, filter Good Bad

7 Visual check of strainer
8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve
Standard value
E. Checking leakage and fuel Measured
Check conditions Unit (Reference Good Bad
return rate value
value)
Leakage through pressure
11 Rating or equivalent cc/min Max. 10
limiter
Rating or equivalent
cc/min 960
1600 rpm
cc/min 1,020
1,700 rpm
Speed:
12 Return rate from injector cc/min 1,080
1,800 rpm
Return rate:
cc/min 1,140
1,900 rpm
cc/min 1,200
2,000 rpm
*1 to *10:
When using the monitoring function for checking, see Monitoring Code List.
Equivalent to rating:
1) Engine at full throttle, 2) Torque converter is relieved.
HM300-2R 23
Failure code [CA689] (Abnormal engine Ne speed sensor) 1
Action code Failure code Abnormal engine Ne speed sensor

Trouble
Contents of
• An abnormality has occurred in engine Ne speed sensor circuit.
trouble
Action of
• Operates using Bkup speed sensor signal.
controller
Problem that
• Engine stops during operation (when Bkup speed sensor is defective at the same time).
appears on
machine • Engine cannot be started while stopping (when Bkup speed sensor is defective at the same time).
Related infor-
mation

Defective sensor power If failure code [CA238] is displayed at the same time, carry out trou-
1
source circuit bleshooting for it first.
Max. 1 z
harness – NE (female) (1) tance
2
Max. 1 z
Min. 1 Mz
Defective harness grounding ENG (female) (16) – NE (female) (1) tance
3
Min. 1 Mz
ENG (female) (48) – NE (female) (2) tance
Possible causes Between ground and wiring harness between Resis-
Min. 1 Mz
and standard ENG (female) (27) – NE (female) (3) tance
Resis-
tance
Harness short
tance
Resis-
tance
Defective mounting of sensor Since defective mounting of Ne speed sensor (improper gap) or
5 or defective parts for speed defective parts for speed detection (flywheel) can be suspected,
detection directly check it.
Engine Ne speed sensor can be suspected to be defective if no
Defective engine Ne speed
6 problem is found in causes 1 – 5 (since this is an internal defect, it
sensor
cannot be diagnosed).
diagnosed).
24 HM300-2R
HM300-2R 25
Failure code [CA731] (Abnormal engine Bkup speed sensor phase) 1
Action code Failure code Abnormal engine Bkup speed sensor phase
Trouble
Contents of
• Abnormal phase has been detected in the engine Bkup sensor circuit.
trouble
Action of
• Operates using engine Ne speed sensor signal.
controller
Problem that
• Engine stops during operation (when Ne speed sensor is defective at the same time).
appears on
machine • Engine cannot be started while stopping (when Ne speed sensor is defective at the same time).
Related infor-
mation

Possible causes
Defective engine Ne speed Since a defect of engine Ne speed sensor can be suspected, carry
and standard 1
sensor circuit out troubleshooting for the following code. [CA689]
value in normal
state Defective engine Bkup Since a defect of engine Bkup speed sensor can be suspected,
2
speed sensor system carry out troubleshooting for the following code. [CA778]
Failure code [CA757] (Loss of all engine controller data) 1
Action code Failure code Loss of all engine controller data

Trouble
Contents of
• Loss of all data in engine controller has been detected.
trouble
Action of
controller
Problem that
appears on
engine is stopped.
machine
Related infor-
mation

and standard
state
26 HM300-2R
HM300-2R 27
Failure code [CA778] (Abnormal engine Bkup speed sensor) 1
Action code Failure code Abnormal engine Bkup speed sensor

Trouble
Contents of
• An abnormality has occurred in engine Bkup speed sensor circuit.
trouble
Action of
• Operates using Ne speed sensor signal.
controller
Problem that
• Engine stops during operation (when Ne speed sensor is defective at the same time).
appears on
machine • Engine cannot be started while stopping (when Ne speed sensor is defective at the same time).
Related infor-
mation

1
Max. 1 z
harness – G (female) (1) tance
2
– G (female) (2) tance
Max. 1 z
– G (female) (3) tance
Min. 1 Mz
Defective harness grounding between ENG (female) (37) – G (female) (1) tance
3
Min. 1 Mz
between ENG (female) (47) – G (female) (2) tance
Possible causes Between ground and wiring harness Resis-
Min. 1 Mz
and standard between ENG (female) (26) – G (female) (3) tance
Resis-
(37) – G (female) (1) and wiring harness Min. 1 Mz
tance
from ENG (female) (47) – G (female) (2)
Harness short
tance
Resis-
tance
Defective mounting of sensor Since defective mounting of Bkup speed sensor (improper gap) or
5 or defective parts for speed defective parts for speed detection (in supply pump) can be
detection suspected, directly check it.
Engine Bkup speed sensor can be suspected to be defective if no
Defective engine Bkup
6 problem is found in causes 1 – 5 (since this is an internal defect, it
speed sensor
cannot be diagnosed).
diagnosed).
28 HM300-2R
HM300-2R 29
Failure code [CA1633] (Abnormal KOMNET) 1
Action code Failure code Abnormal KOMNET

Trouble
Contents of
• An abnormality has occurred in the KOMNET communication circuit to the machine monitor.
trouble
Action of
• Operates in a default mode or keeps the conditions when the abnormality has occurred.
controller
Problem that
appears on
machine
Related infor-
mation

Wiring harnesses among DPC4 (female) (3)
Disconnection in wiring – J2P (female) (46) – ATC2 (female) (32) – Resis-
Max. 1 z
harness BRC2 (female) (32) – TC200 (female) (8) – tance
1
(Disconnection or defective CAN1 (female) (A) – CAN2 (female) (A)
contact of connectors) Wiring harnesses among DPC4 (female) (8)
– J2P (female) (47) – ATC2 (female) (22) – Resis-
Max. 1 z
BRC2 (female) (22) – TC200 (female) (7) – tance
CAN1 (female) (B) – CAN2 (female) (B)
Between ground and wiring harnesses
among DPC4 (female) (3) – J2P (female)
(46) – ATC2 (female) (32) – BRC2 (female) Resis-
Min. 1 Mz
(32) – TC200 (female) (8) – CAN1 (female) tance
Possible causes Defective harness grounding (A) – CAN2 (female) (A) – other related cir-
2
and standard (Contact with ground circuit) cuits.
value in normal Between ground and wiring harnesses
state among DPC4 (female) (8) – J2P (female)
(47) – ATC2 (female) (22) – BRC2 (female) Resis-
Min. 1 Mz
(22) – TC200 (female) (7) – CAN1 (female) tance
(B) – CAN2 (female) (B) – other related cir-
cuits.
ing switch ON.
(46) – ATC2 (female) (32) – BRC2 (female)
Voltage Max. 1 V
(32) – TC200 (female) (8) – CAN1 (female)
Hot short in wiring harness (A) – CAN2 (female) (A) – other related cir-
3
(a contact with 24 V circuit) cuits.
(47) – ATC2 (female) (22) – BRC2 (female)
Voltage Max. 1 V
(22) – TC200 (female) (7) – CAN1 (female)
(B) – CAN2 (female) (B) – other related cir-
cuits.
30 HM300-2R

Possible causes Defective CAN terminal Resis- 120 z ±
4 Between CAN 1(male) (A) – (B)
and standard resistance tance 10%
value in normal Resis- 120 z ±
state Between CAN2 (male) (A) – (B)
tance 10%
Defective machine monitor, If no problem is found in causes 1 – 4, machine monitor, engine
5 engine controller or pump controller or pump controller can be suspected to be defective
controller (since this is an internal defect, it cannot be diagnosed).
HM300-2R 31
Failure code [CA2185] (Throttle sensor power source too high) 1
Action code Failure code Throttle sensor power source too high
Trouble
Contents of
• Excessively high voltage has occurred in the throttle sensor power source (5 V) circuit.
trouble
Action of • Establishes the throttle opening using signals other than throttle sensor signal in order to operate
controller engine. (depends on an equipped machine)
Problem that
appears on • Depends on an equipped machine.
machine
Related infor-
• Connector No. may vary depending on the equipped model.
mation

ing switch ON.
Defective accelerator pedal Disconnect a device

1 shown on the right.
(internal defect)
If the failure code dis- Accelerator pedal AS1 connector
appears, that device
is internally defective.
2 Max. 1 z
(Disconnection or defective AS1 (female) (1) tance
Max. 1 z
value in normal
state Between ground and wiring harness
Resis-
Defective harness grounding between J2P (female) (22) – AS1 (female) Min. 1 Mz
3 tance
(Contact with ground circuit) (1)
Resis-
between J2P (female) (23) – AS1 (female) Min. 1 Mz
tance
(3)
Harness short
4 Between wiring harness from J2P (female)
(22) – AS1 (female) (1) and wiring harness Min. 1 Mz
tance
from E02 (female) (23) – AS1 (female) (3)
ing switch ON.
J2P Voltage
Between (22) – (23) 4.75 – 5.25 V
32 HM300-2R
HM300-2R 33
Failure code [CA2186] (Throttle sensor power source too low) 1
Action code Failure code Throttle sensor power source too low
Trouble
Contents of
• Excessively low voltage has occurred in the throttle sensor power source (5 V) circuit.
trouble
Action of • Establishes the throttle opening using signals other than throttle sensor signal in order to operate
controller engine.
Problem that
appears on
machine
Related infor-
mation

and standard
state
Failure code [CA2249] (Loss of pressure feed from supply pump 2) 1
Action code Failure code Loss of pressure feed from supply pump 2
Trouble
Contents of
• Loss of pressure feed (level 2) from supply pump has occurred.
trouble
Action of
• Limits common rail pressure.
controller
Problem that
machine
Related infor-
mation

and standard
state
34 HM300-2R
Failure code [CA2555] (Disconnection in intake air heater relay) 1

Action code Failure code Disconnection in intake air heater relay
Trouble
Contents of
• There is disconnection in intake air heater relay circuit.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Engine does not start easily at low temperature.
machine
Related • Engine coolant temperature can be checked with monitoring function.
information (Monitoring code: ENGINE - COOLANT - TEMP - 04104)

and standard
value in normal Carry out troubleshooting failure code [CA2556].
state
HM300-2R 35
Failure code [CA2556] (Intake air heater relay short circuit) 1
Action code Failure code Short circuit in intake air heater relay
Trouble
Contents of
• Short circuit has occurred in intake air heater relay circuit.
trouble
Action of
controller
Problem that
appears on • Startability of engine deteriorates in low temperature.
machine
Related infor-
• The drive condition of heater relay varies depending on an equipped model.
mation

Defective intake air heater ing switch still OFF.
1 relay
R07 (male) Resistance
(internal defect)
Between (1) – (2) 200 – 400 z
2 Max. 1 z
(Disconnection or defective R07 (female) (1) tance
and standard R07 (female) (2) tance
3 Min. 1 Mz
(Contact with ground circuit) J2P (female) (40) – R07 (female) (1) tance
Min. 1 Mz
J2P (female) (42) – R07 (female) (2) tance
ing switch ON.
4 Defective engine controlle J2P Heater relay Voltage
At working condition Max. 1 V
Between (40) – (42)
At stopping condition 20 – 30 V
36 HM300-2R
HM300-2R 37
Failure code [DAF9KM] (Machine monitor connector: Error in operation

or setting) 1
Action code Failure code Machine monitor: Error in operation or setting

Trouble (Wrong or defective connection of the connector)
E03 DAF9KM (Machine monitor system)
Contents of
• The connector check signal does not match with internal setting of machine monitor.
trouble
• Only detects during a start.
Action of
• Keeps the abnormal condition until starting switch is turned OFF.
machine monitor
• Does not record as failure history information.
Problem that • Machine monitor mode selector switch is not operable.
appears on • Optional function does not work.
machine • Headlamp high beam pilot lamp, turn signal pilot lamp, output mode pilot lamp, etc. do not work.
Related infor-
• Nothing particular.
mation

Wrong connection of The connector of connector check signal is connected normally.
1
connector a Connector of connector check signal:DPC2A (5) (CLOSE)
harness
and standard 2
(Disconnection or improper Wiring harness between fuse terminal BT3 Resis-
contact) (10) – DPC2A (female) (5) tance
state
Resis-
Between DPC2A (5) – body ground Min. 1 Mz
tance
38 HM300-2R
HM300-2R 39
Failure code [DAFRKR] (Abnormal CAN communication (machine

monitor): Abnormal communication) 1
Action code Failure code Abnormal CAN communication (machine monitor): Abnormal com-
Trouble munication
E03 DAFRKR (Machine monitor system)
Contents of
• Transmission controller stops updating the data received from the machine monitor.
trouble
Action of • Keeps the information at the time when abnormality occurred.
Problem that
• When the network is abnormal, the machine monitor can not correctly display the data from each
appears on
controller.
machine
Related infor-
• Check that the power source circuit of machine monitor is normal.
mation

Wiring harnesses among J2P (female) (46) –
Resis-
CJE4 (female) (2), (8) – CAN1 (female) (A) – Max. 1 z
tance
CJE4 (female) (1) – CAN2 (female) (A)
Wiring harnesses among J2P (female) (47) –
Resis-
Disconnection in wiring CJE4 (female) (4), (6) – CAN1 (female) (B) – Max. 1 z
tance
harness CJE (female) (3) – CAN2 (female) (B)
1
(Disconnection or improper Wiring harnesses among CJE4 (female) (1)
contact) – DPC4 (female) (3) – ATC2 (female) (32) – Resis-
Max. 1 z
BRC2 (female) (32) – DL (female) (3) – tance
CAN2 (female) (A)
Wiring harnesses among CJE4 (female) (3)
– DPC4 (female) (8) – ATC2 (female) (22) – Resis-
Max. 1 z
BRC2 (female) (22) – DL (female) (10) – tance
Possible causes CAN (female) (B)
state Between ground and wiring harness among
Resis-
J2P (female) (46) – CJE4 (female) (2), (8) – Min. 1 Mz
Short circuit of harness tance
2 CAN1 (female) (A)
(Contact with ground circuit)
Between ground and wiring harness among
CJE4 (female) (1) – DPC4 (female) (3) – Resis-
Min. 1 Mz
ATC (female) (32) – BRC2 (female) (32) – tance
DL (female) (3) – CAN2 (female) (A)
Defective CAN terminal Resis- 120 z ±
3 Between CAN1 (male) (A) – (B)
resistance tance 10%
Resis- 120 z ±
Between CAN2 (male) (A) – (B)
tance 10%
Defective machine monitor, If no problem is found in causes 1 and 2, machine monitor, engine
engine controller, controller ,transmission controller or retarder controller can be
4
transmission controller or suspected to be defective (since this is an internal defect, it cannot
retarder controller be diagnosed).
40 HM300-2R
HM300-2R 41
Failure code [DAQ0KK] (Transmission controller: Power source voltage

too low) 1
Action code Failure code Transmission controller: Power source voltage too low and input
Trouble (KK)
E03 DAQ0KK (Transmission controller system)
Contents of • While the engine is running, the voltage of both direct power source voltage circuits have become
trouble below 18V.
Action of • Holds the gear speed.
controller • Keeps the neutral with gear shift lever N.
Problem that
• Suddenly shifts to neutral while traveling, and cannot move off again unless the voltage resumes to
appears on
normal.
machine
• When the failure code [AB00MA] (defective alternator function) has occurred, carry out troubleshoot-
Related infor- ing for it first.
mation • If the fuse is blown, check for ground fault in the line between fuse-BRC3 (female) (1), (11), (14), and
(24).

a Check battery voltage and specific gravity.
1 Defective battery Battery voltage Voltage Min. 24 V
Battery specific gravity Gravity Min. 1.26
Wiring harness between ATC3 (female) (21), Resis-
Max. 1 z
(31), (32), (33) – body ground. tance
ing switch ON.
Disconnection in wiring Between battery relay B terminal – ground. Voltage 20 – 30 V
Possible causes harness
and standard 2 Between ATC3 (1), (11) – (21), (31), (32),
(Disconnection or improper Voltage 20 – 30 V
value in normal contact) (33)
state Between ATC3 (14), (24) – (21), (31), (32),
Voltage 20 – 30 V
(33)
Between battery relay terminal M – ground Voltage 20 – 30 V
If there is voltage between battery relay terminal B – ground but
there is no voltage between ATC3 (1), (11), (14), (24) – ground, the
harness is disconnected.
ing switch ON.
Defective transmission Between ATC3 (1), (11) – (21), (31), (32),
3 Voltage 20 – 30 V
controller (33)
Between ATC3 (14), (24) – (21), (31), (32),
Voltage 20 – 30 V
(33)
42 HM300-2R
HM300-2R 43
Failure code [DAQ0KT] (Transmission nonvolatile memory: Abnormality

in controller) 1
Action code Failure code Transmission nonvolatile memory: Abnormality in controller

Trouble
E01 DAQOKT (Transmission controller system)
Contents of
• An abnormality has occurred in the nonvolatile memory inside the controller.
trouble
• Controls the model selection and option setting with default value.
Action of
controller • Even if the cause of the failure has been eliminated automatically, the machine does not return to
normal unless once resetting the starting switch OFF.
Problem that
• Machine control parameter may change and transmission gear shift shock and hoist seating shock
appears on
may get worse.
machine
Related infor-
• Perform initial setting and initial adjustment as when transmission controller is replaced.
mation

and standard (Since this is an internal defect, it cannot be diagnosed.)
value in normal Defective transmission
1 (It is no problem to keep using controller unless any visible trouble
state controller
symptom appears on machine.)
44 HM300-2R
Failure code [DAQ2KK] (Transmission controller solenoid power

source: Voltage too low) 1
Action code Failure code Transmission controller solenoid power source:

Trouble Power source too low and input
E03 DAQ2KK (Transmission controller system)
Contents of • Battery direct power source voltage of transmission controller has dropped to below 20 V, and
trouble solenoid power source voltage has dropped to below 18 V.
Action of • Holds the gear speed.
controller • Keeps neutral with shift lever neutral.
Problem that
appears on • Suddenly shifts to neutral while traveling, and the machine cannot move off again.
machine
Related infor-
• When the fuse is blown, check for ground fault of line from fuse – ATC3 (female) (2), (12), (22).
mation

ing switch ON.
Disconnection in wiring Between fuse BT3 (11) and ground. Voltage 20 – 30 V
harness Between ATC3 (2), (12), (22) – (21), (31),
Possible causes 1 Voltage 20 – 30 V
(Disconnection or improper (32), (33) – R15 (female) (3)
and standard contact)
value in normal If there is voltage between battery relay terminal M – ground but
state there is no voltage between ATC3 (2), (12), (22) – ground, a discon-
nection exists between them.
Defective transmission ing switch ON.
2
controller Resis-
Between ATC3 (2), (12), (22) – ground 20 – 30 V
tance
HM300-2R 45
Failure code [DAQRKR] (COMMUNICATION LOST: Defective

communication) 1
Action code Failure code COMMUNICATION LOST: Defective communication
Trouble (Transmission controller – machine monitor)
E03 DAQRKR (Machine monitor system)
Contents of
trouble • Machine monitor cannot retrieve the information from transmission controller.
Action of • Keeps the information at the time when abnormality occurred.

Problem that
appears on • The information and special functions which are retrieved from transmission controller do not work or
machine display.
Related infor-
mation

Resis- 120 z ±
tance 10%
Wiring harness between DPC4 (female) (3), Resis-
Max. 1 z
(8) – CAN2 (female) (A), (B) tance
Max. 1 z
(8) – ATC2 (female) (32), (22) tance
Max. 1 z
(8) – BRC2 (female) (32), (22) tance
Disconnection in wiring
harness Max. 1 z
2 (8) – J2P (female) (46), (47) tance
(Disconnection or improper
contact) Wiring harness between DPC4 (female) (3), Resis-
Max. 1 z
Possible causes (8) – CAN1 (female) (A), (B) tance
and standard Wiring harness between DPC4 (female) (3), Resis-
(8) – DL (female) (3), (10) tance
state
Max. 1 z
(8) – TC200 (female) (8), (7) tance
Wiring harness between J2P (female) (46),
Resis-
(47) – CAN1 (female) (A), (B) – CAN2 Max. 1 z
tance
(female) (A), (B)
Between ground and wiring harness among Resis-
Min. 1 Mz
DPC4 (female) (3) – CAN2 (female) (A) tance
Min. 1 Mz
DPC4 (female) (3) – ATC2 (female) (32) tance
Short circuit of harness Between ground and wiring harness between Resis-
3 Min. 1 Mz
(Contact with ground circuit) DPC4 (female) (3) – BRC2 (female) (32) tance
Min. 1 Mz
DPC4 (female) (3) – J2P (female) (46) tance
Min. 1 Mz
Min. 1 Mz
DPC4 (female) (3) – DL (female) (3) tance
46 HM300-2R

Min. 1 Mz
DPC4 (female) (3) – TC200 (female) (8) tance
Short circuit of harness
Possible causes 3
(Contact with ground circuit) Between ground and wiring harness among Resis-
and standard J2P (female) (46) – CAN1 (female) (A) – Min. 1 Mz
value in normal tance
CAN2 (female) (A)
state
Defective machine monitor, If no problem is found in causes 1 – 3, machine monitor, engine
engine controller, controller ,transmission controller and retarder controller can be
4
brake controller be diagnosed).
HM300-2R 47
Failure code [DAQRMA] (Transmission controller option setting:

Malfunction) 1
Action code Failure code Transmission controller option setting: Malfunction

Trouble (Machine monitor-transmission controller)
E03 DAQRMA (Machine monitor system)
Contents of • Option setting signals inputted from machine monitor with the starting switch ON are different from
trouble the option settings that controller memorizes.
• Holds the gear speed in neutral.
Action of
• Controls with the option setting that the controller memorizes.
controller
• It does not return normal unless the starting switch is turned OFF.
Problem that
appears on • The gear speed becomes neutral and the machine cannot move off again.
machine
Related infor-
• Perform initial setting and initial adjustment as when transmission controller is replaced.
mation

and standard
value in normal Defective option setting of machine monitor or internal defect of
state monitor
Failure code [DB10KT] (Retarder controller nonvolatile memory:

Abnormality in controller) 1
Action code Failure code Retarder controller nonvolatile memory: Abnormality in controller
Trouble
E01 DB10KT (Retarder controller system)
Contents of
• An abnormality has occurred in the nonvolatile memory inside the controller.
trouble
• Control the model selection and option setting with default value.
Action of
controller • Even if the cause of the failure has been eliminated automatically, the machine does not return to
normal unless once resetting the starting switch OFF.
Problem that
appears on • Machine parameter may change and power may increase or decrease.
machine
Related infor-
mation

and standard (Since this is an internal defect, it cannot be diagnosed.)
value in normal 1 Defective retarder controller (It is no problem to keep using controller unless any visible trouble
state symptom appears on machine.)
48 HM300-2R
Failure code [DB12KK] (Retarder controller solenoid power source:

Power source voltage too low) 1
Action code Failure code Retarder controller solenoid power source: Power source voltage
Trouble too low
E03 DB12KK (Retarder controller system)
Contents of • While controller power source voltage is normal, solenoid power source voltage has become below
trouble 18 V.
Action of • Turns OFF all of output circuits.
controller • Turns OFF sensor 24 V power source.
Problem that • All systems of retarder controller do not operate. (retarder, dump, automatic suspension, ARSC and
appears on ASR)
machine • Failure code (DHU2KX and DHU3KX) are displayed at the same time.
• If the fuse is blown, check for ground fault of line from fuse – BRC3 (female) (2), (12), (22).
Related infor-
mation • If failure code“DAQ0KK“ or “DAQ2KK“ (transmission controller power source) is displayed, carry out
troubleshooting for it first.

ing switch ON.
Disconnection in wiring Between fuse BT3 (12) – ground. Voltage 20 – 30 V
Possible causes harness Between BRC3 (2), (12), (22) – (21), (31),
1 Voltage Max. 1 z
and standard (Disconnection or improper (32), (33)
value in normal contact)
When the voltage of fuse BT3 (12) is normal and the voltage of
state BRC3 (2), (12), (22) are defective, a disconnection exists in wiring
harness between fuse (12) – BRC3 (female) (2), (12), (22).
2 Defective retarder controller ing switch ON.
Between BRC3 (2), (12), (22) – ground Voltage 20 – 30 V
HM300-2R 49
Failure code [DB13KK] (Retarder controller battery direct power source:

Power source voltage too low) 1
Action code Failure code Retarder controller battery direct power source: Power source
Trouble voltage too low
E03 DB13KK (Retarder controller system)
Contents of
• Direct power source voltage circuit has become below 5V.
trouble
Action of
controller
Problem that
appears on • There is no great influence on the machine.
machine
• When the fuse is blown, check the short circuit of line from fuse – BRC3 (female) (1), (11), (2), (12),
Related infor- (22).
mation • If failure code“DAQ0KK“ or “DAQ2KK“ (transmission controller power source) is displayed, carry out
troubleshooting for it first.

ing switch ON.
Disconnection in wiring Between fuse BT3 (18) – ground. Voltage 20 – 30 V
harness Wiring harness between BRC3 (female) (1),
Possible causes 1 Voltage 20 – 30 V
(Disconnection or improper (11) – ground.
value in normal When the voltage of fuse BT3 (18) is normal and the voltage of
state BRC3 (1), (11) are defective, a disconnection exists in wiring
harness between fuse (18) – BRC3 (female) (1), (11).
ing switch ON.
Between BRC3 (1), (11) – (21), (31), (32),
Voltage 20 – 30 V
(33)
50 HM300-2R
Failure code [DB19KQ] (Retarder controller model select signal:

Inconsistent model selection signal) 1
Action code Failure code Model selection signal: Inconsistent model selection signal
Trouble
— DB19KQ (Retarder controller system)
Contents of • Model selection signals inputted from machine monitor with the starting switch ON are different from
trouble the model setting that controller memorizes.
• Turns OFF all output.
Action of • Even if the cause of failure is repaired, the machine does not return to normal unless the starting
controller switch is reset to OFF once.
Problem that
appears on • Even if the starting operation is carried out, the machine can not move off.
machine
Related infor-
mation

and standard
value in normal 1 Defective machine monitor Improper setting of machine monitor or internal defect of monitor
state
Failure code [DB1QMA] (Retarder controller option setting:

Malfunction) 1
Action code Failure code Inconsistent retarder controller option setting

Trouble
— DB1QMA (Retarder controller system)
Contents of • Option setting signals inputted from machine monitor with the starting switch ON are different from
trouble the option settings that retarder controller memorizes.
• No particular action.
Action of • Controls with the option setting that the controller memorizes.
controller • Even if the cause of failure is repaired, the machine does not return to normal unless the starting
switch is reset to OFF once.
Problem that
appears on
machine
Related infor-
mation

and standard
value in normal 1 Defective machine monitor Improper setting of machine monitor or internal defect of monitor
state
HM300-2R 51
Failure code [DB1RKR] (CAN communication (retarder controller):

Communication disabled) 1
Action code Failure code Abnormal CAN communication (retarder controller): Communication
disabled
Trouble
E03 DB1RKR (Between retarder controller – transmission controller)
(Retarder controller system)
Contents of
trouble • Updating of received data from retarder controller has stopped.
• AISS is locked in LOW or Hi.(until starting switch is turned OFF.)
Action of
controller • Keeps the information at the time when abnormality occurred.
Problem that
appears on • The information and special functions which are retrieved from retarder controller do not work or
machine display.
Related infor-
mation

Resis- 120 z ±
tance 10%
Max. 1 z
Max. 1 z
(8) – BRC2 (female) (32), (22) tance
Max. 1 z
(8) – ATC2 (female) (32), (22) tance
harness Max. 1 z
2 (8) – J2P (female) (46), (47) tance
Max. 1 z
(8) – DL (female) (3), (10) tance
Max. 1 z
Possible causes
Max. 1 z
value in normal (8) – TC200 (female) (8), (7) tance
state Wiring harness between J2P (female) (46),
Resis-
tance
(female) (A), (B)
Min. 1 Mz
Min. 1 Mz
DPC4 (female) (3) – BRC2 (female) (32) tance
Min. 1 Mz
Short circuit of harness Min. 1 Mz
3 DPC4 (female) (3) – J2P (female) (46) tance
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
Resis-
J2P (female) (46) – CAN1 (female) (A) – Min. 1 Mz
tance
CAN2 (female) (A)
52 HM300-2R

Possible causes
and standard Defective machine monitor, If no problem is found in causes 1 – 3, machine monitor, engine
value in normal engine controller, controller ,transmission controller and retarder controller can be
4
state transmission controller or suspected to be defective (since this is an internal defect, it cannot
HM300-2R 53
Failure code [DB2RKR] (CAN communication (engine controller):

Communication disabled) 1
Action code Failure code CAN communication (engine controller): Communication disabled
Trouble (Between engine controller – transmission controller)
E03 DB2RKR (Engine controller system)
Contents of
trouble • Updating of received data from engine controller has stopped.
• Holds the gear speed.
Action of
controller • Keeps the neutral with gear shift lever N.
Problem that
appears on • The information and special functions which are retrieved from engine controller do not work or
machine display.
Related infor-
mation

Resis- 120 z ±
tance 10%
Max. 1 z
Max. 1 z
(8) – J2P (female) (46), (47) tance
Max. 1 z
(8) – ATC2 (female) (32), (22) tance
harness Max. 1 z
2 (8) – BRC2 (female) (32), (22) tance
Max. 1 z
Max. 1 z
(8) – DL (female) (3), (10) tance
Possible causes
Max. 1 z
value in normal (8) – TC200 (female) (8), (7) tance
state Wiring harness between J2P (female) (46),
Resis-
tance
(female) (A), (B)
Min. 1 Mz
Min. 1 Mz
DPC4 (female) (3) – J2P (female) (46) tance
Min. 1 Mz
Short circuit of harness Min. 1 Mz
3 DPC4 (female) (3) – BRC2 (female) (32) tance
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
Resis-
J2P (female) (46) – CAN1 (female) (A) – Min. 1 Mz
tance
CAN2 (female) (A)
54 HM300-2R

Possible causes Detective engine controller As the engine controller power supply can be detective, carry out
4
power supply troubleshooting for "Failure code CA111".
and standard
value in normal Defective machine monitor, If no problem is found in causes 1 – 3, machine monitor, engine
engine controller, controller ,transmission controller and retarder controller can be
state 5
HM300-2R 55
Failure code [DDTHKA] (Fill switch for Hi clutch: Disconnection) 1
Action code Failure code Fill switch for Hi clutch: Disconnection

Trouble (Specified holding pressure, fill switch OFF, no slip)
E03 DDTHKA (Transmission controller system)
Contents of • When output to Hi clutch ECMV is turned “ON“, clutch engages, but the signal from fill switch does
trouble not come “ON“.
Action of • Holds gear speed during traveling.
Problem that
• Cannot change gear speed.
appears on
machine • Once gear shift lever is set to “N“, cannot restart until machine stops.
• Since a fill signal is detected when it is output to ECMV, be sure to perform the duplication operation
Related infor-
under the same conditions for the confirmation after repair.
mation
• Input state of fill signal can be checked with monitoring function (code: 41801).

When Resis-
1 Defective Hi clutch fill switch Min. 1 Mz
Between CN11 (male) (30) – released tance
ground When Resis-
Max. 1 z
engaged tance
Possible causes
and standard
value in normal 2
state (Disconnection or defective Wiring harness between ATC3 (female) (30) Resis-
contact) Max. 1 z
3 Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
56 HM300-2R
HM300-2R 57
Failure code [DDTJKA] (Fill switch for Lo clutch: Disconnection ) 1
Action code Failure code Fill switch for Lo clutch : Disconnection

E03 DDTJKA (Transmission controller system)
Contents of • When output to Lo clutch ECMV is turned “ON“, clutch engages, but signal from fill switch does
Problem that
appears on
Related infor-
mation

When Resis-
1 Defective Lo clutch fill switch Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
Possible causes
and standard
value in normal 2
contact) Max. 1 z
Defective transmission con- When Resis-
3 Min. 1 Mz
troller Between ATC3 (female) (20) – released tance
ground When Resis-
Max. 1 z
engaged tance
58 HM300-2R
HM300-2R 59
Failure code [DDTKKA] (Fill switch for 1st clutch: Disconnection) 1
Action code Failure code Fill switch for 1st clutch: Disconnection
E03 DDTKKA (Transmission controller system)
Contents of • When output to 1st clutch ECMV is turned “ON“, clutch engages, but signal from fill switch does
Problem that
appears on
Related infor-
mation

When Resis-
1 Defective 1st clutch fill switch Min. 1 Mz
Between CN13 (male) (1) – released tance
ground When Resis-
Max. 1 z
engaged tance
Possible causes
and standard
value in normal 2
contact) Max. 1 z
3 Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
60 HM300-2R
Failure code [DDTLKA] (Fill switch for 2nd clutch: Disconnection) 1
Action code Failure code Fill switch for 2nd clutch: Disconnection
E03 DDTLKA (Transmission controller system)
Contents of • When output to 2nd clutch ECMV is turned “ON“, clutch engages, but signal from fill switch does
Problem that
appears on
Related infor-
mation

Defective fill switch for 2nd When Resis-
1 Min. 1 Mz
clutch Between CN15 (male) (1) – released tance
ground When Resis-
Max. 1 z
engaged tance
Possible causes
and standard
value in normal 2
state (Disconnection or defective Wiring harness between ATC3 (female) (9) – Resis-
contact) Max. 1 z
3 Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
HM300-2R 61
Failure code [DDTMKA] (Fill switch for 3rd clutch: Disconnection) 1
Action code Failure code Fill switch for 3rd clutch: Disconnection
E03 DDTMKA (Transmission controller system)
Contents of • When output to 3rd clutch ECMV is turned “ON“, clutch engages, but signal from fill switch does
Problem that
appears on
Related infor-
mation

Defective 3rd clutch fill When Resis-
1 Min. 1 Mz
switch Between CN17 (male) (1) – released tance
ground When Resis-
Max. 1 z
engaged tance
Possible causes
and standard
value in normal 2
contact) Max. 1 z
3 Min. 1 Mz
Max. 1 z
engaged tance
62 HM300-2R
Failure code [DDTNKA] (Fill switch for R clutch: Disconnection) 1
Action code Failure code Fill switch for R clutch: Disconnection

E03 DDTNKA (Transmission controller system)
Contents of • When output to R clutch ECMV is turned “ON“, clutch engages, but signal from fill switch does
Problem that
appears on
Related infor-
mation

Defective for R clutch fill When Resis-
1 Min. 1 Mz
switch Between CN9 (male) (1) – released tance
ground When Resis-
Max. 1 z
engaged tance
Possible causes
and standard
value in normal 2
contact) Max. 1 z
3 Min. 1 Mz
ground When Resis-
Max. 1 z
engaged tance
HM300-2R 63
Failure code [DF10KA] (Gear shift lever: Disconnection) 1

Action code Failure code Gear shift lever: Disconnection
Trouble
E03 DF10KA (Transmission controller system)
Contents of
trouble • Gear shift lever signal is not input at all.
Action of
controller • Controls according to previous gear shift lever information before abnormality occurs.
Problem that • Gear speed is still in neutral and cannot start vehicle.
appears on • Cannot shift between forward and reverse positions.
machine • All gear shift lever position lamps go out.
Related infor-
mation • Nothing particular.

• Gear shift lever is being pushed even though it is not operated.
1 Operational error • Gear shift lever has been stopped at the midway point between
each of the gear positions.
Harness between BT3 (14) – SF1 (female) Resis-
Max. 1 z
(1) tance
Max. 1 z
– SF1 (female) (3) tance
Max. 1 z
Wiring harness between ATC1 (female) (6) – Resis-
Max. 1 z
SF1 (female) (5) tance
Disconnection in wiring Wiring harness between ATC2 (female) (15) Resis-
Max. 1 z
harness – SF1 (female) (6) tance
2
(Disconnection or defective Wiring harness between ATC2 (female) (5) – Resis-
Max. 1 z
Possible causes Wiring harness between ATC2 (female) (26) Resis-
value in normal
state Max. 1 z
Max. 1 z
Max. 1 z
Min. 1 Mz
ATC2 (female) (35) – SF1 (female) (3) tance
Min. 1 Mz
Min. 1 Mz
Defective harness grounding ATC1 (female) (6) – SF1 (female) (5) tance
3
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
64 HM300-2R

Min. 1 Mz
3 Min. 1 Mz
(Contact with ground circuit) ATC2 (female) (6) – SF1 (female) (11) tance
Min. 1 Mz
ing switch ON.
In shift range “R2“ Voltage 20 – 30 V
Between SF1 (3) –
ground In shift range other
Voltage Max. 1 V
than “R2“
Between SF1 (4) –
Voltage Max. 1 V
than “R1“
In shift range “N“ Voltage 20 – 30 V
Between SF1 (5) –
Voltage Max. 1 V
than “N“
In shift range “D“ Voltage 20 – 30 V
Between SF1 (6) –
Voltage Max. 1 V
than “D“
In shift range “5“ Voltage 20 – 30 V
Between SF1 (7) –
4 Defective gear shift lever Voltage Max. 1 V
than “5“
Possible causes
and standard In shift range “4“ Voltage 20 – 30 V
Between SF1 (8) –
value in normal In shift range other
ground Voltage Max. 1 V
state than “4“
Between SF1 (9) –
Voltage Max. 1 V
than “3“
Between SF1 (10) –
Voltage Max. 1 V
than “2“
Voltage Max. 1 V
than “1“
In shift range “HOLD“ Voltage 20 – 30 V
Voltage Max. 1 V
than “HOLD“
ing switch ON.
Between ATC2 (35) –
Voltage Max. 1 V
than “R2“
5 In shift range “R1“ Voltage 20 – 30 V
controller Between ATC2 (25) –
Voltage Max. 1 V
than “R1“
In shift range “N“ Voltage 20 – 30 V
Voltage Max. 1 V
than “N“
HM300-2R 65

Voltage Max. 1 V
than “D“
Voltage Max. 1 V
than “5“
Voltage Max. 1 V
Possible causes than “4“
and standard In shift range “3“ Voltage 20 – 30 V
value in normal Defective transmission Between ATC2 (26) –
5 In shift range other
state controller ground Voltage Max. 1 V
than “3“
Voltage Max. 1 V
than “2“
Voltage Max. 1 V
than “1“
Voltage Max. 1 V
than “HOLD“
66 HM300-2R
Failure code [DF10KB] (Gear shift lever: Short circuit) 1

Action code Failure code Gear shift lever: Short circuit
Trouble
E03 DF10KB (Transmission controller system)
Contents of
trouble • Gear shift lever signals have been inputted at the same time from 2 or more systems.
• Controls according to high priority signal.

(1): N > D > 5 > 4 > 3 > 2 > 1
Action of
(2): N > R2 > R1
controller
• Shifts gear speed to neutral when signals have been inputted from system (1) and system (2) at the
same time.
• There are cases where the gear speed is shifted to a higher gear speed than that which has been set
Problem that by the gear shift lever.
appears on
machine • Gear speed is still in neutral and cannot start vehicle.
• Gear shift lever position lamp does not indicate actual gear shift lever position.
Related infor-

ing switch ON.
Voltage Max. 1 V
ATC2 (female) (35) – SF1 (female) (3)
Voltage Max. 1 V
Voltage Max. 1 V
Voltage Max. 1 V
Hot short in wiring harness Between ground and wiring harness between
1 Voltage Max. 1 V
(a contact with 24 V circuit) ATC2 (female) (5) – SF1 (female) (7)
Voltage Max. 1 V
Voltage Max. 1 V
Voltage Max. 1 V
Possible causes
and standard Between ground and wiring harness between
Voltage Max. 1 V
value in normal ATC2 (female) (6) – SF1 (female) (11)
state Wiring harness between ATC1 (female) (12)
Voltage Max. 1 V
– SF1 (female)
ing switch ON.
Between SF1 (3) –
Voltage Max. 1 V
than “R2“
Between SF1 (4) –
Voltage Max. 1 V
than “R1“
2 Defective gear shift lever In shift range “N“ Voltage 20 – 30 V
Between SF1 (5) –
Voltage Max. 1 V
than “N“
Between SF1 (6) –
Voltage Max. 1 V
than “D“
Between SF1 (7) –
Voltage Max. 1 V
than “5“
HM300-2R 67

Between SF1 (8) –
Voltage Max. 1 V
than “4“
Between SF1 (9) –
Voltage Max. 1 V
than “3“
2 Defective gear shift lever In shift range other
ground Voltage Max. 1 V
than “2“
Voltage Max. 1 V
than “1“
Voltage Max. 1 V
than “HOLD“
ing switch ON.
If right FNR switch is installed (with right FNR switch “ON“)
Voltage Max. 1 V
than “R2“
Possible causes Between ATC2 (25) –
and standard Voltage Max. 1 V
than “R1“
value in normal
state In shift range “N“ Voltage 20 – 30 V
Voltage Max. 1 V
than “N“
Voltage Max. 1 V
than “D“
Defective transmission Between ATC2 (5) –
3 In shift range other
controller ground Voltage Max. 1 V
than “5“
Voltage Max. 1 V
than “4“
Voltage Max. 1 V
than “3“
Voltage Max. 1 V
than “2“
Voltage Max. 1 V
than “1“
Voltage Max. 1 V
than “HOLD“
68 HM300-2R
HM300-2R 69

© 2007 KOMATSU
All Rights Reserved
70 HM300-2R
SEN03427-02
HM300-2R

Failure code [DGF1KX] (Transmission oil temperature sensor: Input signal out of range)............................. 4
Failure code [DGR3KZ] (Center brake oil temperature sensor: Disconnection or short circuit) ..................... 6
Failure code [DGR3L8] (Center brake oil temperature sensor: Inconsistent analog signals) ......................... 8
Failure code [DGR4KZ] (Front brake oil temperature sensor: Disconnection or short circuit) ...................... 10
Failure code [DGR4L8] (Front brake oil temperature sensor: Inconsistent analog signals) ......................... 12
Failure code [DGR6KX] (Steering oil temperature sensor: Input signal out of range) .................................. 14
Failure code [DGT1KX] (Torque converter oil temperature sensor: Input signal out of range) ..................... 16
Failure code [DHT5KX] (Torque converter oil pressure sensor: Input signal out of range)........................... 18
Failure code [DHT5L6] (Torque converter oil pressure sensor: Inconsistent signals during a travel
and stop) .................................................................................................................................. 20
Failure code [DHU2KX] (Front accumulator oil pressure sensor: Input signal out of range) ........................ 22
Failure code [DHU3KX] (Rear accumulator oil pressure sensor: Input signal out of range) ......................... 24
Failure code [DJF1KA] (Fuel level sensor: Disconnection)........................................................................... 26
HM300-2R 1
Failure code [DK51L5] (Retarder lever potentiometer: Potentiometer signal is inconsistent with
switch signal)............................................................................................................................ 28
Failure code [DK52KX] (Dump lever potentiometer failure 1: Input signal out of range) .............................. 30
Failure code [DK53L8] (Dump lever potentiometer failure 2: Inconsistent analog signal) ............................ 32
Failure code [DK54KX] (Body positioner sensor: Input signal out of range) ................................................. 34
Failure code [DKH0KX] (Inclination sensor: Inclination out of range) ........................................................... 36
Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection) ........................................ 38
Failure code [DLF1LC] (Transmission input shaft speed sensor: Inconsistent rotation speed signal) .......... 39
Failure code [DLF2KA] (Transmission intermediate shaft speed sensor: Disconnection) ............................ 40
Failure code [DLF2LC] (Transmission intermediate shaft speed sensor: Inconsistent speed signal)........... 41
Failure code [DLF4KA] (Differential speed sensor: Disconnection) .............................................................. 42
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection) ...................................... 43
Failure code [DV00KB] (Alarm buzzer output: Short circuit) ......................................................................... 44
Failure code [DW72KZ] (Kick-out solenoid output system: Disconnection or short circuit) .......................... 46
Failure code [DW73KZ] (Hoist selector valve output system: Disconnection or short circuit)....................... 48
Failure code [DW78KZ] (Rear brake BCV command output system: Disconnection or short circuit) ........... 50
Failure code [DW79KZ] (Front brake BCV command output system: Disconnection or short circuit) .......... 52
Failure code [DX11K4] Trouble in rear wheel proportional solenoid pressure reducing valve 1 ................... 54
Failure code [DX11KA] (Rear brake proportional pressure reducing solenoid valve output circuit:
Disconnection) ......................................................................................................................... 56
Failure code [DX11KB] (Rear brake proportional pressure reducing solenoid valve: Short circuit) .............. 57
Failure code [DX11KY] (Rear brake proportional pressure reducing solenoid valve: Short circuit to power
source line)............................................................................................................................... 58
Failure code [DX11MA] (Rear brake proportional pressure reducing solenoid valve: Malfunction) .............. 60
Failure code [DX12K4] (Front brake proportional pressure reducing solenoid valve: Out of control) ........... 62
Failure code [DX12KA] (Front brake proportional pressure reducing solenoid valve output circuit:
Disconnection) ......................................................................................................................... 64
Failure code [DX12KB] (Front brake proportional pressure reducing solenoid valve: Short circuit) ............. 65
2 HM300-2R
HM300-2R 3
Failure code [DGF1KX] (Transmission oil temperature sensor: Input

signal out of range) 1
Action code Failure code Transmission oil temperature sensor: Input signal out of range
Trouble
E03 DGF1KX (Transmission controller system)
Contents of • Signal circuit voltage of transmission oil temperature sensor has become below 0.97 V (more than
trouble 150°C), or the sensor signal is greatly inconsistent with torque converter oil temperature signal.
Action of
• Controls clutch oil pressure assuming the oil temperature is high and constant.
controller
Problem that
appears on • Gear shift shocks become large.
machine
• Input signal from oil temperature sensor can be checked with monitoring function (codes: 32500 and
32501).
Related infor-
mation • Check that sensor has returned to normal after taking corrective measures, and then implement
initial learning procedure for the transmission controller referring to “Setting and adjusting various
equipments“ in “Testing and adjusting“.

Defective transmission oil Between Oil temperature: Resis-
1 37 – 50 kz
temperature sensor CN24 25°C tance
(male) (1) Oil temperature: Resis-
– (2) 3.5 – 4.0 kz
100°C tance
harness Wiring harness between ATC1 (female) (3) – Resis-
2 Max. 1 z
(Disconnection or defective CN24 (female) (1) tance
and standard
state Defective harness grounding ing switch still OFF.
3
Min. 1 Mz
ATC1 (female) (3) – CN24 (female) (1) tance
Hot short in wiring harness ing switch ON.
4
(a contact with 24V circuit) Between ground and wiring harness between
Voltage Max. 1 V
ATC1 (female) (3) – CN24 (female) (1)
Defective transmission Between Oil temperature: Resis-
5 37 – 50 kz
controller ATC1 25°C tance
(female) Oil temperature: Resis-
(3) – (21) 3.5 – 4.0 kz
100°C tance
4 HM300-2R
HM300-2R 5
Failure code [DGR3KZ] (Center brake oil temperature sensor:

Disconnection or short circuit) 1
Action code Failure code Center brake oil temperature sensor: Disconnection or short circuit
Trouble
E01 DGR3KZ (Machine monitor system)
Contents of
• Signal circuit voltage of retarder brake oil temperature sensor has become below 0.96 V.
trouble
Action of
controller
Problem that
machine
Related infor- • Input signal from oil temperature sensor can be checked with monitoring function (codes: 30203 and
mation 30206).

Defective center brake oil Between Brake oil Resis-
1 37 – 50 kz
temperature sensor M04 temperature: 25°C tance
(male) (1) Brake oil Resis-
– (2) 3.5 – 4.0 kz
temperature: 100°C tance
2 Max. 1 z
(Disconnection or defective – M04 (female) (1) tance
Possible causes contact) Wiring harness between DPC3B (female) (6) Resis-
Max. 1 z
and standard – M04 (female) (2) tance
Min. 1 Mz
3 (Contact with GND circuit or DPC3B (female) (2) – M04 (female) (1) tance
contact among harnesses) Between wiring harnesses from DPC3B
Resis-
(female) (2) – M04 (female) (1) and from Min. 1 Mz
tance
DPC3B (female) (6) – M04 (female) (2)
Between Brake oil Resis-
4 Defective machine monitor 37 – 50 kz
DPC3B temperature: 25°C tance
(female) Brake oil Resis-
(2) – (6) 3.5 – 4.0 kz
6 HM300-2R
HM300-2R 7
Failure code [DGR3L8] (Center brake oil temperature sensor:

Inconsistent analog signals) 1
Action code Failure code Center brake oil temperature sensor: Inconsistent analog signals
Trouble
E01 DGR3L8 (Machine monitor system)
Contents of • Signal voltage of front brake oil temperature sensor has become above 4.72 V and signal voltage of
trouble center brake oil temperature sensor has become below 3.606 V.
Action of
controller
Problem that
machine
• Input signal from oil temperature sensor can be checked with monitoring function (codes : 30203 and
Related infor-
30206).
mation
• If ARSC is not installed or ARSC system switch is turned [OFF], code [DGR2L8] is displayed.

Defective center brake oil Between Brake oil Resis-
1 37 – 50 kz
– (2) 3.5 – 4.0 kz
Possible causes
and standard
value in normal 2
state (Contact with ground circuit) Wiring harness between DPC3B (female) (2) Resis-
Min. 1 Mz
(2) – (6) 3.5 – 4.0 kz
8 HM300-2R
HM300-2R 9
Failure code [DGR4KZ] (Front brake oil temperature sensor:

Action code Failure code Front brake oil temperature sensor: Disconnection or short circuit
Trouble
E01 DGR4KZ (Machine monitor system)
Contents of
• Signal circuit voltage of retarder brake oil temperature sensor has become below 0.96 V.
trouble
Action of
controller
Problem that
machine
mation 30204).

Defective front brake oil Between Brake oil Resis-
1 37 – 50 kz
– (2) 3.5 – 4.0 kz
2 Max. 1 z
Possible causes contact) Wiring harness between DPC3B (female) (6) Resis-
Max. 1 z
and standard – M07 (female) (2) tance
Min. 1 Mz
3 (Contact with GND circuit or DPC3B (female) (7) – M07 (female) (1) tance
contact among harnesses) Between wiring harnesses from DPC3B
Resis-
(female) (7) – M07 (female) (1) and from Min. 1 Mz
tance
(7) – (6) 3.5 – 4.0 kz
10 HM300-2R
HM300-2R 11
Failure code [DGR4L8] (Front brake oil temperature sensor:

Inconsistent analog signals) 1
Action code Failure code Front brake oil temperature sensor system: Inconsistent analog
Trouble signals
E01 DGR4L8 (Machine monitor system)
Contents of • Signal voltage of front brake oil temperature sensor has become above 4.72 V and signal voltage of
trouble center brake oil temperature sensor has become below 3.606 V.
Action of • When both of the signals from front brake and center brake are out of standard values, failure code is
controller displayed.
Problem that
machine
mation 30204).

Defective front brake oil Between Brake oil Resis-
1 37 – 50 kz
– (2) 3.5 – 4.0 kz
Possible causes
and standard
value in normal 2
state (Contact with ground circuit) Wiring harness between DPC3B (female) (7) Resis-
Min. 1 Mz
(7) – (6) 3.5 – 4.0 kz
12 HM300-2R
HM300-2R 13
Failure code [DGR6KX] (Steering oil temperature sensor: Input signal

out of range) 1
Action code Failure code Steering oil temperature sensor: Input signal out of range
Trouble
E01 DGR6KX (Transmission controller system)
• Signal circuit voltage of steering oil temperature sensor has reached 0.97 V (more than 150°C) or
only steering oil temperature is low (signal circuit voltage of steering oil temperature sensor is above
Contents of
4.56 V (less than 15°C)).
trouble
• Oil temperature sensor voltages of torque converter and brake are below 3.7 V (more than 55°C )
and normal.
Action of
controller
Problem that
appears on • Steering oil temperature gauge does not indicate properly.
machine
• Input signal from oil temperature sensor can be checked with monitoring function.
1) Steering oil temperature sensor (codes: 32701 and 32702)
Related infor-
2) Torque converter oil temperature sensor (codes: 30100 and 30101)
mation
3) Brake oil temperature sensor (F) (codes: 30201 and 30204)
4) Brake oil temperature sensor (M) (codes: 30203 and 30206)

Defective steering oil Oil temperature: Resis-
1 Between 25°C 37 – 50 kz
temperature sensor tance
T04 (male)
(1) – (2) Oil temperature: Resis-
3.5 – 4.0 kz
100°C tance
harness Wiring harness between ATC1 (female) (14) Resis-
2 Max. 1 z
(Disconnection or defective – T04 (female) (1) tance
and standard
3
Min. 1 Mz
ATC1 (female) (14) – T04 (female) (1) tance
4
(a contact with 24 V circuit) Between ground and wiring harness between
Voltage Max. 1V
ATC1 (female) (14) – T04 (female) (1)
Defective transmission Between Oil temperature: Resis-
5 37 – 50 kz
controller ATC1 25°C tance
(14) – (21) 3.5 – 4.0 kz
100°C tance
14 HM300-2R
HM300-2R 15
Failure code [DGT1KX] (Torque converter oil temperature sensor: Input

Action code Failure code Torque converter oil temperature sensor: Input signal out of range
Trouble
E01 DGT1KX (Transmission controller system)
Contents of • Signal circuit voltage of torque converter oil temperature sensor has become below 0.97 V (more than
trouble 150°C), or the sensor signal is greatly inconsistent with transmission valve oil temperature signal.
Action of
controller
Problem that
appears on • Torque converter oil temperature gauge does not indicate properly.
machine
mation 30101).

Defective torque converter Between Oil temperature: Resis-
1 37 – 50 kz
oil temperature sensor CN23 25°C tance
(male) (1) Oil temperature: Resis-
– (2) 3.5 – 4.0 kz
100°C tance
2 Max. 1 z
(Disconnection or defective CN23 (female) (1) tance
and standard
3
Min. 1 Mz
4
(a contact with 24V circuit) Between ground and wiring harness between Resis-
Max. 1 V
ing switch ON.
Defective transmission con- Between Oil temperature: Resis-
5 37 – 50 kz
troller ATC1 25°C tance
(9) – (21) 3.5 – 4.0 kz
100°C tance
16 HM300-2R
HM300-2R 17
Failure code [DHT5KX] (Torque converter oil pressure sensor: Input

Action code Failure code Torque converter oil pressure sensor: Input signal out of range
Trouble
E01 DHT5KX (Transmission controller system)
Contents of
• Signal circuit voltage of torque converter oil pressure sensor has become below 0.5 V or above 4.5 V.
trouble
Action of
• Controls torque converter oil pressure to be a predetermined constant value stored in the controller.
controller
Problem that
appears on • Large shock at lockup operation
machine
Related infor-
• Signal from oil pressure sensor can be checked with monitoring function (codes: 32600 and 32605).
mation

Defective torque converter ing switch ON.
1
oil pressure sensor Between CN22 (B) – (A) Voltage 20 – 30 V
Between CN22 (C) – (A) Voltage 0.8 – 2.0 V
Max. 1 z
harness – CN22 (female) (C) tance
2
(Disconnection and Wiring harness between ATC1 (female) (21) Resis-
defective contact) Max. 1 z
– CN22 (female) (A) tance
CN22 (female) (B) tance
and standard
Defective harness grounding Wiring harness between ATC1 (female) (19) Resis-
3 Min. 1 Mz
(Contact with ground circuit) – CN22 (female) (C) tance
Min. 1 Mz
ATC3 (female) (8) – CN22 (female) (B) tance
4
Voltage 0.8 – 2.0 V
ATC1 (female) (19) – CN22 (female) (C)
5
controller Between ATC3 (8) – ATC1 (21) Voltage 20 – 30 V
Between ATC1 (19) – (21) Voltage 0.8 – 2.0 V
18 HM300-2R
HM300-2R 19
Failure code [DHT5L6] (Torque converter oil pressure sensor:

Inconsistent signals during a travel and stop) 1
Action code Failure code Torque converter oil pressure sensor: Inconsistent signal
(Signals are inconsistent with the engine states of running and
Trouble
E01 DHT5L6 stop.)
Contents of
• While engine stop, oil pressure signal is input to signal circuit of torque converter oil pressure sensor.
trouble
Action of
• Controls torque converter oil pressure to be a predetermined constant value stored in the controller.
controller
Problem that
appears on • Large shock at lockup operation
machine
Related infor-
mation

Defective torque converter ing switch ON.
1
oil pressure sensor Between CN22 (B) – (A) Voltage 20 – 30 V
Between CN22 (C) – (A) Voltage 0.8 – 2.0 V
Possible causes
and standard
value in normal 2
state (a contact with 24 V circuit) Between ground and wiring harness between
Voltage Max. 1.2 V
ATC1 (female) (19) – CN22 (female) (C)
3
controller Between ATC3 (8) – ATC1 (21) Voltage 20 – 30 V
20 HM300-2R
HM300-2R 21
Failure code [DHU2KX] (Front accumulator oil pressure sensor: Input

Action code Failure code Front accumulator oil pressure sensor: Input signal out of range
Trouble
E01 DHU2KX (Retarder controller system)
Contents of
• Signal circuit voltage of front accumulator oil pressure sensor has become below 0.5 V or above 4.5 V.
trouble
Action of
controller
Problem that
machine
Related infor-
mation

Disconnection in wiring Wiring harness between BRC1 (female) (7) – Resis-
Max. 1 z
harness B25 (female) (C) tance
1
(Disconnection and Wiring harness between BRC1 (female) (21) Resis-
– B25 (female) (A) tance
Wiring harness between BRC1 (female) (16) Resis-
Max. 1 z
– B25 (female) (B) tance
2 Min. 1 Mz
(Contact with ground circuit) BRC1 (female) (7) – B25 (female) (C) tance
Min. 1 Mz
BRC1 (female) (16) – B25 (female) (B) tance
and standard Hot short in wiring harness ing switch ON.
value in normal 3
state Voltage Max. 1 V
BRC1 (female) (7) – B25 (female) (C)
ing switch ON.
Resis-
B25 Differential lockup oil pressure
tance
Defective front accumulator Max. 4.9 MPa
4 Min. 1 Mz
oil pressure sensor {Max. 50 kg/cm²}
Between (A) – (B)
Min. 4.9 MPa
Max. 1 z
{Min. 50 kg/cm²}
Between B25 (B) – (A) Voltage 20 – 30 V
Between B25 (C) – (A) Voltage 1.8 – 3.5 V
ing switch ON.
Between BRC1 (16) – BRC1 (21) Voltage 20 – 30 V
Between BRC1 (7) – (21) Voltage 0.5 – 4.5 V
22 HM300-2R
HM300-2R 23
Failure code [DHU3KX] (Rear accumulator oil pressure sensor: Input

Action code Failure code Rear accumulator oil pressure sensor: Input signal out of range
Trouble
E01 DHU3KX (Retarder controller system)
Contents of
• Signal circuit voltage of front accumulator oil pressure sensor has become below 0.5 V or above 4.5 V.
trouble
Action of
controller
Problem that
machine
Related infor-
mation

Disconnection in wiring Wiring harness between BRC1 (female) (1) – Resis-
Max. 1 z
harness B24 (female) (C) tance
1
(Disconnection and Wiring harness between BRC1 (female) (21) Resis-
– B24 (female) (A) tance
Max. 1 z
– B24 (female) (B) tance
2 Min. 1 Mz
(Contact with ground circuit) BRC1 (female) (1) – B24 (female) (C) tance
Min. 1 Mz
BRC1 (female) (16) – B24 (female) (B) tance
and standard Hot short in wiring harness ing switch ON.
value in normal 3
state Voltage Max. 1 V
BRC1 (female) (1) – B24 (female) (C)
ing switch ON.
Resis-
B24 (male) Differential lockup oil pressure
tance
Defective rear accumulator Max. 4.9 MPa
4 Min. 1 Mz
oil pressure sensor {Max. 50 kg/cm²}
Between (A) – (B)
Min. 4.9 MPa
Max. 1 z
{Min. 50 kg/cm²}
Between B24 (B) – (A) Voltage 20 – 30 V
Between B24 (C) – (A) Voltage 1.8 – 3.5 V
ing switch ON.
Between BRC1 (16) – (21) Voltage 20 – 30 V
24 HM300-2R
HM300-2R 25
Failure code [DJF1KA] (Fuel level sensor: Disconnection) 1
Action code Failure code Fuel level sensor: Disconnection

Trouble
E01 DJF1KA (Machine monitor system)
Contents of
• Signal circuit voltage of fuel level sensor has become above 4.0 V.
trouble
Action of
controller
Problem that
appears on • Fuel gauge does not indicate properly.
machine
Related infor-
• Signal from level sensor can be checked with monitoring function (codes: 04200 and 04201).
mation

Between Fuel level: At full (FULL) Resis-
1 Defective fuel level sensor Max. 12 z
M06 tance
(male) (1) Resis- 74 – 100
– (2) Fuel level: At empty (EMPTY)
tance z
value in normal Wiring harness between DPC3B (female) (6) Resis-
Max. 1 z
state – M06 (female) (2) tance
3
Voltage Max. 1 V
Between Resis-
4 Defective machine monitor Fuel level: At full (FULL) Max. 12 z
DPC3B tance
(female) Resis- 74 – 100
(3) – (6) Fuel level: At empty (EMPTY)
tance z
26 HM300-2R
HM300-2R 27
Failure code [DK51L5] (Retarder lever potentiometer: Potentiometer

signal is inconsistent with switch signal) 1
Action code Failure code Retarder lever potentiometer: Potentiometer signal is inconsistent
Trouble
E03 DK51L5 with switch signal (Retarder controller system).
Contents of • Potentiometer signal voltage of retarder lever circuit has become below 0.3 V or above 4.7 V, or
trouble potentiometer signal is inconsistent with switch signal.
Controls as follows depending on situation of failure occurrence.
Action of • Controls according to potentiometer signal.
controller • Limits output to solenoid to 70 %.
• Turns output to solenoid [OFF].
As follows depending on action taken.
Problem that • There is no great influence on the machine.
appears on
machine • Cannot perform a fine control of retarder.
• Retarder does not work (foot brake works).
Related infor-
mation • Can be checked with monitoring function (code: 33900).

Max. 1 z
– RE1 (female) (2) tance
Wiring harness between RE1 (female) (1) – Resis-
Max. 1 z
RTL (female) (1) tance
Disconnection in wiring Wiring harness between BRC1 (female) (21) Resis-
Max. 1 z
harness – RTL (female) (3) tance
1
(Disconnection or defective Wiring harness between BRC1 (female) (14) Resis-
contact) Max. 1 z
– RTL (female) (2) tance
Max. 1 z
Max. 1 z
Max. 1 z
Possible causes
and standard
value in normal
state Between ground and wiring harness between Resis-
Min. 1 Mz
Defective harness grounding BRC1 (female) (22) – RE1 (female) (2) tance
2
Min. 1 Mz
between RE1 (female) (1) – RTL (female) (1) tance
Min. 1 Mz
BRC1 (female) (14) – RTL (female) (2) tance
ing switch ON.
Voltage Max. 1 V
Hot short in wiring harness BRC1 (female) (22) – RE1 (female) (1)
3
(a contact with 24V circuit) Between ground and wiring harness
Voltage Max. 1 V
between RE1 (female) (1) – RTL (female) (1)
Voltage Max. 1 V
BRC1 (female) (14) – RTL (female) (2)
4 Defective resistor (RE1)
Resis-
Between RE1 (male) (1) – (2) 250 ± 5 z
tance
28 HM300-2R

ing switch ON.
Between RTL (1) – (3) Voltage 4.1 – 4.8 V
Between RTL (2) – (3) Voltage 0.3 – 4.7 V
Defective retarder lever Released lever Resis-
5 Max. 1 z
potentiometer Between RTL (male) position tance
(4) – (6) Operating lever Resis-
Min. 1 Mz
position tance
Released lever Resis-
Min. 1 Mz
Between RTL (male) position tance
Possible causes (5) – (6) Operating lever Resis-
position tance
value in normal
ing switch ON.
6 Defective retarder controller Released lever Resis-
Between BRC1 Max. 1 z
position tance
(female) (24) –
ground Operating lever Resis-
Min. 1 Mz
position tance
Released lever Resis-
Between BRC1 Min. 1 Mz
position tance
(female) (18) –
ground Operating lever Resis-
Max. 1 z
position tance
HM300-2R 29
Failure code [DK52KX] (Dump lever potentiometer failure 1: Input signal

out of range) 1
Action code Failure code Dump lever potentiometer failure 1: Input signal out of range
Trouble (Input signal of lever potentiometer 1 or 2 is out of range)
E03 DK52KX (Transmission controller system)
Contents of • Signal voltage of dump lever potentiometer 1 or 2 signal circuit has become below 0.3 V or
trouble above 4.7 V.
Action of
controller • Recognizes dump lever position as [HOLD] position.
Problem that
appears on • Dump body does not operate.
machine
Related infor-
mation • Can be checked with monitoring function (codes: 34506 and 34507).

Max. 1 z
– HSL (female) (4) tance
1 Max. 1 z
(Disconnection or defective HSL (female) (2) tance
contact)
Max. 1 z
HSL (female) (3) tance
Max. 1 z
– HSL (female) (1) tance
Min. 1 Mz
Defective harness grounding ATC1 (female) (22) – HSL (female) (4) tance
2
Min. 1 Mz
ATC1 (female) (1) – HSL (female) (2) tance
Min. 1 Mz
and standard ATC1 (female) (7) – HSL (female) (3) tance
state ing switch ON.
Voltage Max. 1 V
Hot short in wiring harness ATC1 (female) (22) – HSL (female) (4)
3
Voltage Max. 1 V
ATC1 (female) (1) – HSL (female) (2)
Voltage Max. 1 V
ATC1 (female) (7) – HSL (female) (3)
ing switch ON.
4 Defective hoist lever Between HSL (4) – (1) Voltage 4.6 – 5.4 V
Between HSL (2) – (1) Voltage 0.3 – 4.7 V
ing switch ON.
Defective transmission Between ATC1 (22) – (21) Voltage 4.6 – 4.8 V
5
controller
Between ATC (7) – (21) Voltage 0.3 – 4.7 V
30 HM300-2R
HM300-2R 31
Failure code [DK53L8] (Dump lever potentiometer failure 2: Inconsistent

analog signal) 1
Action code Failure code Dump lever potentiometer failure 2: Inconsistent analog signal
(Total input signal voltage of lever potentiometer 1 and 2 is out of
Trouble
E03 DK53L8 range.)
Contents of • Total voltage of dump lever potentiometer 1 and 2 signal circuit has become below 4.4 V or
trouble above 5.6 V.
Action of
• Recognizes dump lever position as [NEUTRAL] position.
controller
Problem that
machine
Related infor- • Can be checked with monitoring function (codes: 34506 and 34507).
mation • When failure code [DK52KX] is displayed, troubleshooting corresponding code.

ing switch ON.
Possible causes
and standard 1 Defective hoist lever Between HSL (4) – (1) Voltage 4.6 – 5.4 V
value in normal Between HSL (2) – (1) Voltage 0.3 – 4.7 V
state
Defective transmission • If abnormality is not solved even after carrying out the diagnosis
2
controller of item 1, retarder controller is defective.
32 HM300-2R
HM300-2R 33
Failure code [DK54KX] (Body positioner sensor: Input signal out of

range) 1
Action code Failure code Body positioner sensor: Input signal out of range
Trouble (Input signal of lever potentiometer 1 or 2 is out of range)
E03 DK54KX (Transmission controller system)
Contents of
• Signal circuit voltage of body positioner sensor has become below 0.3 V or above 4.7 V.
trouble
Action of • Conducts dump control according to the dump lever signal.
controller • Controls dump with recognition that the body has not yet been seated.
• Shock when body is seated becomes large.
Problem that
• Function of dump lever positioner does not work.
appears on
machine • Highest gear speed is restricted.
• Machine cannot move backward in the dump lever position other than [FLOAT].
Related infor-
• Can be checked with monitoring function (code: 34603).
mation

Max. 1 z
harness – T14 (female) (C) tance
1
(Disconnection and Wiring harness between ATC1 (female) (2) – Resis-
T14 (female) (B) tance
Max. 1 z
– T14 (female) (A) tance
2 Min. 1 Mz
(Contact with ground circuit) ATC1 (female) (22) – T14 (female) (C) tance
ATC1 (female) (2) – T14 (female) (B) tance
value in normal
state
ing switch ON.
Hot short in wiring harness Between ground and wiring harness between
3 Voltage Max. 1 V
(a contact with 24 V circuit) ATC1 (female) (22) – T14 (female) (C)
Voltage Max. 1 V
ATC1 (female) (2) – T14 (female) (B)
Defective body positioner ing switch ON.
4
sensor Between T14 (C) – (A) Voltage 4.6 – 5.4 V
Between T14 (B) – (A) Voltage 0.3 – 4.7 V
ing switch ON.
34 HM300-2R
HM300-2R 35
Failure code [DKH0KX] (Inclination sensor: Inclination out of range) 1
Action code Failure code Inclination sensor: Input signal out of range
Trouble
E01 DKH0KX (Transmission controller system)
Contents of
trouble • Voltage in signal circuit of Inclination sensor has become below 0.5 V or above 4.5 V.
Action of
controller • No particular action.
Problem that
appears on
machine
Related infor- • Signal from Inclination sensor can be checked with monitoring function (Code: 32900 and 32902).
mation • Cannot detect tipping over.

ing switch ON.
1 Defective inclination sensor
Between T10 (A) – (C) Voltage 11 – 13 V
Between T10 (A) – (B) Voltage 1.4 – 4.6 V
Max. 1 z
harness – T10 (female) (B) tance
2
(Disconnection or defective Wiring harness between ATC1 (female) (16) Resis-
contact) Max. 1 z
– T10 (female) (C) tance
and standard
3 Min. 1 Mz
(Contact with ground circuit) ATC1 (female) (13) – T10 (female) (B) tance
Min. 1 Mz
ATC1 (female) (16) – T10 (female) (C) tance
4
Voltage Max. 4.6 V
ATC1 (female) (13) – T10 (female) (B)
5
controller Between ATC1 (female) (16) – (21) Voltage 20 – 30 V
Between ATC1 (female) (13) – (21) Voltage 1.0 – 4.6 V
36 HM300-2R
HM300-2R 37
Failure code [DLF1KA] (Transmission input shaft speed sensor:

Disconnection) 1
Action code Failure code Transmission input shaft speed sensor: Disconnection
TroubleTrouble
E03 DLF1KA (Transmission controller system)
Contents of • There is a disconnection in signal circuit of transmission input shaft speed sensor and the signal is
trouble not inputted.
• Holds gear speed for traveling and turns lockup to OFF.
Action of
• Even if failure is repaired, it does not return to normal unless the starting switch is once turned OFF.
Problem that • During travel, lockup is released and gear can not be shifted.
appears on
Related infor-
mation • Signal from input shaft speed sensor can be checked with monitoring function (Code: 31200).

Screw the sensor gently until it bottoms to the speed detection gear,
Improper adjustment of
then turn it back by 1/2 – 1 turn.
1 transmission input shaft
a See Testing and adjusting “Adjusting transmission speed sensor“
speed sensor
for details.
Defective transmission input Resis- 500 –
2 Between CN3 (male) (1) – (2)
shaft speed sensor tance 1,000 z
Possible causes Resis-
and standard Between CN3 (male) (1), (2) – ground Min. 1 Mz
tance
value in normal
3 Max. 1 z
(Disconnection or improper – CN3 (female) (1) tance
Max. 1 z
4
controller Resis- 500 –
Between ATC2 (female) (40) – (39)
tance 1,000 z
38 HM300-2R
Failure code [DLF1LC] (Transmission input shaft speed sensor:

Inconsistent rotation speed signal) 1
Action code Failure code Transmission input shaft speed sensor: Inconsistent speed signal
Trouble
E03 DLF1LC (Transmission controller system)
• There is an abnormality in the speed calculated from engine speed sensor signal, transmission
Contents of
trouble intermediate shaft speed sensor signal and transmission output shaft speed sensor signal, and the
speed of transmission input shaft sensor signal.
Action of • Holds gear speed for traveling and turns lockup to OFF.
Problem that • Lockup is released and gear cannot be shifted.
appears on
Related infor-
mation • Signal from input shaft speed sensor can be checked with monitoring function (Code: 31200).

Defective transmission input Resis- 500 –
shaft speed sensor tance 1,000 z
Resis-
tance
and standard 2
value in normal Min. 1 Mz
state ATC2 (female) (40) – CN3 (female) (1) tance
3
Voltage Max. 1 V
Defective transmission con- ing switch still OFF.
4
troller Resis- 500 –
tance 1,000 z
HM300-2R 39
Failure code [DLF2KA] (Transmission intermediate shaft speed sensor:

Disconnection) 1
Action code Failure code Transmission intermediate shaft speed sensor: Disconnection
Trouble
Contents of • There is a disconnection in signal circuit of transmission intermediate shaft speed sensor and no
trouble signal is inputted.
• Holds gear speed during traveling.
Action of
• Even if failure is repaired, it does not return to normal unless starting switch is once turned OFF.
appears on
Related infor-
mation • Signal from intermediate shaft speed sensor can be checked with monitoring function (Code: 31300).

• Screw the sensor gently until it bottoms to the speed detection
Improper adjustment of the
gear, then turn it back by 1/2 – 1 turn.
1 transmission intermediate
shaft speed sensor
for details.
Resis- 500 –
2 intermediate shaft speed Between CN4 (male) (1) – (2)
tance 1,000 z
sensor
and standard Between CN4 (male) (1), (2) – ground Min. 1 Mz
tance
value in normal
3 Max. 1 z
Max. 1 z
4
tance 1,000 z
40 HM300-2R
Failure code [DLF2LC] (Transmission intermediate shaft speed sensor:

Inconsistent speed signal) 1
Action code Failure code Transmission intermediate shaft speed sensor: Inconsistent speed
Trouble signal
E03 DLF2LC (Transmission controller system)
• There is an abnormality in the speed calculated from engine speed sensor signal, transmission input
Contents of
trouble shaft speed sensor signal and transmission output shaft speed sensor signal, and the speed of
transmission intermediate shaft sensor signal.
• Holds gear speed during traveling.
Action of
Problem that • Cannot change gear speed.
appears on
Related infor-
mation • Signal from intermediate shaft speed sensor can be checked with monitoring function (Code: 31300).

Resis- 500 –
1 intermediate shaft speed Between CN4 (male) (1) – (2)
tance 1,000 z
sensor
Resis-
tance
and standard 2
value in normal Min. 1 Mz
state ATC2 (female) (20) – CN4 (female) (1) tance
3
Voltage Max. 1V
4
tance 1,000 z
HM300-2R 41
Failure code [DLF4KA] (Differential speed sensor: Disconnection) 1
Action code Failure code Differential speed sensor: Disconnection

Trouble
Contents of
trouble • There is a disconnection in signal circuit of differential speed sensor and no signal is inputted.
Action of
controller • Turns inter-axle differential lockup command OFF and holds it.
Problem that
appears on • Inter-axle differential lockup does not work.
machine
Related infor-
mation • Signal from differential speed sensor can be checked with monitoring function (Code: 31402).

Screw the sensor gently until it bottoms to the differential gear, turn
Improper adjustment of it back by 1/2 – 3/4 turn.
1
differential speed sensor a See Testing and adjusting “Adjusting transmission speed sensor“
for details.
Defective differential speed Resis- 500 –
2 Between B09 (male) (1) – (2)
sensor tance 1,000 z
and standard Between B09 (male) (1), (2) – ground Min. 1 Mz
tance
value in normal
3 Max. 1 z
(Disconnection or improper – B09 (female) (1) tance
Max. 1 z
– B09 (female) (2) tance
4
tance 1,000 z
42 HM300-2R
Failure code [DLT3KA] (Transmission output shaft speed sensor:

Disconnection) 1
Action code Failure code Transmission output shaft speed sensor: Disconnection
Trouble
E03 DLT3KA (Transmission controller system)
Contents of • There is a disconnection in signal circuit of transmission output shaft speed sensor and no signal is
trouble inputted.
• Holds gear speed for traveling and turns lockup to OFF.
Action of
appears on
machine • When gear shift lever is shifted to N, transmission is set to neutral.
Related infor-
mation • Signal from output shaft speed sensor can be checked with monitoring function (Code: 31400).

• Screw the sensor gently until it bottoms to the speed detection
Improper adjustment of
gear, then turn it back by 1/2 – 1 turn.
1 transmission output shaft
speed sensor
for details.
Defective transmission Resis- 500 –
output shaft speed sensor tance 1,000 z
Possible causes Between CN5 (male) (1), (2) – machine Resis-
ground tance
value in normal
3 Max. 1 z
Max. 1 z
4
tance 1,000 z
HM300-2R 43
Failure code [DV00KB] (Alarm buzzer output: Short circuit) 1
Action code Failure code Alarm buzzer output: Short circuit

Trouble
E01 DV00KB (Machine monitor system)
Contents of
trouble • An excess current has occurred while outputting to alarm buzzer circuit.
Action of • Keeps the abnormal condition until starting switch is turned OFF.
controller • Turns alarm buzzer output OFF.
Problem that
appears on • Alarm buzzer does not sound.
machine
Related infor-

Short circuit of harness Between wiring harness from DPC1 (female)
Resis-
1 (Contact with ground circuit (13) – BZ2 (female) (2) and wiring harness Min. 1 Mz
tance
or contact among harnesses) from BZ2 (female) (1) – BT3 (10).
Min. 1 Mz
DPC1 (female) (13) – BZ2 (female) (2) tance
Possible causes
and standard
ing switch ON.
value in normal
(Remove buzzer and connect +24 V to BZ2 (male) (1) and connect
state
GND to BZ2 (male) (2)).
2 Defective alarm buzzer Alarm buzzer is
Alarm buzzer sounds.
normal.
Defective alarm
Alarm buzzer does not sound.
buzzer
a Check alarm buzzer unit.
• If no problem is found in above 1) and 2), machine monitor is
defective.
44 HM300-2R
HM300-2R 45
Failure code [DW72KZ] (Kick-out solenoid output system:

Action code Failure code Kick-out solenoid output system: Disconnection or short circuit
Trouble
E01 DW72KZ (Transmission controller system)
Contents of • Excessive current flows when output is ON to dump lever kick-out solenoid circuit, current does not
trouble flow when output is ON, or current flows when output is OFF.
Action of
controller • Takes no particular action.
Problem that
appears on
machine
Related infor-
mation

Defective hoist lever kick-out Resis- 39 z ±
1 Between LK0 (male) (1) – (2)
solenoid tance 5%
Resis-
Between LKO (male) (1), (2) – ground Min. 1 Mz
tance
harness Wiring harness between ATC (female) (3) – Resis-
2 Max. 1 z
Possible causes (Disconnection or improper LK0 (female) (2) tance
and standard contact) Wiring harness between ATC3 (female) (38) Resis-
– LK0 (female) (1) tance
state
Min. 1 Mz
3 (Contact with ground circuit ATC3 (female) (38) – LKO (female) (1) tance
or contact among harnesses) Between wiring harness from ATC3 (female)
Resis-
(38) – LKO (female) (1) and wiring harness Min. 1 Mz
tance
from ATC3 (female) (3) – LKC (female) (2)
4
controller Resis- 39 z ±
Between ATC3 (female) (38) – ground
tance 5%
46 HM300-2R
HM300-2R 47
Failure code [DW73KZ] (Hoist selector valve output system:

Action code Failure code Hoist selector valve output system: Disconnection or short circuit
Trouble
E03 DW73KZ (Transmission controller system)
Contents of • Excessive current flows when output is ON to hoist selector valve solenoid circuit, or, current does
trouble not flow when output is ON, or, current flows when output is OFF.
Action of • Turn output to hoist selector valve solenoid OFF.
controller • Turn output to hoist EPC valve solenoid OFF.
Problem that
machine
Related infor-
mation

Defective hoist selector valve Resis-
1 Between T01 (male) (A) – (B) 15 – 35 z
solenoid tance
Resis-
Between T01 (male) (A), (B) – ground Min. 1 Mz
tance
2 Max. 1 z
Possible causes (Disconnection or improper T01 (female) (B) tance
and standard contact) Wiring harness between ATC3 (female) (17) Resis-
state
Min. 1 Mz
3 (Contact with ground circuit ATC3 (female) (17) – T01 (female) (A) tance
Resis-
(17) – T01 (female) (A) and wiring harness Min. 1 Mz
tance
from ATC3 (female) (3) – T01 (female) (B)
4
controller Resis-
tance
48 HM300-2R
HM300-2R 49
Failure code [DW78KZ] (Rear brake BCV command output system:

Action code Failure code Rear brake BCV command output: Disconnection or short circuit
Trouble
E01 DW78KZ (Retarder controller system)
Contents of
trouble • Current does not flow to rear brake BCV solenoid, or excessive current flows when output is ON.
Action of • Current does not flow to solenoid.

controller • Continues to control.
Problem that
appears on
machine
Related infor-
mation • Output current to rear brake BCV can be checked with monitoring function (Code: 33806).

Resis-
1 Defective rear BCV solenoid Between B07 (male) (1) – (2) Max. 1 z
tance
Resis-
Between B07 (male) (1), (2) – ground Min. 1 Mz
tance
harness Wiring harness between BRC3 (female) (37) Resis-
2 Max. 1 z
Possible causes contact) Wiring harness between BRC3 (female) (13) Resis-
value in normal
state
Min. 1 Mz
3 (Contact with ground circuit BRC3 (female) (37) – B07 (female) (1) tance
or contact among harnesses) Between wiring harness from BRC3 (female)
Resis-
(37) – B07 (female) (1) and wiring harness Min. 1 Mz
tance
from BRC3 (female) (13) – B07 (female) (2)
ing switch ON.
4 Defective retarder controller Between When solenoid output is ON Voltage 20 – 30 V

BRC3
(female)
When solenoid output is OFF Voltage Max. 1 V
(37) – (13)
50 HM300-2R
HM300-2R 51
Failure code [DW79KZ] (Front brake BCV command output system:

Action code Failure code Front brake BCV command output: Disconnection or short circuit
Trouble
E01 DW79KZ (Retarder controller system)
Contents of
trouble • Current does not flow to front brake BCV solenoid, or excessive current flows when output is ON.
Action of • Current does not flow to solenoid.

Problem that
appears on
machine
Related infor-
mation • Output current to front brake BCV can be checked with monitoring function (Code: 33807).

Resis-
1 Defective front BCV solenoid Between B06 (male) (1) – (2) Max. 1 z
tance
Resis-
Between B06 (male) (1), (2) – ground Min. 1 Mz
tance
2 Max. 1 z
Possible causes contact) Wiring harness between BRC3 (female) (23) Resis-
value in normal
state
Min. 1 Mz
Resis-
tance
ing switch ON.
4 Defective retarder controller Between When solenoid output is ON Voltage 20 – 30 V

BRC3
(female)
When solenoid output is OFF Voltage Max. 1 V
(37) – (13)
52 HM300-2R
HM300-2R 53
Failure code [DX11K4] Trouble in rear wheel proportional solenoid

pressure reducing valve 1 1
Action code Failure code Trouble in rear wheel proportional solenoid pressure reducing
Trouble valve 1
E03 DX11K4 (Retarder controller system)
Contents of • When output to retarder proportional pressure reducing valve (rear) is turned OFF, signal from
trouble retarder oil pressure switch (rear) is kept ON.
Action of • Continues control of retarder control lever.
controller • Continues control of overrun prevention retarder and accelerator-linked retarder.
Problem that • If solenoid is defective, rear brake drags.
appears on • If switch is defective or switch circuit has ground fault, gear is difficult to shift up and easy to shift
machine down.
• Condition of retarder oil pressure switch can be checked with monitoring function.
Related
(Monitoring code: BRAKE - D-IN--0------7 - 40932)
information
• Method of reproducing failure code: Start engine + operate retarder control lever to apply brake.

a Prepare with starting switch OFF, then start engine and carry
out troubleshooting.
Defective retarder oil pres- Retarder control
1 sure switch (rear) (Internal B23 (male) Resistance
lever
defect)
Brake Max. 1 z
Between (1) – (2)
Release Min. 1 Mz
Ground fault in wiring har- ing without turning starting switch ON.
2 ness (Short circuit with GND
Possible causes circuit) Wiring harness between BRC1 (female) (5) Resis-
Min. 1 Mz
and standard – B23 (female) (1) tance
value in normal a Prepare with starting switch OFF, then turn starting switch ON
state and carry out troubleshooting.
Retarder control
BRC1, BRC3 Voltage
3 Defective retarder controller lever
Between BRC1 (5) – Brake Max. 1 V
BRC3 (21), (31),
(32), (33) Release 8 – 30 V
Defective rear brake circuit

If causes 1 – 3 are not detected, rear brake circuit or hydraulic and
or hydraulic and mechanical
mechanical system of retarder proportional pressure reducing
4 system of retarder propor-
valve (rear) may be defective. Carry out troubleshooting for
tional pressure reducing
hydraulic and mechanical system.
valve (rear)
54 HM300-2R
HM300-2R 55
Failure code [DX11KA] (Rear brake proportional pressure reducing

solenoid valve output circuit: Disconnection) 1
Action code Failure code Rear brake proportional pressure reducing solenoid valve:
Trouble Disconnection
E03 DX11KA (Retarder controller system)
Contents of
trouble • When output to rear brake pressure reducing valve solenoid circuit is ON, current does not flow.
Action of
controller • Turns output to rear brake pressure reducing valve solenoid OFF.
Problem that
appears on • Retarder (rear brake) does not operate.
machine
Related infor-

Defective rear brake
Resis-
1 proportional pressure Between B18 (male) (1) – (2) 10 – 30 z
tance
reducing solenoid valve
Between B18 (female) (1), (2) – machine Resis-
Min. 1 Mz
ground tance
Possible causes
and standard
value in normal
state harness Wiring harness between BRC3 (female) (16) Resis-
2 Max. 1 z
contact) Wiring harness between BRC3 (female) (23) Resis-
Max. 1 z
Resis-
Between BRC3 (female) (16) – (23) 10 – 30 z
tance
56 HM300-2R
Failure code [DX11KB] (Rear brake proportional pressure reducing

solenoid valve: Short circuit) 1
Action code Failure code Rear brake proportional pressure reducing solenoid valve: Short
Trouble circuit
E03 DX11KB (Retarder controller system)
Contents of
trouble • When output is ON to rear brake pressure reducing valve solenoid circuit, excessive current flows.
Action of
Problem that
machine
Related infor-

Resis-
tance
Between B18 (male) (1), (2) – machine Resis-
Min. 1 Mz
ground tance
value in normal Short circuit of harness Between ground and wiring harness between Resis-
state Min. 1 Mz
2 (Contact with GND circuit or BRC3 (female) (16) – B18 (female) (1) tance
contact among harnesses) Between wiring harness from BRC3 (female)
Resis-
tance
Resis-
tance
HM300-2R 57
Failure code [DX11KY] (Rear brake proportional pressure reducing

solenoid valve: Short circuit to power source line) 1
Trouble circuit to power source line
E03 DX11KY (Retarder controller system)
Contents of
trouble • When output to rear brake pressure reducing valve solenoid circuit is OFF, electric current flows.
Action of
Problem that
machine
Related infor-

Resis-
tance
Resis-
Possible causes Between B18 (male) (1), (2) – ground Min. 1 Mz
tance
and standard
state Hot short in wiring harness ing switch ON.
2
Voltage Max. 1 V
BRC3 (female) (16) – B18 (female) (1)
Resis-
tance
58 HM300-2R
HM300-2R 59
Failure code [DX11MA] (Rear brake proportional pressure reducing

solenoid valve: Malfunction) 1
Action code Failure code Rear brake proportional pressure reducing solenoid valve:
Trouble Malfunction
E03 DX11MA (Retarder controller system)
Contents of
trouble • Rear brake proportional pressure reducing solenoid valve does not operate (does not move).
Action of
controller • Releases retarder solenoid output.
Problem that
appears on • Retarder (rear brake), ARSC and over run prevention do not operate.
machine
Related infor-
mation • Retarder oil pressure switch state can be checked with monitoring function (Code: 33806).

• Check rear brake proportional pressure reducing solenoid valve.
1 proportional pressure
If there is an abnormality (mechanical failure), repair or replace it.
Oil
Defective rear brake Resis-
pressure Max. 1 z
2 proportional pressure tance
is ON.
reducing solenoid valve Between B18 (male) (1) – (2)
Oil
Resis-
pressure Min. 1 Mz
tance
Possible causes is OFF.
value in normal Disconnection in wiring ing switch still OFF.
state harness Wiring harness between BRC3 (female) (16) Resis-
3 Max. 1 z
Max. 1 z
ing switch ON.
Oil
pressure Voltage Max. 1 V
is ON.
Between BRC3 (16) – (23)
Oil
pressure Voltage 20 – 30 V
is OFF.
60 HM300-2R
HM300-2R 61
Failure code [DX12K4] (Front brake proportional pressure reducing

solenoid valve: Out of control) 1
Action code Failure code Front brake proportional pressure reducing solenoid valve: Out of
control
Trouble
E03 DX12K4 (Valve is stuck in operated condition)
(Retarder controller system)
Contents of • Front brake proportional pressure reducing solenoid valve is stuck in the operated condition and do
trouble not close, or even if it is closed, condition cannot be identified because of defect of detection switch.
Action of
Problem that • If solenoid is defective, front brake is dragging.

appears on • When switch is defective or switch input circuit has a grounding failure, shift up becomes difficult and
machine shift down becomes easy.
Related infor-

RTL (male) Retarder lever Resistance
Defective retarder lever Between (5) – (6) Max. 1 z
1
validation switch During operation
Between (4) – (6) Min. 1 Mz
When not operating
Between (4) – (6) Max. 1 z
Defective front brake
Resis-
tance
Resis-
Between B19 (male) (1) (2) – ground Min. 1 Mz
Possible causes tance
state
3 Min. 1 Mz
(Contact with ground circuit) BRC1 (female) (18) – RTL (female) (5) tance
Min. 1 Mz
BRC1 (female) (24) – RTL (female) (4) tance
4
Voltage Max. 1 V
ing switch ON.
Between BRC3 (6) – Retarder operation Voltage 20 – 30 V
(13) Retarder neutral Voltage Max. 1 V
Malfunction of front brake If no problem is found in above 1 – 5, defective operation of
6
pressure reducing valve pressure reducing valve unit is suspected.
62 HM300-2R
HM300-2R 63
Failure code [DX12KA] (Front brake proportional pressure reducing

solenoid valve output circuit: Disconnection) 1
Action code Failure code Front brake proportional pressure reducing solenoid valve output
Trouble circuit: Disconnection
E03 DX12KA (Retarder controller system)
Contents of
trouble • When output to front brake pressure reducing valve solenoid circuit is ON, current does not flow.
Action of
controller • Turns the output to front brake pressure reducing valve solenoid OFF.
Problem that
appears on • Retarder (front brake) does not operate.
machine
• As solenoid detects disconnection while output is ON, be sure to turn output ON to check operation
Related infor-
after repair.
mation
• Can be checked with monitoring function (Code: 33807).

Resis-
1 proportional pressure Between B19 (female) (1) – (2) 10 – 30 z
tance
Min. 1 Mz
ground tance
Possible causes
and standard
value in normal
state harness Wiring harness between BRC3 (female) (6) – Resis-
2 Max. 1 z
(Disconnection or improper B19 (female) (1) tance
Max. 1 z
Resis-
tance
64 HM300-2R
Failure code [DX12KB] (Front brake proportional pressure reducing

solenoid valve: Short circuit) 1
Trouble circuit
E03 DX12KB (Retarder controller system)
Contents of
trouble • When output to front brake pressure reducing valve solenoid circuit is ON, excessive current flows.
Action of
Problem that
machine
Related infor-

Resis-
tance
Min. 1 Mz
ground tance
state Min. 1 Mz
Resis-
tance
Resis-
tance
HM300-2R 65

© 2010 KOMATSU
All Rights Reserved
66 HM300-2R
SEN03428-01
HM300-2R

Failure code [DX12KY] (Front brake proportional pressure reducing solenoid valve: Short circuit to power
source line) ................................................................................................................................ 3
Failure code [DX12MA] (Front brake proportional pressure reducing solenoid valve: Malfunction) ............... 4
Failure code [DX13KA] (Hoist EPC valve output circuit: Disconnection) ........................................................ 6
Failure code [DX13KB] (Hoist EPC valve output circuit: Short circuit)............................................................ 7
Failure code [DX13KY] (Hoist EPC valve output circuit: Short circuit in power source line)........................... 8
Failure code [DXH0KA] (Inter-axle differential lock pressure control valve: Disconnection)........................... 9
Failure code [DXH0KB] (Inter-axle differential lock pressure control valve: Short circuit) ............................ 10
Failure code [DXH0KY] (Inter-axle differential lockup pressure control valve: Short circuit to power source
line) ...........................................................................................................................................11
Failure code [DXH1KA] (Lockup clutch solenoid output circuit: Disconnection) ........................................... 12
Failure code [DXH1KB] (Lockup clutch solenoid output circuit: Short circuit)............................................... 13
Failure code [DXH1KY] (Lockup clutch solenoid output circuit: Short circuit to power source line) ............. 14
Failure code [DXH2KA] (Hi clutch solenoid output circuit: Disconnection) ................................................... 16
HM300-2R 1
Failure code [DXH2KB] (Hi clutch solenoid output circuit: Short circuit) ....................................................... 18
Failure code [DXH2KY] (Hi clutch solenoid output circuit: Short circuit to power source line)...................... 20
Failure code [DXH3KA] (Lo clutch solenoid output circuit: Disconnection)................................................... 24
Failure code [DXH3KB] (Lo clutch solenoid output circuit: Short circuit) ...................................................... 26
Failure code [DXH3KY] (Lo clutch solenoid output circuit: Short circuit in power source line) ..................... 28
Failure code [DXH4KA] (1st clutch solenoid output circuit: Disconnection) .................................................. 32
Failure code [DXH4KB] (1st clutch solenoid output circuit: Short circuit)...................................................... 34
Failure code [DXH4KY] (1st clutch solenoid output circuit: Short circuit to power source line) .................... 36
Failure code [DXH5KA] (2nd clutch solenoid output circuit: Disconnection)................................................. 40
Failure code [DXH5KB] (2nd clutch solenoid output circuit: Short circuit) .................................................... 42
Failure code [DXH5KY] (2nd clutch solenoid output circuit: Short circuit in power source line) ................... 44
Failure code [DXH6KA] (3rd clutch solenoid output circuit: Disconnection).................................................. 48
Failure code [DXH6KB] (3rd clutch solenoid output circuit: Short circuit) ..................................................... 50
Failure code [DXH6KY] (3rd clutch solenoid output circuit: Short circuit to power source line) .................... 52
Failure code [DXH7KA] (R clutch solenoid output circuit: Disconnection) .................................................... 56
Failure code [DXH7KB] (R clutch solenoid output circuit: Short circuit)........................................................ 58
Failure code [DXH7KY] (R clutch solenoid output circuit: Short circuit to power source line)....................... 60
2 HM300-2R
Failure code [DX12KY] (Front brake proportional pressure reducing

solenoid valve: Short circuit to power source line) 1
Action code Failure code Front brake proportional pressure reducing solenoid valve output
Trouble circuit: Short circuit to power source line
E03 DX12KY (Retarder controller system)
Contents of
trouble • When output to front brake pressure reducing valve solenoid circuit is OFF, current flows
Action of
Problem that
machine
Related infor-

Resis-
tance
Resis-
Possible causes Between B19 (female) (1) (2) – ground Min. 1 Mz
tance
and standard
2
Voltage Max. 1 V
Resis-
tance
HM300-2R 3
Failure code [DX12MA] (Front brake proportional pressure reducing

solenoid valve: Malfunction) 1
Action code Failure code Front brake pressure proportional reducing solenoid valve:
Trouble Malfunction
E03 DX12MA (Retarder controller system)
Contents of • Front brake proportional pressure reducing solenoid valve is stuck in the operated condition and do
trouble not close, or even if it is closed, condition cannot be identified because of defect of detection switch.
Action of
Problem that • If the solenoid is defective, front retarder cannot be used.

appears on
machine • When switch is defective or there is a disconnection in switch input circuit, there is no change.
Related infor-

RTL (male) Retarder lever Resistance
Defective retarder lever Between (5) – (6) Max. 1 z
1
validation switch During operation
When not operating
Resis-
tance
Resis-
Possible causes Between B19 (female) (1), (2) – ground Min. 1 Mz
tance
and standard
value in normal
state
Wiring harness between BRC3 (female) (6) – Resis-
Max. 1 z
Disconnection in wiring B19 (female) (1) tance
3 Max. 1 z
Max. 1 z
– RLT (female) (5) tance
Max. 1 z
– RLT (female) (4) tance
Resis-
4 Defective retarder controller Between BRC3 (female) (6) – (13) 10 – 30 z
tance
If no problem is found in above 1 – 3, pressure reducing valve is
defective.
4 HM300-2R
HM300-2R 5
Failure code [DX13KA] (Hoist EPC valve output circuit: Disconnection)1
Action code Failure code Hoist EPC valve output circuit: Disconnection
Trouble
E03 DX13KA (Transmission controller system)
Contents of
trouble • When output to hoist EPC valve solenoid circuit is ON, current does not flow.
Action of • Turns output to hoist selector valve solenoid OFF.

controller • Turns output to hoist EPC valve solenoid OFF.
Problem that
appears on • Body does not operate.
machine
Related infor-
after repair.
mation
• Output current to hoist EPC can be checked with monitoring function (Code: 45601).

Defective hoist EPC valve Resis-
1 Between T02 (female) (1) – (2) 15 – 20 z
solenoid tance
Resis-
Between T02 (female) (1), (2) – body ground Min. 1 Mz
tance
Possible causes
and standard
value in normal
2 Max. 1 z
(Disconnection or improper – T02 (female) (1) tance
Max. 1 z
3
controller Resis-
tance
6 HM300-2R
Failure code [DX13KB] (Hoist EPC valve output circuit: Short circuit) 1
Action code Failure code Hoist EPC valve output circuit: Short circuit
Trouble
E03 DX13KB (Transmission controller system)
Contents of
trouble • When output is ON to hoist EPC valve solenoid circuit, excessive current flows.

Problem that
machine
Related infor-

solenoid tance
Resis-
Between T02 (female) (1), (2) – ground Min. 1 Mz
tance
state Min. 1 Mz
2 (Contact with ground circuit ATC3 (female) (28) – T02 (female) (1) tance
Resis-
(28) – T02 (female) (1) and wiring harness Min. 1 Mz
tance
from ATC3 (female) (13) – T02 (female) (2)
3
controller Resis-
tance
HM300-2R 7
Failure code [DX13KY] (Hoist EPC valve output circuit: Short circuit in
power source line) 1
Action code Failure code Hoist EPC valve output circuit: Short circuit in power source line
Trouble
E03 DX13KY (Transmission controller system)
Contents of
trouble • When output to hoist EPC valve solenoid circuit is OFF, electric current flows.

Problem that
machine
Related infor-

solenoid tance
Resis-
Between T02 (female) (1), (2) – body ground Min. 1 Mz
tance
Possible causes
and standard
ing switch ON.
value in normal
state Hot short in wiring harness Between ground and wiring harness between
2 Voltage Max. 1 V
(a contact with 24 V circuit) ATC3 (female) (28) – T02 (female) (1)
Voltage Max. 1 V
ATC3 (female) (13) – T02 (female) (2)
3
controller Resis-
tance
8 HM300-2R
Failure code [DXH0KA] (Inter-axle differential lock pressure control

valve: Disconnection) 1
Action code Failure code Inter-axle differential lock pressure control valve: Disconnection
Trouble
E01 DXH0KA (Transmission controller system)
Contents of
trouble • Current does not flow when the output to differential lock clutch solenoid is ON.
Action of
controller • Turns differential lock OFF and hold it.
Problem that
machine
Related infor-
mation

1 Between CN20 (female) (1) – (2) 4 – 14 z
Resis-
Between CN20 (female) (1), (2) – ground Min. 1 Mz
tance
Possible causes
and standard
value in normal
state harness Wiring harness between ACT3 (female) (35) Resis-
2 Max. 1 z
contact of connector) Wiring harness between ACT3 (female) (23) Resis-
Max. 1 z
3
controller Resis-
tance
HM300-2R 9
Failure code [DXH0KB] (Inter-axle differential lock pressure control

valve: Short circuit) 1
Action code Failure code Inter-axle differential lock pressure control valve: Short circuit
Trouble
E01 DXH0KB (Transmission controller system)
Contents of
trouble • Abnormally excessive current flows when output to differential lockup clutch solenoid is ON.
Action of
controller • Turns output to inter-axle differential lockup solenoid OFF.
Problem that
machine
Related infor-
mation

Resis-
tance
Possible causes
and standard 2 Min. 1 Mz
(Contact with ground circuit) ATC3 (female) (35) – CN20 (female) (1) tance
value in normal
Min. 1 Mz
3
Voltage Max. 1 V
4
controller Resis-
tance
10 HM300-2R
Failure code [DXH0KY] (Inter-axle differential lockup pressure control

valve: Short circuit to power source line) 1
Action code Failure code Inter-axle differential lockup pressure control valve: Short circuit to
Trouble power source line
E03 DXH0KY (Transmission controller system)
Contents of
trouble • Electric current flows when output to differential lockup pressure control valve is OFF.
Action of
controller • Turns output to inter-axle differential lockup pressure control valve OFF.
Problem that
appears on • Differential lockup keeps operating.
machine
Related infor-
mation

and standard tance
2
Voltage Max. 1 V
3
controller
HM300-2R 11
Failure code [DXH1KA] (Lockup clutch solenoid output circuit:

Disconnection) 1
Action code Failure code Lockup clutch solenoid: Disconnection

Trouble
Contents of
trouble • Current does not flow when output to lockup clutch solenoid is ON.
Action of • Holds gear speed during travel.

controller • Turns lockup actuation OFF.
Problem that • Lockup does not operate.
appears on
machine • When gearshift lever is set to neutral position, machine cannot move off again.
Related infor-
after repair.
mation
• Output current to lockup solenoid can be checked with monitoring function (Code: 31609).

1 Between CN18 (male) (1) – (2) 5 – 15 z
solenoid tance
Resis-
tance
Possible causes
and standard
value in normal
state harness Wiring harness between ATC3 (female) (6) – Resis-
2 Max. 1 z
(Disconnection or improper CN18 (female) (1) tance
Max. 1 z
3
controller Resis-
tance
12 HM300-2R
Failure code [DXH1KB] (Lockup clutch solenoid output circuit: Short

circuit) 1
Action code Failure code Lockup clutch solenoid: Short circuit

Trouble
Contents of • Abnormally excessive current flows while output to lockup clutch solenoid is ON, or current flows
trouble while output is OFF.
Problem that • Lockup is either released or operated all the time and gear cannot be shifted.
appears on • Once gearshift lever is set to “N“, the machine cannot move off again until it is stopped (Will not even
machine move forward depending on the failure condition.)
Related infor-
mation • Output current to lockup solenoid can be checked with monitoring function (Code: 31609).

1 Between CN18 (male) (1) – (2) 5 – 15 z
solenoid tance
Resis-
tance
state Min. 1 Mz
2 (Contact with ground circuit ATC3 (female) (6) – CN18 (female) (1) tance
Resis-
(6) – CN18 (female) (1) and wiring harness Min. 1 Mz
tance
from ATC3 (female) (23) – CN18 (female) (2)
3
5 – 15 z
(23) tance
HM300-2R 13
Failure code [DXH1KY] (Lockup clutch solenoid output circuit: Short

circuit to power source line) 1
Action code Failure code Lockup clutch solenoid output circuit: Short circuit to power source line
Trouble
Contents of
trouble • While output to lockup clutch solenoid is OFF, electric current flows.
Problem that • Cannot change gear speed.
appears on • Keeps lockup OFF
machine • When gear shift lever is operated to N, machine cannot move off.
Related infor-
mation • Output current to lockup solenoid can be checked with monitoring function (Code: 31609)

1 Between CN18 (male) (1) – (2) 5 – 15 z
solenoid tance
Resis-
Possible causes Between CN18 (male) (1), (2) – ground Min. 1 Mz
tance
and standard
2
Voltage Max. 1 V
3
controller Resis-
tance
14 HM300-2R
HM300-2R 15
Failure code [DXH2KA] (Hi clutch solenoid output circuit: Disconnection)1
Action code Failure code Hi clutch solenoid output circuit: Disconnection

Trouble
Contents of
trouble • No electric current flows when the output to Hi clutch ECMV is ON.
• The gear speed is shifted to Neutral.

Action of
controller • Shifts up and holds the gear speed as shown in Table 1 depending on the gear speed before failure.
Problem that • Once the gear shift lever is set to neutral, the machine can not move off in any gear speeds.
appears on • Shift to neutral when traveling.
machine • Machine cannot move off again until it is stopped.
Related infor-
after repair.
mation
• Electric current of output to ECMV can be checked with monitoring function (code: 31600).

Resis-
tance
Resis-
tance
Possible causes
and standard
value in normal
2 Max. 1 z
(Disconnection and – CN10 (female) (1) tance
defective contact) Wiring harness between ATC3 (female) (13) Resis-
Max. 1 z
Defective transmission con- ing switch still OFF.
3
troller Wiring harness between ATC3 (female) (26) Resis-
5 – 15 z
– (13) tance
16 HM300-2R
Table 1
Trouble clutch
signal lost)
F6
F5
Low Low 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
High High 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Low Low 2H F4 OFF
1st 1st 2L F3 OFF
F2
High High 2L F3 OFF
1st 1st 2L F3 OFF
F1
Low Low 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM300-2R 17
Failure code [DXH2KB] (Hi clutch solenoid output circuit: Short circuit)1
Action code Failure code Hi clutch solenoid output circuit: Short circuit
Trouble
Contents of • Abnormally excessive current flows while output to Hi clutch ECMV is ON, or current flows while out-
trouble put is OFF.
Problem that
machine
Related infor-
mation • Electric current of output to ECMV can be checked by monitoring function (code: 31600).

Resis-
tance
Resis-
tance
state Min. 1 Mz
2 (Contact with GND circuit or ATC3 (female) (26) – CN10 (female) (1) tance
contact among harnesses) Between wiring harness from ATC3 (female)
Resis-
tance
3
controller Resis-
tance
18 HM300-2R
Table 1
Trouble clutch
signal lost)
F6
F5
Low Low 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
High High 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Low Low 2H F4 OFF
1st 1st 2L F3 OFF
F2
High High 2L F3 OFF
1st 1st 2L F3 OFF
F1
Low Low 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM300-2R 19
Failure code [DXH2KY] (Hi clutch solenoid output circuit: Short circuit
to power source line) 1
Action code Failure code Hi clutch solenoid output circuit: Short circuit to power source line
Trouble
Contents of
trouble • When output to Hi clutch ECMV is OFF, electric current flows.
• The gear speed is shifted to Neutral.

Action of
controller • Shifts up and holds the gear speed as shown in Table 2 depending on the gear speed before failure.
Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
and standard
2
Voltage Max. 1V
3
controller Resis-
tance
20 HM300-2R
Table 2
Trouble clutch
[Command on]
(Fill SW ON)
2nd OFF Neutral OFF
F6
Low OFF Neutral OFF
2nd OFF Neutral OFF
F5
High 3H F6 OFF
3rd 3L F5 OFF
F4
Low 3L F5 OFF
3rd 3L F5 OFF
F3
High 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Low 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
High 1H F2 OFF
2nd OFF Neutral OFF
R3
Low OFF Neutral OFF
3rd 3R R3 OFF
R2
Low OFF Neutral OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Low OFF Neutral OFF
HM300-2R 21
22 HM300-2R
HM300-2R 23
Failure code [DXH3KA] (Lo clutch solenoid output circuit:

Disconnection) 1
Action code Failure code Lo clutch solenoid output circuit: Disconnection

Trouble
Contents of
trouble • Current does not flow when output to Lo clutch ECMV is ON.
Problem that
machine
Related infor-
after repair.
mation

Resis-
tance
Resis-
tance
Possible causes
and standard
value in normal
2 Max. 1 z
Max. 1 z
3
5 – 15 z
– (3) tance
24 HM300-2R
Table 1
Trouble clutch
signal lost)
F6
F5
Low Low 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
High High 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Low Low 2H F4 OFF
1st 1st 2L F3 OFF
F2
High High 2L F3 OFF
1st 1st 2L F3 OFF
F1
Low Low 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM300-2R 25
Failure code [DXH3KB] (Lo clutch solenoid output circuit: Short

circuit) 1
Action code Failure code Lo clutch solenoid output circuit: Short circuit (KB)
Trouble
Contents of
trouble • Excessive current flows while output to Lo clutch ECMV is ON, or current flows while output is OFF.
Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
state Min. 1 Mz
Resis-
tance
3
5 – 15 z
– (3) tance
26 HM300-2R
Table 1
Trouble clutch
signal lost)
F6
F5
Low Low 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
High High 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Low Low 2H F4 OFF
1st 1st 2L F3 OFF
F2
High High 2L F3 OFF
1st 1st 2L F3 OFF
F1
Low Low 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM300-2R 27
Failure code [DXH3KY] (Lo clutch solenoid output circuit: Short circuit
in power source line) 1
Action code Failure code Lo clutch solenoid output circuit: Short circuit to power source line
Trouble
Contents of
trouble • When output to Lo clutch ECMV is turned “OFF“, current flows to circuit.
Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
and standard
2
Voltage Max. 1 V
3
controller Resis-
tance
28 HM300-2R
Table 2
Trouble clutch
[Command ON]
(Fill SW ON)
2nd OFF Neutral OFF
F6
Low OFF Neutral OFF
2nd OFF Neutral OFF
F5
High 3H F6 OFF
3rd 3L F5 OFF
F4
Low 3L F5 OFF
3rd 3L F5 OFF
F3
High 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Low 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
High 1H F2 OFF
2nd OFF Neutral OFF
R3
Low OFF Neutral OFF
3rd 3R R3 OFF
R2
Low OFF Neutral OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Low OFF Neutral OFF
HM300-2R 29
30 HM300-2R
HM300-2R 31
Failure code [DXH4KA] (1st clutch solenoid output circuit:

Disconnection) 1
Action code Failure code 1st clutch solenoid output circuit: Disconnection
Trouble
Contents of
trouble • Current does not flow when output to 1st clutch ECMV is ON.
Problem that
machine
Related infor-
after repair.
mation

Resis-
tance
Resis-
tance
Possible causes
and standard
value in normal
2 Max. 1 z
Max. 1 z
3
5 – 15 z
– (13) tance
32 HM300-2R
Table 1
Trouble clutch
signal lost)
F6
F5
Low Low 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
High High 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Low Low 2H F4 OFF
1st 1st 2L F3 OFF
F2
High High 2L F3 OFF
1st 1st 2L F3 OFF
F1
Low Low 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM300-2R 33
Failure code [DXH4KB] (1st clutch solenoid output circuit: Short circuit)1
Action code Failure code 1st clutch solenoid output circuit: Short circuit
Trouble
Contents of • Abnormally excessive current flows when output to 1st clutch ECMV is ON, or current flows while
trouble output is OFF.
Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
state Min. 1 Mz
Resis-
tance
3
5 – 15 z
– (13) tance
34 HM300-2R
Table 1
Trouble clutch
signal lost)
F6
F5
Low Low 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
High High 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Low Low 2H F4 OFF
1st 1st 2L F3 OFF
F2
High High 2L F3 OFF
1st 1st 2L F3 OFF
F1
Low Low 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM300-2R 35
Failure code [DXH4KY] (1st clutch solenoid output circuit: Short circuit
Action code Failure code 1st clutch solenoid output circuit: Short circuit in power source line
Trouble
Contents of
trouble • When output to 1st clutch ECMV is “OFF“, current flows to circuit.
Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
and standard
2
Voltage Max. 1 V
3
controller Resis-
tance
36 HM300-2R
Table 2
Trouble clutch
[Command ON]
(Fill SW ON)
2nd OFF Neutral OFF
F6
Low OFF Neutral OFF
2nd OFF Neutral OFF
F5
High 3H F6 OFF
3rd 3L F5 OFF
F4
Low 3L F5 OFF
3rd 3L F5 OFF
F3
High 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Low 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
High 1H F2 OFF
2nd OFF Neutral OFF
R3
Low OFF Neutral OFF
3rd 3R R3 OFF
R2
Low OFF Neutral OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Low OFF Neutral OFF
HM300-2R 37
38 HM300-2R
HM300-2R 39
Failure code [DXH5KA] (2nd clutch solenoid output circuit:

Disconnection) 1
Action code Failure code 2nd clutch solenoid output circuit: Disconnection
Trouble
Contents of
trouble • Current does not flow when output to 2nd clutch ECMV is ON.
Problem that • Once the gear shift lever is set to neutral, the machine can not move off in any gear speeds.
appears on • As solenoid detects disconnection while output is ON, be sure to turn output ON to check operation
machine after repair.
Related infor-

Resis-
tance
Resis-
tance
Possible causes
and standard
value in normal
state harness Wiring harness between ATC3 (female) (5) – Resis-
2 Max. 1 z
(Disconnection or improper CN14 (female) (1) tance
Max. 1 z
3
5 – 15 z
(3) tance
40 HM300-2R
Table 1
Trouble clutch
signal lost)
F6
F5
Low Low 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
High High 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Low Low 2H F4 OFF
1st 1st 2L F3 OFF
F2
High High 2L F3 OFF
1st 1st 2L F3 OFF
F1
Low Low 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM300-2R 41
Failure code [DXH5KB] (2nd clutch solenoid output circuit: Short

circuit) 1
Action code Failure code 2nd clutch solenoid output circuit: Short circuit
Trouble
Contents of • Abnormally excessive current flows while output to 2nd clutch ECMV is ON, or current flows while
Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
state Min. 1 Mz
2 (Contact with GND circuit or ATC3 (female) (5) – CN14 (female) (1) tance
contact among harnesses) Between wiring harness from ATC3 (female)
Resis-
tance
3
5 – 15 z
(3) tance
42 HM300-2R
Table 1
Trouble clutch
signal lost)
F6
F5
Low Low 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
High High 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Low Low 2H F4 OFF
1st 1st 2L F3 OFF
F2
High High 2L F3 OFF
1st 1st 2L F3 OFF
F1
Low Low 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM300-2R 43
Failure code [DXH5KY] (2nd clutch solenoid output circuit: Short circuit
in power source line) 1
Action code Failure code 2nd clutch solenoid output circuit: Short circuit in power source line
Trouble
Contents of
trouble • When output to 2nd clutch ECMV is “OFF“, current flows to circuit.
Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
and standard
2
Voltage Max. 1 V
3
controller Resis-
tance
44 HM300-2R
Table 2
Trouble clutch
[Command ON]
(Fill SW ON)
2nd OFF Neutral OFF
F6
Low OFF Neutral OFF
2nd OFF Neutral OFF
F5
High 3H F6 OFF
3rd 3L F5 OFF
F4
Low 3L F5 OFF
3rd 3L F5 OFF
F3
High 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Low 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
High 1H F2 OFF
2nd OFF Neutral OFF
R3
Low OFF Neutral OFF
3rd 3R R3 OFF
R2
Low OFF Neutral OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Low OFF Neutral OFF
HM300-2R 45
46 HM300-2R
HM300-2R 47
Failure code [DXH6KA] (3rd clutch solenoid output circuit:

Disconnection) 1
Action code Failure code 3rd clutch solenoid output circuit: Disconnection
Trouble
Contents of
trouble • Current does not flow when output to 2nd clutch ECMV is ON.
Problem that
machine
Related infor-
after repair.
mation

Resis-
tance
Resis-
tance
Possible causes
and standard
value in normal
2 Max. 1 z
Max. 1 z
3
5 – 15 z
– (23) tance
48 HM300-2R
Table 1
Trouble clutch
signal lost)
F6
F5
Low Low 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
High High 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Low Low 2H F4 OFF
1st 1st 2L F3 OFF
F2
High High 2L F3 OFF
1st 1st 2L F3 OFF
F1
Low Low 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM300-2R 49
Failure code [DXH6KB] (3rd clutch solenoid output circuit: Short

circuit) 1
Action code Failure code 3rd clutch solenoid output circuit: Short circuit
Trouble
Contents of • Abnormally excessive current flows while output to 3rd clutch ECMV is ON, or current flows while
Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
state Min. 1 Mz
Resis-
tance
3
5 – 15 z
– (23) tance
50 HM300-2R
Table 1
Trouble clutch
signal lost)
F6
F5
Low Low 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
High High 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Low Low 2H F4 OFF
1st 1st 2L F3 OFF
F2
High High 2L F3 OFF
1st 1st 2L F3 OFF
F1
Low Low 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM300-2R 51
Failure code [DXH6KY] (3rd clutch solenoid output circuit: Short circuit
Action code Failure code 3rd clutch solenoid output circuit: Short circuit to power source line
Trouble
Contents of
trouble • When output to 3rd clutch ECMV is OFF, current flows to circuit.
Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
and standard
state Hot short in wiring harness ing switch still OFF.
2
Voltage Max. 1 V
3
controller Resis-
tance
52 HM300-2R
Table 2
Trouble clutch
[Command ON]
(Fill SW ON)
2nd OFF Neutral OFF
F6
Low OFF Neutral OFF
2nd OFF Neutral OFF
F5
High 3H F6 OFF
3rd 3L F5 OFF
F4
Low 3L F5 OFF
3rd 3L F5 OFF
F3
High 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Low 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
High 1H F2 OFF
2nd OFF Neutral OFF
R3
Low OFF Neutral OFF
3rd 3R R3 OFF
R2
Low OFF Neutral OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Low OFF Neutral OFF
HM300-2R 53
54 HM300-2R
HM300-2R 55
Failure code [DXH7KA] (R clutch solenoid output circuit:

Disconnection) 1
Action code Failure code R clutch solenoid output circuit: Disconnection

Trouble
Contents of
trouble • Current does not flow when output to R clutch ECMV is ON.
Problem that
machine
Related infor-
after repair.
mation

Resis-
tance
Resis-
tance
Possible causes
and standard
value in normal
2 Max. 1 z
Max. 1 z
3
5 – 15 z
– (23) tance
56 HM300-2R
Table 1
Trouble clutch
signal lost)
F6
F5
Low Low 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
High High 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Low Low 2H F4 OFF
1st 1st 2L F3 OFF
F2
High High 2L F3 OFF
1st 1st 2L F3 OFF
F1
Low Low 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM300-2R 57
Failure code [DXH7KB] (R clutch solenoid output circuit: Short circuit)1
Action code Failure code R clutch solenoid output circuit: Short circuit
Trouble
Contents of • Abnormally excessive current flows while output to R clutch ECMV is ON, or current flows while out-
trouble put is OFF.
Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
state Min. 1 Mz
Resis-
tance
3
5 – 15 z
– (23) tance
58 HM300-2R
Table 1
Trouble clutch
signal lost)
F6
F5
Low Low 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
High High 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Low Low 2H F4 OFF
1st 1st 2L F3 OFF
F2
High High 2L F3 OFF
1st 1st 2L F3 OFF
F1
Low Low 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM300-2R 59
Failure code [DXH7KY] (R clutch solenoid output circuit: Short circuit to

power source line) 1
Action code Failure code R clutch solenoid output circuit: Short circuit to power source line
Trouble
Contents of
trouble • When output to R clutch ECMV is OFF, current flows to circuit.
Problem that
machine
Related infor-

Resis-
tance
Resis-
tance
and standard
2
Voltage Max. 1 V
3
controller Resis-
tance
60 HM300-2R
Table 2
Trouble clutch
[Command ON]
(Fill SW ON)
2nd OFF Neutral OFF
F6
Low OFF Neutral OFF
2nd OFF Neutral OFF
F5
High 3H F6 OFF
3rd 3L F5 OFF
F4
Low 3L F5 OFF
3rd 3L F5 OFF
F3
High 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Low 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
High 1H F2 OFF
2nd OFF Neutral OFF
R3
Low OFF Neutral OFF
3rd 3R R3 OFF
R2
Low OFF Neutral OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Low OFF Neutral OFF
HM300-2R 61
62 HM300-2R
HM300-2R 63

© 2010 KOMATSU
All Rights Reserved
64 HM300-2R
SEN03429-01

HM300-2R

Troubleshooting of electrical system
(E-mode)
Before troubleshooting of electrical system .................................................................................................... 3
Contents of troubleshooting table ................................................................................................................... 6
E-1 Engine does not start ............................................................................................................................... 7
E-2 Automatic preheating does not operate ................................................................................................. 10
E-3 Machine monitor does not display all, when starting switch is turned ON.............................................. 14
E-4 Machine monitor does not operate when starting switch is OFF............................................................ 16
E-5 Alarm buzzer does not sound................................................................................................................. 18
E-6 Gauges of machine monitor, caution lamps or character display
section do not display properly. ............................................................................................................. 19
E-7 Selection of display in character display section cannot be changed .................................................... 20
E-8 Power mode selecting function does not operate properly .................................................................... 24
E-9 AISS function does not operate properly................................................................................................ 25
E-10 Seat belt caution lamp does not display properly................................................................................. 26
E-11 Turn signal lamp or turning lamp (hazard lamp) does not work properly.............................................. 27
HM300-2R 1
E-12 Night illumination (lighting) does not work properly .............................................................................. 30

E-13 Emergency steering does not operate.................................................................................................. 37
E-14 Dump lever does not operate normally................................................................................................. 42
E-15 KOMTRAX system does not operate normally..................................................................................... 44
E-16 Electric priming pump does not operate or does not stop automatically .............................................. 48
E-17 Air conditioner does not operate normally ............................................................................................ 50
2 HM300-2R
Before troubleshooting of electrical system 1

Wiring table for circuit breaker and slow blow fuse
a This wiring table shows the components which are supplied with power by each power source of the cir-
cuit breaker or the slow blow fuse.
(Switched power source refers to the power source supplied with the starting switch ON, and constant
power source refers to the power source supplied with the starting switch OFF.)
a When proceeding to a troubleshooting by failure code, first of all, inspect the circuit breaker or slow blow
fuse to check if the power source is supplied properly.
Type of power source Breaker name Capacity Destinations of electric power distribution
80 A • Fuse (BT3) (inlet terminal No.)
(Terminals No. 80A (3), (5), (7), (9), (11), (13), (15), (17), (19)
65, 64) (21), (23), (25), (27)
Power source of switch (1), (3), (13), (15), (17), (19)
(Terminal M of battery • Fuse (BT2) (inlet terminal No.)
relay) 80 A
(11), (13)
(Terminals No. 80A
62, 63)
(1)
(1), (3), (5), (7), (9), (13), (15), (17), (19)
30A
(Terminals No. 30A
(29)
Constant power source 81, 83)
(Terminal B of battery • Fuse (BT2) (inlet terminal No.)
relay) 30A
(15), (17), (19), (21), (23), (25), (27), (29)
(Terminals No. 30A
82, 84)
(11)
(Terminal M of battery Slow blow fuse 120A • Engine intake air heater relay
relay)
HM300-2R 3
Wiring table for fuse box

a This wiring table shows the components which are supplied with power by each power source of the
fuse box.
(Switched power source refers to the power source supplied with the starting switch ON, and constant
power source refers to the power source supplied with the starting switch OFF.)
a When proceeding to a troubleshooting by failure code, first inspect the fuse box to check if the power
source is supplied properly.
Fuse numbers are mentioned in the order of the fuse outlet No. o inlet No.
Fuse
Type of power source Fuse No. Destinations of electric power distribution
capacity
(10) – (9) 10A Machine monitor
(14) – (13) 10A Transmission controller
(Terminal M of battery
relay) Emergency steering
BT3 (16) – (15) 10A
(Circuit breaker) Parking brake relay
(80A)
(18) – (17) 20A Power window (rear)
(Terminal No. 65, 64)
(20) – (19) 20A Power window (left)
(22) – (21) —
(24) – (23) —
(26) – (25) —
(28) – (27) 30A Rear heater
(2) – (1) 20A Main lamp
(4) – (3) 10A Turning lamp
(14) – (13) 10A Stop lamp
BT1
(16) – (15) 20A Backup lamp, buzzer
(18) – (17) 20A Working lamp (F)
(20) – (19) 20A Spare
(12) – (11) 20A Front wiper
Power source of switch BT2
(14) – (13) 20A Rear wiper
(Terminal M of battery
relay) BT3 (2) – (1) 20A Fog lamp
(Circuit breaker) (2) – (1) 10A Room lamp
(80A)
(4) – (3) 10A Radio
(6) – (5) 10A Revolving warning lamp
(8) – (7) 20A Side lamp
BT4 (10) – (9) 10A Auto preheater
(14) – (13) 10A Tachograph
(16) – (15) 10A Cigarette lighter
(18) – (17) 10A Air suspension seat
(Terminal B of battery
relay) BT3 (30) – (29) 30A Engine controller
30A
4 HM300-2R
Fuse
Type of power source Fuse No. Destinations of electric power distribution
capacity
Machine monitor
(16) – (15) 10A
KOMTRAX
Constant power source (20) – (19) 20A Terminal B of starting switch
(Terminal B of battery BT2 (22) – (21) 10A Transmission controller
relay)
30A (24) – (23) 20A Hazard lamp
(Terminal No. 82, 84) (26) – (25) 10A Emergency steering
(28) – (27) 10A Room lamp
(30) – (29) 20A Spare
BT4 (12) – (11) 10A Horn
(6) – (5) 20A Head lamp (Hi)
(8) – (7) 20A Head lamp (Lo)
BT1
(10) – (9) 10A Small lamp (right)
(12) – (11) 10A Small lamp (left)
Fuse in a circuit (2) – (1) 5A Starting switch ACC – engine controller
(4) – (3) 10A Starting switch ACC – KOMTRAX
BT2 (6) – (5) 10A Starting switch ACC – machine monitor
(8) – (7) 10A Starting switch BR – parking brake
(10) – (9) 10A Starting switch BR – backup monitor
HM300-2R 5
Contents of troubleshooting table 1

a Troubleshooting Table and Circuit Diagram Related collectively carry the following information. Carry out
troubleshooting work after fully grasping their contents.
Trouble Phenomenon occurring on machine
Related
Information on the failure occurred as well as the troubleshooting
information

<Contents>
• The standard values in normalcy by which to judge “Good“
or “No Good“ about presumed causes.
1 • References for making judgement of “Good“ or “No Good“.
<Symptoms of defective harness>

• Disconnection in wiring
The connector connection is defective or the wiring har-
ness is disconnected.
• Defective grounding
A harness not connected to GND (ground) circuit comes
2 into contact with the GND (ground) circuit.
• Hot short defect
A harness not connected to the electric power supply (24V)
circuit comes into contact with the electric power supply
(24V) circuit.
• Short circuit
Possible causes Cause for presumed A harness abnormally comes into contact with a harness of
and standard failure (The attached No. is separate circuit.
value in normal 3 for filing and reference
state <Points to remember in troubleshooting>
purpose only. It does not
1) Connector denotation method and handling of T-adapters
stand for any priority.)
Insert or connect T-adapters in the following manner, unless
specifically owhterwise instructed.
• If there is no indication of “male“ or “female“ in the con-
nector No., pull off a connector and insert a T-adapter into
both sides of male and female
4 • If there is an indication of “male“ and “female“ in the con-
nector No., pull off a connector and insert a T-adapter into
only one side of “male“ or “female“.
2) Description sequence of pin No. and handling of circuit
tester leads
Connect the positive lead (+) and negative lead (-) for trou-
bleshooting in the following manner unless specifically oth-
erwise instructed.
5 • Connect the positive lead (+) to a pin No. marked at the
front or wiring harness.
• Connect the negative lead (-) to a pin No. marked at the
rear of wiring harness.
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
• Connector No.: Indicates (Type - numbers of a pin) (color)
• Arrow ( ) : Roughly indicates the location in the machine where it is installed.
6 HM300-2R
E-1 Engine does not start 1
Trouble Engine does not start.

Related • When failure code related to engine controller or transmission is present, troubleshooting the corre-
information sponding failure code first.

Gravity Min. 1.26
1 Defective battery
Voltage Min. 25 V
Defective circuit breaker (64
When circuit breaker (64 – 65), (82 – 84) is shut off, or fuse BT2 (19
– 65) and (82 – 84) or defec-
2 – 20), BT3 (13 – 14) is blown, it is highly possible that a defective
tive fuse BT2 (19 – 20) and
grounding has occurred in the circuit.
BT3 (13 – 14)
a Prepare with the starting switch OFF, then start engine to trouble-
shooting.
Defective engine starter The problem is
3 Replace relay (R01) Defective relay
relay (R01) resolved.
with other relay
(5 terminals) The problem is not
Relay is normal
resolved.
4 Defective diode (D01), (D09) Between (1) – (2) Continuity None
D01, D09 (male)
Between (2) – (1) Continuity Yes
• Troubleshooting in a diode range.
Defective alternator ing switch ON.
and standard 5
(regulator)
value in normal Between 78 (2) – ground Voltage Max. 12V
state
Wiring harness between BT2 (19) – battery Resis-
Max. 1 z
relay (66) terminal B tance
Wiring harness between BT3 (13) – battery Resis-
Max. 1 z
relay (69) terminal M tance
Harness between battery (+) terminal-battery Resis-
Max. 1 z
relay (66) terminal B tance
Harness between BT2 (20) – starting switch Resis-
harness Max. 1 z
(terminal B) tance
6 (Disconnection or defective
contact) Harness between BT3 (14) – SF1 (female) Resis-
Max. 1 z
(Power supply circuits) (1) tance
Harness between starting switch (terminal
BR) – battery relay (53) terminal BR
Continuity Continue
(Troubleshooting in the diode range from
starting switch (terminal BR) side)
Harness between battery relay (50) terminal Resis-
Max. 1 z
(-) – frame ground (ER) tance
Harness between battery relay (69) terminal Resis-
Max. 1 z
M – starting motor (terminal B) tance
HM300-2R 7

Harness between starting switch (terminal C) Resis-
Max. 1 z
– R38 (female) (3) tance
harness Harness between R38 (female) (6) – R01 Resis-
Max. 1 z
(Disconnection or defective (female) (5) tance
6
contact) Harness between R01 (female) (3) – 78 Resis-
(Related circuit after starting Max. 1 z
(female) (1) tance
switch terminal C)
Harness between R01 (female) (1) – SF1 Resis-
Max. 1 z
(female) (5) tance
Harness between R01 (female) (2) – ground Resis-
Max. 1 z
(ER2) tance
ing switch ON.
Possible causes Between ground and wiring harness
and standard between alternator (terminal R) – 78 (male) Voltage Max. 1V
Hot short of wiring harness
value in normal 7 (2)
(a contact with 24 V circuit)
state
between CJU (female) (1) – ATC1 (female)
Voltage Max. 1V
(15), BRC1 (female) (15), and D01 (female)
(2)
Defective starting switch ing switch still OFF.
8
(Between terminals B – C) Resis-
Starting switch unit (between B – C) Max. 1 z
tance
ing switch ON.
Between starting motor (B terminal) – ground Voltage 20 – 30 V
9 Defective starting motor
a Prepare with the starting switch OFF, then start engine to trouble-
shooting.
Between 78 (1) – ground Voltage 20 – 30 V
Detective engine controller As the engine controller power supply can be detective, carry out
10
power supply troubleshooting for "Failure code CA111".
8 HM300-2R
HM300-2R 9
E-2 Automatic preheating does not operate 1

Automatic preheating does not operate when coolant temperature is below 0°C and starting switch is
Trouble
ON.
Related • When failure code CA2555 or CA2556 is not displayed
information (if failure code is displayed, troubleshooting the code first.)

Defective circuit breaker 30 When the circuit breaker is shut off or the fuse is blown, it is highly
1 A, 80 A or defective fuse possible that a defective grounding has occurred in the circuit
BT2 (20), BT4 (10) (troubleshooting cause 8).
Defective high current fuse Fuse is normal if continuity exists between inlet and outlet of high
2
(fuse is blown) current fuse (disconnect the inlet and outlet terminals).
ing switch ON.
Between heater inlet terminal – ground Voltage 15 – 28 V
Defect intake air heater
(inside disconnection)
Wiring harness between heater (-) terminal – Resis-
Max. 1 z
ground tance
• If no problem is found by above diagnoses, intake air heater is
defective.
ing switch ON.
Between heater relay terminal (E12) –
Voltage 15 – 28 V
ground
Between heater relay terminal (PHO) –
Voltage 15 – 28 V
ground
Defective heater relay
Between heater relay terminal (E11) –
4 (Internal disconnection or Voltage 15 – 28 V
ground
Possible causes defective contact)
value in normal
Between heater relay coil side (-) terminal – Resis-
state Max. 1 z
ground tance
• If no problem is found by above diagnoses, heater relay is defec-
tive.
ing switch ON.
Between R07 (5) – ground Voltage 15 – 28 V
Defective auto preheater
5 Between R07 (3) – ground Voltage 15 – 28 V
relay (R07)
When a failure code is not displayed and no problem is found in
above diagnoses, pre-auto heater relay is defective.
* It can be also diagnosed by replacing relay with another one.
ing switch ON.
Defective starting switch Between starting switch terminal B – ground Voltage 15 – 28 V
6 (Defective contact between Between starting switch terminal ACC –
Voltage 15 – 28 V
contact points B and ACC) ground
• If no problem is found by above diagnoses, starting switch is
defective.
a Prepare with the starting switch OFF and troubleshooting with the
Disconnection in wiring starting switch still OFF (disconnect the terminals).
harness Wiring harness between heater relay termi- Resis-
7 Max. 1 z
(Disconnection or defective nal (PHO) – air heater inlet terminal tance
contact) Wiring harness between heater relay termi- Resis-
Max. 1 z
nal (E12) – high current fuse outlet terminal tance
10 HM300-2R

starting switch still OFF (disconnect the terminals).
Wiring harness between high current fuse inlet Resis-
Max. 1 z
– battery relay terminal M (69) tance
Wiring harness between battery relay terminal Resis-
Max. 1 z
M (69) – circuit breaker 80 A terminal (62) tance
Disconnection in wiring Wiring harness among circuit breaker 80A ter-
Resis-
harness minal (63) – fuse BT4 (9), (10) – R07 (female) Max. 1 z
7 tance
(Disconnection or defective (5)
contact) Wiring harness between battery relay terminal Resis-
Max. 1 z
M (69) – circuit breaker 30A terminal (82) tance
Wiring harness among circuit breaker 30A ter-
Resis-
minal (84) – fuse BT2 (19), (20) – starting Max. 1 z
tance
switch terminal B
Wiring harness among starting switch terminal Resis-
Max. 1 z
ACC-fuse BT2 (1), (2) – J2P (female) (39) tance
starting switch still OFF (disconnect the terminals).
Possible causes Between ground and wiring harness between
Resis-
and standard heater relay terminal (PHO) – air heater inlet Min. 1 Mz
tance
value in normal terminal
Resis-
heater relay terminal (E12) – high current fuse Min. 1 Mz
tance
outlet terminal
Resis-
high current fuse inlet – battery relay terminal Min. 1 Mz
tance
M (69)
Short circuit of harness Resis-
battery relay terminal M (69) – circuit breaker Min. 1 Mz
8 (Contact with ground cir- tance
80 A terminal (62)
cuit)
Resis-
circuit breaker 80 A terminal (63) – fuse BT4 Min. 1 Mz
tance
(9), (10) – R07 (female) (5)
Resis-
battery relay terminal B (69) – circuit breaker Min. 1 Mz
tance
30 A terminal (82)
Resis-
circuit breaker 30 A terminal (84) – fuse BT2 Min. 1 Mz
tance
(19), (20) – starting switch terminal B
Resis-
starting switch terminal ACC-fuse BT2 (1), (2) Min. 1 Mz
tance
– J2P (female) (39)
HM300-2R 11
12 HM300-2R
HM300-2R 13
E-3 Machine monitor does not display all, when starting switch is turned
ON 1
Trouble Lamps and gauges of machine monitor do not display all, when starting switch is turned ON.
Related
• When the machine related failure code is not displayed (if displayed, troubleshooting the code first.)
information

Defective fuse BT2 (6) or When the fuse BT2 (6) or (20) is blown or the circuit breaker (30 A) is
1 (20) or defective circuit shut off, it is highly possible that a defective grounding has occurred in
breaker (30 A) the circuit (troubleshooting cause 3).
a Prepare with starting switch OFF and troubleshooting with starting
switch still OFF.
Wiring harness between DPC1 (female) (6), (7) Resis-
Max. 1 z
– fuse BT2 (6) tance
Disconnection in wiring Wiring harness between BT2 (5) – starting Resis-
Max. 1 z
harness switch terminal ACC tance
2
(Disconnection or defec- Wiring harness between BT2 (20) – starting Resis-
tive contact) Max. 1 z
switch terminal B tance
Wiring harness between circuit breaker (30A) – Resis-
fuse BT2 (19) tance
and standard
(10) – ground ER tance
state
switch still OFF.
Min. 1 Mz
DPC1 (female) (6), (7) – fuse BT2 (6) tance
3 (Contact with ground cir- Min. 1 Mz
BT2 (5) – starting switch terminal ACC tance
cuit)
Min. 1 Mz
fuse BT2 (20) – starting switch terminal B tance
Min. 1 Mz
circuit breaker (30A) – fuse BT2 (19) tance
Defective machine switch ON.
4
monitor
Between DPC1 (6), (7) – (9), (10) Voltage 20 – 30 V
14 HM300-2R
HM300-2R 15
E-4 Machine monitor does not operate when starting switch is OFF 1
Service meter and travel distance integrating meter, turn signal pilot lamp, and high beam pilot lamp do
Trouble
not flash, if the switches are operated with starting switch OFF.
Related
information

Defective fuse BT2 (16) or When the fuse BT2 (16) is blown or the circuit breaker (30 A) is shut
1 defective circuit breaker off, it is highly possible that a defective grounding has occurred in the
(30A) circuit (troubleshooting cause 3).
switch still OFF.
Disconnection in wiring Wiring harness between DPC1 (female) (4), (5) Resis-
Max. 1 z
harness – fuse BT2 (16) tance
2
(Disconnection or defec- Wiring harness between circuit breaker (30A) – Resis-
Possible causes tive contact) Max. 1 z
fuse BT2 (15) tance
and standard
state
switch still OFF.
DPC1 (female) (4), (5) – fuse BT2 (16) tance
cuit)
Min. 1 Mz
circuit breaker (30A) – fuse BT2 (15) tance
Defective machine moni- switch ON.
4
tor
Between DPC1 (4), (5) – (9), (10) Voltage 20 – 30 V
16 HM300-2R
HM300-2R 17
E-5 Alarm buzzer does not sound 1
The alarm buzzer does not sound when the starting switch is ON, emergency stop item lamps are ON,
Trouble
and centralized warning lamp is ON.
Related
information

When the fuse BT3 (10) is blown, it is highly possible that a defective
1 Defective fuse BT3 (10)
grounding has occurred in the circuit (troubleshooting cause 3).
switch still OFF.
Disconnection in wiring Wiring harness between DPC1 (female) (13) – Resis-
Max. 1 z
harness BZ2 (female) (2) tance
2
(Disconnection or defec- Wiring harness between BZ2 (female) (1) – Resis-
fuse BT3 (10) tance
Max. 1 z
Possible causes a Prepare with starting switch OFF and troubleshooting with starting
and standard switch still OFF.
value in normal Short circuit of harness
state 3 (Contact with ground cir- Min. 1 Mz
DPC1 (female) (13) – BZ2 (female) (2) tance
cuit)
Min. 1 Mz
BZ2 (female) (1) – fuse BT3 (10) tance
switch ON.
Measurement
DPC1 Voltage
conditions
Defective machine moni-
4 When the buzzer
tor 20 – 30 V
does not sound
Between (13) – (9), (10)
When the buzzer
Max. 1V
sounds
* Set up the conditions to actuate the buzzer for the measurement.
18 HM300-2R
E-6 Gauges of machine monitor, caution lamps or character display

section do not display properly 1
Trouble Gauges, lamps or character display section are malfunctioning

Related
information

Defective sensors or Troubleshooting corresponding sensors or switches by the failure
Possible causes 1
switches code.
and standard
value in normal Defective CAN communi-
2 Troubleshooting by the communication related failure code
state cation circuit
Defective machine moni- If no problem is found in above 1 and 2, machine monitor is defective
3
tor (since this is an internal defect, it cannot be diagnosed).
HM300-2R 19
E-7 Selection of display in character display section cannot be changed1
Trouble (1) When the mode selector switch 1 circuit for machine monitor is defective
Related
information

When the fuse BT2 (16) is blown, it is highly possible that a defec-
tive grounding has occurred in the circuit (troubleshooting cause 4).
Resis-
CH1 (male) Operation of switch (switch unit)
tance
Defective monitor mode
2 Press the switch [U]. Max. 1 z
selector switch 1 (CH1)
Between (3) – (2)
Switch is in the neutral. Min. 1 Mz
Press the switch [t]. Max. 1 z
Between (3) – (1)
Disconnection in wiring har- Wiring harness between CH1 (female) (1) – Resis-
Max. 1 z
ness DPC2A (female) (14) tance
3
(Disconnection or defective Wiring harness between CH1 (female) (2) – Resis-
contact) Max. 1 z
Possible causes DPC2A (female) (8) tance
and standard Wiring harness between CH1 (female) (3) – Resis-
fuse BT2 (16) tance
state
Resis-
between CH1 (female) (1) – DPC2A (female) Min. 1 Mz
tance
Short circuit of harness (14)
4
(Contact with ground circuit) Between ground and wiring harness
Resis-
tance
(8)
Min. 1 Mz
between CH1 (female) (3) – fuse BT2 (16) tance
ing switch ON.
DPC2A Operation of switch Voltage
5 Defective machine monitor Press the switch [U]. 20 – 30 V
Between (8) – ground
Switch is in the neutral. Max. 1V
Between (14) – Press the switch [t]. 20 – 30 V
ground Switch is in the neutral. Max. 1V
20 HM300-2R
HM300-2R 21
Trouble (2) When the mode selector switch 2 circuit for machine monitor is defective
Related
information

Resis-
CH2 (male) Operation of switch (switch unit)
tance
Defective monitor mode
2 Press the switch [>]. Max. 1 z
selector switch 2 (CH2)
Between (3) – (2)
Press the switch [<]. Max. 1 z
Between (3) – (1)
Disconnection in wiring har- Wiring harness between CH2 (female) (1) – Resis-
Max. 1 z
ness DPC2A (female) (15) tance
3
(Disconnection or defective Harness between CH2 (female) (2) – DPC2A Resis-
contact) Max. 1 z
Possible causes (female) (6) tance
and standard Wiring harness between CH2 (female) (3) – Resis-
fuse BT3 (10) tance
state
Resis-
tance
Short circuit of harness (15)
4
(Contact with ground circuit) Between ground and wiring harness
Resis-
tance
(6)
Min. 1 Mz
between CH2 (female) (3) – fuse BT3 (10) tance
ing switch ON.
DPC2A Operation of switch Voltage
5 Defective machine monitor Press the switch [>]. 20 – 30 V
Switch is in the neutral. Max. 1V
Between (15) – Press the switch [<]. 20 – 30 V
ground Switch is in the neutral. Max. 1V
22 HM300-2R
HM300-2R 23
E-8 Power mode selecting function does not operate properly 1
When power mode selector function does not operate properly, even if the power mode selector switch
Trouble
is operated.
Related
information

Defective power mode Resis-
2 PWM (male) Operation of switch (switch unit)
selector switch tance
Switch: down Max. 1 z
Between (1) – (3)
Switch: up Min. 1 Mz
ness Wiring harness between DPC2A (female) Resis-
(Disconnection or defective (13) – PWM (female) (3) tance
value in normal Wiring harness between PWM (female) (1) – Resis-
Max. 1 z
state fuse BT3 (10) tance
4 between DPC2A (female) (13) – PWM Min. 1 Mz
(female) (3)
Min. 1 Mz
between PWM (female) (1) – fuse BT3 (10) tance
ing switch ON.
5 Defective machine monitor DPC2A Operation of switch Voltage
Between (13) – Switch: down 20 – 30 V
ground Switch: up Max. 1V
24 HM300-2R
E-9 AISS function does not operate properly 1
Trouble When AISS function does not operate properly, even if the AISS LOW switch is operated.
Related
information

Resis-
2 Defective AISS switch AISS (male) Operation of switch (switch unit)
tance
Switch: up Min. 1 Mz
Between (1) – (3)
Switch: down Max. 1 z
harness Wiring harness between DPC2A (female) (2) Resis-
(Disconnection or defective – AISS (female) (3) tance
value in normal Wiring harness between AISS (female) (1) – Resis-
Max. 1 z
4 between DPC2A (female) (2) – AISS Min. 1 Mz
(female) (3)
Min. 1 Mz
between AISS (female) (1) – fuse BT3 (10) tance
ing switch ON.
5 Defective machine monitor DPC2A Operation of switch Voltage
Switch: down 20 – 30 V
Switch: up Max. 1V
HM300-2R 25
E-10 Seat belt caution lamp does not display properly 1
The lamp lights up even if the seat belt is fastened, or the lamp does not light up even if the seat belt is
Trouble
not fastened.
Related
information

a Prepare with the starting switch OFF and troubleshooting with
starting switch still OFF (switch unit).
Resis-
2 Defective seat belt switch SBS Seat belt
tance
Fastened Max. 1 z
Between (1) – (2)
Unfastened Min. 1 Mz
ness Wiring harness between DPC2B (female) Resis-
(Disconnection or defective (11) – SBS (female) (1) tance
value in normal Wiring harness between SBS (female) (2) – Resis-
Max. 1 z
4 between DPC2B (female) (11) – SBS Min. 1 Mz
(female) (1)
Min. 1 Mz
between SBS (female) (2) – fuse BT3 (10) tance
ing switch ON.
5 Defective machine monitor DPC2B Seat belt Voltage
Between (11) – Fastened 20 – 30 V
ground Unfastened Max. 1V
26 HM300-2R
E-11 Turn signal lamp or turning lamp (hazard lamp) does not work
properly 1
Trouble Turn signal lamp or turning lamp (hazard lamp) does not flash.
Related
information

Defective fuse BT1 (4) or When the fuse BT1 (4) or BT2 (24) is blown, it is highly possible that a defective
1
BT2 (24) grounding has occurred in the circuit (troubleshooting cause 7).
Since the lamp can be suspected to be defective, visually check it or
2 Defective lamp
replace it with known good lamp to make a judgement.
switch ON.
Defective turn signal FLS Turn signal switch Voltage
3
lamp Between (3) – GND At any positions 20 – 30 V
Turned to the left or 20 – 30 V – 0 V
Between (4) – GND
right repeatedly
switch still OFF.
CM (male) Turn signal switch (lever) Resistance
Defective turn signal Turned to the left Max. 1 z
4
switch Between (6) – (7)
Turned to the right Min. 1 Mz
Turned to the right Max. 1 z
Between (6) – (8)
Turned to the left Min. 1 Mz
When the relay can be suspected to be defective, replace it with
another relay to make a judgement.
• As for the relay R12 (6 terminals): Replace with the relay R11, R16
5 Defective relay
or R09, etc.
• As for the relay R13 (5 terminals): Replace with the relay R14, R15
Possible causes or R17, etc.
and standard a Prepare with starting switch OFF and troubleshooting with starting
value in normal switch still OFF.
state
Wiring harness between BT1 (4) – R13 Resis-
Max. 1 z
(female) (6) tance
Wiring harness among BT2 (24) – R13 Resis-
Max. 1 z
(female) (3) – HAZ (female) (5) tance
Wiring harness among HAZ (female) (3) – Resis-
Max. 1 z
R13 (female) (1) – R12 (female) (5) tance
Max. 1 z
FLS (female) (3) tance
Wiring harness among R12 (female) (4) – CM Resis-
Max. 1 z
Disconnection in wiring (female) (7) – DPC2A (female) (7) tance
harness Wiring harness among R12 (female) (2) – CM Resis-
6 Max. 1 z
(Disconnection or defec- (female) (8) – DPC2A (female) (16) tance
tive contact) Wiring harness among R12 (female) (1), (3) – Resis-
Max. 1 z
FLS (female) (4) – DPC2A (female) (6) tance
Wiring harness between CM (female) (7) – Resis-
Max. 1 z
CJS (female) (7) tance
Wiring harness between CJS (female) (1) – Resis-
Max. 1 z
P02 (female) (3) (right front) tance
Wiring harness between CJS (female) (2) – Resis-
Max. 1 z
P21 (female) (1) (right rear) tance
Wiring harness between CM (female) (8) – Resis-
Max. 1 z
CJR (female) (5) tance
Wiring harness between CJR (female) (3) – Resis-
Max. 1 z
P20 (female) (1) (left rear) tance
HM300-2R 27

Wiring harness between CJR (female) (4) – P02 Resis-
Max. 1 z
(female) (3) (left front) tance
Wiring harness among P02 (female) (2) – CJY (2), Resis-
Max. 1 z
(8) – ground (G1) (left front) tance
Wiring harness between P02 (female) (6) – CJY Resis-
Max. 1 z
(6), (4) – ground (G1) (right front) tance
Wiring harness among P21 (female) (6) – CJK (4), Resis-
Max. 1 z
(6) – ground (94) (right rear) tance
Disconnection in
wiring harness Wiring harness between P21 (female) (6) – CJK Resis-
6 Max. 1 z
(Disconnection or (3), (6) – ground (94) (left rear) tance
defective contact) Wiring harness between HAZ (female) (4) – Resis-
Max. 1 z
ground (EG2) tance
Wiring harness among R13 (female) (2) – JCA (9), Resis-
Max. 1 z
(16) – ground (EG2) tance
Wiring harness among R12 (female) (6) – JCA (8), Resis-
Max. 1 z
(16) – ground (EG2) tance
Wiring harness between FLS (female) (1) – ground Resis-
Max. 1 z
(EG2) tance
switch still OFF.
Between ground and wiring harness between BT1 Resis-
Min. 1 Mz
(4) – R13 (female) (6) tance
Possible causes Between ground and wiring harness between BT2 Resis-
(24) – R13 (female) (3) – HAZ (female) (5) tance
value in normal
Between ground and wiring harness between HAZ Resis-
state Min. 1 Mz
(female) (3) – R13 (female) (1) – R12(female) (5) tance
Between ground and wiring harness between R13 Resis-
Min. 1 Mz
(female) (3) – FLS (female) (3) tance
Between ground and wiring harness among R12
Resis-
(female) (4) – CM (female) (7) – DPC2A (female) Min. 1 Mz
tance
(7)
Between ground and wiring harness among R12
Resis-
Short circuit of harness (female) (2) – CM (female) (8) – DPC2A (female) tance
Min. 1 Mz
7 (Contact with ground (16)
circuit) Between ground and wiring harness among R12
Resis-
(female) (1) – FLS (female) (4) – DPC2A (female) Min. 1 Mz
tance
(6)
Between ground and wiring harness between CM Resis-
Min. 1 Mz
(female) (7) – CJS (female) (7) tance
Between ground and wiring harness between CJS Resis-
Min. 1 Mz
(female) (1) – P02 (female) (3) (right front) tance
Between ground and wiring harness between CJS Resis-
Min. 1 Mz
(female) (2) – P21 (female) (1) (right rear) tance
Between ground and wiring harness between CM Resis-
Min. 1 Mz
(female) (8) – CJR (female) (5) tance
Between ground and wiring harness between CJR Resis-
Min. 1 Mz
(female) (3) – P20 (female) (1) (left rear) tance
Between ground and wiring harness between CJR Resis-
Min. 1 Mz
(female) (4) – P02 (female) (3) (left front) tance
28 HM300-2R
HM300-2R 29
E-12 Night illumination (lighting) does not work properly 1
Trouble (1) Small lamps (clearance lamp, tail lamp), night illumination and head lamp do not light up at all.
Related
information

1 Defective fuse BT1(2)
switch still OFF.
CM (male) Lamp switch Resistance
2 Defective lamp switch Between (1) – (2) Max. 1 z
1st detent
2nd detent
Disconnection in wiring a Prepare with starting switch OFF and troubleshooting with starting
Possible causes harness switch still OFF.
3
and standard (Disconnection or defec- Wiring harness between fuse BT1 (2) – CM Resis-
value in normal tive contact) Max. 1 z
(female) (1), (4) tance
state
switch still OFF.
Resis-
fuse BT1 (2) – CM (female) (1), (4) – R14 Min. 1 Mz
tance
(female) (5) – R16 (female) (3), (1)
Short circuit of harness Between ground and wiring harness among
Resis-
4 (Contact with ground fuse BT1 (5) – R15 (female) (5) – R16 (female) Min. 1 Mz
tance
circuit) (2), (4) – DPC2A (female) (1)
Min. 1 Mz
fuse BT1 (5) – R15 (female) (6) tance
fuse BT1 (9), (7) – CM (female) (2) – LS
(female) (1) – DPC2A (female) (5)
Small lamps (clearance lamp and tail lamp) or night illumination do not light up at the first detent
Trouble (2)
position of the lamp switch.
Related
• When the head lamps light up.
information

switch still OFF.
Possible causes 1 Defective lamp switch
and standard
value in normal Between (1) – (2) 1st detent Max. 1 z
state Disconnection in wiring a Prepare with starting switch OFF and troubleshooting with starting
harness switch still OFF.
2
(Disconnection or defec- Wiring harness between CM (female) (2) – Resis-
fuse BT1 (9), (11) (branched point) tance
30 HM300-2R
Trouble (3) Left small lamps (clearance lamp and tail lamp) do not light up.
Related
• When right side and head lamps light up.
information

When the lamp (bulb) can be suspected to be defective, judge by
2 Defective lamp (bulb)
visual check or replacing the lamp bulb.
switch still OFF.
Wiring harness between P20 (female) (4) – Resis-
Max. 1 z
CJS (female) (3) tance
Max. 1 z
Disconnection in wiring CJS (female) (4) tance
harness Wiring harness between CJS (female) (5) – Resis-
3 Max. 1 z
(Disconnection or defec- fuse BT1 (12) tance
Possible causes tive contact) Wiring harness between BT1 (9), (11) – CM Resis-
Max. 1 z
and standard (female) (2) (to branched point) tance
value in normal Wiring harness among P20 (female) (6) – CJK Resis-
state Max. 1 z
(3), (6) – ground (94) tance
Wiring harness among P20 (female) (2) – CJY Resis-
Max. 1 z
(2), (8) – ground (G1) tance
switch still OFF.
Min. 1 Mz
P20 (female) (4) – CJS (female) (3) tance
Min. 1 Mz
4 (Contact with ground P02 (female) (1) – CJS (female) (4) tance
circuit) Between ground and wiring harness between Resis-
Min. 1 Mz
CJS (female) (5) – fuse BT1 (12) tance
Resis-
BT1 (9), (11) – CM (female) (2) (to branched Min. 1 Mz
tance
point)
HM300-2R 31
Trouble (4) Right small lamps (clearance lamp and tail lamp) do not light up.
Related
• When left side and head lamps light up.
information

switch still OFF.
Max. 1 z
CJT (female) (5) tance
Max. 1 z
Disconnection in wiring CJT (female) (3) tance
harness Wiring harness between CJT(female) (4) – Resis-
3 Max. 1 z
(Disconnection or defec- fuse BT1 (10). tance
Possible causes tive contact) Wiring harness between BT1 (9), (11) – CM Resis-
Max. 1 z
and standard (female) (2) (to branched point) tance
value in normal Wiring harness among P21 (female) (6) – CJK Resis-
state Max. 1 z
(4), (6) – ground (94) tance
Wiring harness among P20 (female) (2) – CJY Resis-
Max. 1 z
(6), (4) – ground (G1) tance
switch still OFF.
Min. 1 Mz
P21 (female) (4) – CJT (female) (5) tance
Min. 1 Mz
4 (Contact with ground cir- P02 (female) (1) – CJT (female) (3) tance
cuit) Between ground and wiring harness between Resis-
Min. 1 Mz
CJT (female) (4) – fuse BT1 (10) tance
Resis-
BT1 (9), (11) – CM (female) (2) (to branched Min. 1 Mz
tance
point)
32 HM300-2R
Trouble (5) Head lamps ”Lo beam” do not light up.

Related
• When the lamps light up in the Hi beam side.
information

switch still OFF.
3 Defective lamp switch
Between (1) – (3) Turn to 2nd detent. Max. 1 z
switch still OFF.
Max. 1 z
CJU (female) (3) (right side) tance
Max. 1 z
CJU (female) (5) (left side) tance
Wiring harness between CJU (female) (4) – Resis-
Max. 1 z
Disconnection in wiring fuse BT1 (8). tance
harness Wiring harness between fuse BT1 (7) – R15 Resis-
4 Max. 1 z
(Disconnection or defec- (female) (6) tance
Possible causes tive contact)
and standard Wiring harness between CM (female) (3) – Resis-
Max. 1 z
value in normal R14 (female) (1) tance
state Wiring harness between R14 (female) (3) – Resis-
Max. 1 z
R15 (female) (3) tance
Max. 1 z
CJY(5), (4) – ground (G1) (right side) tance
Max. 1 z
CJY(7), (8) – ground (G1) (left side) tance
switch still OFF.
Min. 1 Mz
P01 (female) (1) – CJU (female) (3) (right side) tance
Min. 1 Mz
P01 (female) (1) – CJU (female) (5) (left side) tance
CJU (female) (4) – fuse BT1 (8) tance
cuit)
Min. 1 Mz
Min. 1 Mz
CM (female) (3) – R14 (female) (1) tance
Min. 1 Mz
HM300-2R 33
Trouble (6) Head lamps ”Hi beam” do not light up.

Related
• When the lamps light up in the Lo beam side.
information

switch still OFF.
Max. 1 z
CJT (female) (7) (right side) tance
Max. 1 z
CJT (female) (2) (left side) tance
Disconnection in wiring Wiring harness between CJT (female) (1) – Resis-
Max. 1 z
harness fuse BT1 (6). tance
3
(Disconnection or defec- Wiring harness between fuse BT1 (5) – R15 Resis-
(female) (5) tance
Max. 1 z
Possible causes Wiring harness between DPC1 (female) (14) – Resis-
Max. 1 z
and standard R15 (female) (2) tance
value in normal Wiring harness between DPC2A (female) (1) – Resis-
state Max. 1 z
R15 (female) (5) (to branched point) tance
switch still OFF.
Min. 1 Mz
P01 (female) (3) – CJT (female) (7) (right side) tance
Min. 1 Mz
P01 (female) (3) – CJT (female) (2) (left side) tance
Min. 1 Mz
Short circuit of harness CJT (female) (1) – fuse BT1 (6) tance
4 (Contact with ground Between ground and wiring harness between Resis-
circuit) Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
DPC1 (female) (14) – R15 (female) (2) tance
Resis-
DPC2A (female) (1) – R15 (female) (5) (to Min. 1 Mz
tance
branched point)
34 HM300-2R
Trouble (7) At passing position, “Hi“ beam lamps do not light up.
Related
• When head lamps light up properly.
information

switch still OFF.
1 Defective passing switch CM (male) Passing switch Resistance
Operated Max. 1 z
Between (4) – (5)
Possible causes Not operated Min. 1 Mz
and standard a Prepare with starting switch OFF and troubleshooting with starting
value in normal switch still OFF.
state
Disconnection in wiring Wiring harness between CM (female) (5) – Resis-
Max. 1 z
harness R16 (female) (5) tance
2
(Disconnection or defec- Wiring harness between R16 (female) (2), (4) Resis-
– R15 (female) (5) (to branched point) tance
Wiring harness between DPC2A (female) (4) – Resis-
Max. 1 z
CM (female) (5) (to branched point) tance
Trouble (8) The brightness of the night illumination does not change, even if the rheostat is operated.
Related
information

switch ON.
LS Rheostat Voltage
1 Defective rheostat
Between (1) – ground Neutral 20 – 30 V
Left end 6 – 12 V
Right end 18 – 27 V
and standard Disconnection in wiring switch still OFF.
value in normal harness Wiring harness between LS (female) (2) – Resis-
2 Max. 1 z
state (Disconnection or defec- DPC2B (female) (12) tance
tive contact) Wiring harness between LS (female) (3) – Resis-
Max. 1 z
ground (EG2) tance
switch still OFF.
LS (female) (2) – DPC2B (female) (12) tance
cuit)
Min. 1 Mz
LS (female) (3) – ground (EG2) tance
HM300-2R 35
36 HM300-2R
E-13 Emergency steering does not operate 1
Trouble (1) When the steering pomp stops operating, it does not operate with auto.
Related
• Check that the parking brake is released.
information

a Prepare with starting switch OFF, then start the engine to trouble-
shooting.
• Connect T-adapter to B17 (male).
Defective parking brake
2 switch Resis-
B17 (male) Parking brake operations
(internal defective contact) tance
Released (CLOSE) Max. 1 z
Between (1) – (2)
Operated (OPEN) Min. 1 Mz
a Prepare with starting switch OFF, then start the engine to trouble-
shooting.
• Connect T-adapter to E02 (male).
Defective emergency oil
3 pressure switch Resis-
E02 (male) Steering pump
(internal defective contact) tance
Operated (OPEN) Min. 1 Mz
Between (A) – (B)
Stopped (CLOSE) Max. 1 z
ing switch ON. (parking brake ON)
1) Between EM (female) (3) – ground Voltage 20 – 30 V
2) Between EM (female) (5) – ground Voltage 20 – 30 V
Defective emergency a Prepare with starting switch OFF and troubleshooting with start-
steering timer
Possible causes
Resis-
and standard 3) Between EM (female) (1) – ground Max. 1 z
tance
value in normal
state • When the voltage of the above 1) is within the range and 2) is out
of range, the timer is defective.
• If the voltage of the above 1) is defective, troubleshooting cause 7.
ing switch ON. (parking brake ON)
1) Between relay terminal (74) – ground Voltage 20 – 30 V
Defective emergency a Prepare with starting switch OFF and troubleshooting with start-
5
steering relay ing switch still OFF.
Resis-
4) Between relay terminal (58) – ground Max. 1 z
tance
• When the voltage of the above 1), 3) and 4) are within the ranges,
and 2) is out of range, the relay is defective.
• If the voltage of the above 1) is defective, troubleshooting cause 7.
ing switch ON.
Between motor terminal M-2 and ground Voltage 20 – 30 V
Defective emergency ing switch still OFF.
6
steering motor
Resis-
Between motor terminal E-2 and ground Max. 1 z
tance
• If no problem is found in above diagnoses, the steering motor is
defective.
HM300-2R 37

Wiring harness between fuse BT-3 (16) – Resis-
Max. 1 z
B17 (female) (1) tance
Wiring harness between B17 (female) (2) – Resis-
Max. 1 z
CJR (female) (1) tance
Wiring harness between CJR (female) (2) – Resis-
Max. 1 z
E02 (female) (A) tance
Wiring harness between E02 (female) (C) – Resis-
Max. 1 z
Disconnection in wiring EM (female) (3) tance
harness Wiring harness between EM (female) (5) – Resis-
7 Max. 1 z
(Disconnection or defective relay terminal (61) tance
contact) Wiring harness between relay terminal (77) – Resis-
Max. 1 z
motor terminal M-2 tance
Wiring harness between EM (female) (1) – Resis-
Max. 1 z
ground tance
Wiring harness between motor terminal E-2 Resis-
– ground tance
and standard
value in normal Wiring harness between motor terminal (58) Resis-
Max. 1 z
state – ground tance
Wiring harness between relay terminal (74) – Resis-
Max. 1 z
battery (+) tance
Min. 1 Mz
between fuse BT-3 (16) – B17 (female) (1) tance
Min. 1 Mz
between B17 (female) (2) – CJR (female) (1) tance
Short circuit (ground fault) of Min. 1 Mz
between CJR (female) (2) – E02 (female) (A) tance
8 harness
Min. 1 Mz
between E02 (female) (C) – EM (female) (3) tance
Resis-
between EM (female) (5) – relay terminal Min. 1 Mz
tance
(61)
Resis-
between relay terminal (77) – motor terminal Min. 1 Mz
tance
M-2
38 HM300-2R
Trouble (2) When the steering pump stops operating, it does not operate with manual.
Related • When it operates with auto (troubleshooting the symptom of failure (1) first, if it does not operate with
information auto), check that the parking brake is released.

If fuse BT2 (24) is blown, it is highly possible that a defective harness
grounding has occurred in the circuit.
switch still OFF.
Defective manual switch Manual switch
2 Manual switch terminal Resistance
(internal defective contact) operation
Between ST1 – ST2 Switch (pressed) Max. 1 z
(Switch unit) Switch (not pressed) Min. 1 Mz
and standard switch still OFF.
value in normal
harness Wiring harness between BT2 (24) – manual Resis-
state 3 Max. 1 z
(Disconnection or defec- switch terminal ST1 tance
tive contact) Wiring harness between manual switch termi- Resis-
Max. 1 z
nal ST2 – J02 (female) (8) (to branched point) tance
switch still OFF.
Short circuit (ground fault)
of harness Min. 1 Mz
4 BT2 (24) – manual switch terminal ST1 tance
(Contact with ground
circuit) Between ground and wiring harness between
Resis-
manual switch terminal ST2 – J02 (female) (8) Min. 1 Mz
tance
(to branched point)
HM300-2R 39
40 HM300-2R
HM300-2R 41
E-14 Dump lever does not operate normally 1
Hoist lever does not operate normally.

Trouble (1) Dump lever is not fixed at RAISE position.
(2) Dump lever raise fixing device (detent) is not reset before body raising position.
• Failure code [DW72KZ] checks kick-out solenoid and [DK54KX] checks body positioner sensor.
Accordingly, if these codes are not displayed, it is judged that there is not breakage in solenoid coil
or disconnection/short circuit in sensor and wiring is normal.
Related • If detent is not reset, dump lever kick-out is judge to be normal (solenoid is turned ON and OFF nor-
information mally). It should be judged that signal from body positioner sensor is not sent to controller normally.
If body is not hoisted at all, see failure codes [DK52KX] and [DK53L8] (Troubleshooting for dump
lever potentiometer sensor).
• If kick-out solenoid is defective, replace dump lever.

1) Turn starting switch OFF and insert T-adapter in LK0.
2) Start engine.
1 Defective hoist lever kick-out 3) Set hoist lever in RAISE position and check.
LK0 Voltage
Between (1) – (2) 20 – 30 V
Possible causes
and standard 1) Turn starting switch OFF and insert T-adapter in ATC1 (or in
value in normal connector on route to body positioner sensor).
state Defective body positioner 2) Start engine.
2 3) Set hoist lever in RAISE position and check until body is raised.
sensor
Change between
Between ATC1 (2) – (21) Voltage
0–5V
If causes 1 – 2 are not detected, transmission controller may be
Defective transmission con-
3 defective. (Since trouble is in system, troubleshooting cannot be
troller
carried out.)
42 HM300-2R
HM300-2R 43
E-15 KOMTRAX system does not operate normally 1
Trouble • KOMTRAX system does not operate normally.

• If KOMTRAX system administrator makes request for checking system on machine side for trouble,
Related carry out following troubleshooting.
information • Even if KOMTRAX system has trouble, it does not particularly appear on machine.
a Though connector name is TC200, KOMTRAX is TC301.

a Turn starting switch OFF, then carry out troubleshooting.
LED (1) Normal state
LED-A1 ON
1 Defective power supply a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
TC200 Signal Voltage
Between (39), (40) – Constant
20 – 30 V
(37), (38) power supply
a Turn starting switch ON and carry out troubleshooting.
2 Defective GPS LED (2) Normal state
LED-A2 ON
a Start engine and carry out troubleshooting.
LED-C1 ON
a Prepare with starting switch OFF, then start engine and carry out
Defective starting switch
troubleshooting.
3 ACC signal and alternator R
signal TC200 Signal Voltage
Possible causes Between (36) –
and standard Starting switch ACC 20 – 30 V
(37), (38)
value in normal
state Between (28) –
Alternator R 20 – 30 V
(37), (38)
LED-C3 ON
Defective starting switch C a Prepare with starting switch OFF, then turn starting switch ON
4
signal and carry out troubleshooting.
TC200 Signal Voltage
Between (27) –
Starting switch C Max. 1 V
(37), (38)
LED-C4 ON
5 State of CAN connection
a Prepare with starting switch OFF and carry out trouble-shooting.
TC200 Signal Resistance
Between (7) – (8) CAN 40 – 80 z
Number of mails not trans-
6 LED (12) Normal state
mitted yet
7-segment 0–9
44 HM300-2R

a Turn starting switch ON and carry out troubleshooting (See *)
Possible causes
and standard
value in normal 7 State of positioning with GPS Dot ON
state * In an outdoor location within radio waves' penetration range, it
sometimes takes more than a minute from turning on of the starting
switch to completion of the positioning.
LED display unit TC200 connector
HM300-2R 45
46 HM300-2R
HM300-2R 47
E-16 Electric priming pump does not operate or does not stop
automatically 1
Trouble • Electric priming pump does not operate or does not stop automatically
Relative
information

1 Low battery charge level Battery charge level may be low. Check battery directly.
If fuse (EPE) is turned OFF, circuit probably has ground fault. (Check
2 Defective fuse (EPE)
cause No. 5)
Disconnection in wiring a Prepare with battery ground cable disconnected, then connect it
harness (Power supply and carry out troubleshooting (since power supply is unswitched).
system)
3
(Disconnection in wiring or
defective contact in con- Between EPTS (1) – (2) Voltage 20 – 30 V
nector)
a Prepare with battery ground cable disconnected, then connect bat-
tery and turn electric priming pump ON and carry out troubleshoot-
ing.
harness • Lamp blinks but stops in about 5 seconds.
(Drive power supply sys- Between EP (1) – (2) Voltage 20 – 30 V
4
tem) (Disconnection in wir-
a Prepare with battery ground cable disconnected, then carry out
ing or defective contact in
troubleshooting without reconnecting (since power supply is
connector)
unswitched).
Resis-
Between EPTS (female) (2) – ground Max. 1 z
tance
Possible causes a Prepare with battery ground cable disconnected, then carry out
and standard troubleshooting without reconnecting (since power supply is
value in normal unswitched).
Min. 1 Mz
Ground fault in wiring har- EPTS (female) (1) – EPE (female) (1) tance
5 ness (Contact with GND Between ground and wiring harness between Resis-
Min. 1 Mz
circuit) EPTS (female) (3) – EP (female) (1) tance
Min. 1 Mz
EPTS (female) (4) – EP (female) (2) tance
Resis-
Between EP (female) (1) – (2) 1–3z
tance
a Prepare with battery ground cable disconnected, then connect bat-
tery and turn electric priming pump ON and carry out troubleshoot-
ing.
Between EPTS (3) – (4) Voltage 20 – 30 V
Defective electric priming
6 pump switch (Malfunction • Lamp blinks but output voltage is improper.
or automatic stop failure) • Results of troubleshooting steps 1 – 4 are normal and lamp does
not blink.
a When electric priming pump does not stop automatically, electric
priming pump switch may be defective. (Turn toggle switch OFF to
stop pump and then replace switch.)
• Lamp blinks but stops in about 5 seconds.
Overload on electric prim-
7 a If pump is overloaded, power supply is turned OFF automatically to
ing pump
protect circuit (Priming switch is reset automatically).
48 HM300-2R

a Prepare with battery ground cable disconnected, then carry out
troubleshooting without reconnecting (since power supply is
Possible causes unswitched).
and standard Resis-
Between EP (male) (1) – (2) 1–3z
value in normal 8 Trouble in electric priming tance
state pump
Resis-
Between EP (male) (1) – pump body Min. 1 Mz
tance
Resis-
Between EP (male) (2) – pump body Min. 1 Mz
tance
HM300-2R 49
E-17 Air conditioner does not operate normally 1

Trouble (1) When air conditioner switch is operated, air conditioner does not operate at all.
Related
information

If fuse in unit is broken, circuit in unit probably has ground fault
1 Defective fuse in unit
(See cause 5).
Defective wiring harness Between (4) (brown) on wiring harness side Resis-
2 Max. 1 z
(ground cable) of connector [1] – ground tance
Between wiring harness side (black) of con- Resis-
Max. 1 z
nector [13] – ground tance
Defective relay (Short circuit ing without turning starting switch ON.
3
in relay coil) Resis-
Between blower relay (1) – (2) 320 z
tance
Defective wiring harness or Between (16) (WG) – (4) (brown) of connec-
4 Voltage 20 – 30 V
defective control amplifier tor [1]
Between (1) (red) – (4) (black) of connector
Voltage 20 – 30 V
[13]
Possible causes
and standard
value in normal
state Between connector (1) (white) – (9) (black) Resis-
Min. 1 Mz
of [12] (machine side) tance
Between connector (1) (white) of [12] Resis-
Min. 1 Mz
(machine side) – ground tance
Between (1) (WG) – (9) (black) of connector Resis-
Min. 1 Mz
[11] (air conditioner side) tance
Between (1) (WG) of connector [11] (air con- Resis-
Min. 1 Mz
ditioner side) – ground tance
Ground fault in wiring har-
Between (6) (red) – (3) (black) of connector Resis-
5 ness (Contact with GND cir- Min. 1 Mz
[12] (machine side) tance
cuit)
Between (6) (red) of connector [12] Resis-
Min. 1 Mz
(machine side) – ground tance
Between (6) (red) – (3) (black) of connector Resis-
Min. 1 Mz
[11] (air conditioner unit side) tance
Between (6) (red) of connector [11] (air con- Resis-
Min. 1 Mz
ditioner unit side) – ground tance
Between connector [9] (wiring harness side) Resis-
Min. 1 Mz
(red) – ground tance
Between connector [9] (wiring harness side) Resis-
Min. 1 Mz
(blue) – ground tance
50 HM300-2R

Resis-
Between (2) – (1) of connector AC2 [13] Min. 1 Mz
Short circuit with another tance
wire (Communication Resis-
Possible causes 6 Between (2) – (4) of connector AC2 [13] Min. 1 Mz
between control panel and tance
and standard control amplifier is defective)
value in normal Resis-
state tance
Resis-
tance
If causes 1 – 6 are not detected, control amplifier may be defective.
7 Defective control amplifier
(Since trouble is in system, troubleshooting cannot be carried out.)
If causes 1 – 6 are not detected, control panel may be defective.
8 Defective control panel
(Since trouble is in system, troubleshooting cannot be carried out.)
HM300-2R 51
Trouble (2) Air does not come out (Air flow is insufficient).
Related
information

Between wiring harness terminals on blower
Defective blower (fan) motor, motor side of connector [9] There is continuity
defective blower-OFF relay,
1
defective blower amplifier or a Prepare with starting switch OFF, then turn starting switch ON
defective wiring harness and carry out troubleshooting.
Between red and blue wiring harness termi-
nals on control amplifier side of connector Voltage 20 – 30 V
[9]
a When test result for cause 1 is abnormal (When continuity is
2 Defective blower (fan) motor broken or when motor does not rotate while voltage is normal),
blower (fan) motor is defective.
• Referring to test of relay, check turn-on
Click is heard.
sound of blower-OFF relay
a If test result for cause 3 is abnormal but relay is normal, go to
cause 7.
Defective blower-OFF relay
3 a Prepare with starting switch OFF, then turn starting switch ON
(Does not turn ON)
Turn main power of control panel ON. Air comes out.
a If air does not come out even when blower motor is turned ON
Possible causes forcibly without using relay, cause is part other than relay.
and standard Defective wiring harness
value in normal 4 a If ground fault occurs, 20 A fuse (BT3, No. 27) is broken.
(ground fault)
state
Between terminals (blue/black) and (black)
Approx.
of connector [10] (Input voltage of blower Voltage
10 V
amplifier)
Between terminal (blue) and ground of con-
Change
nector [9] (Output voltage of blower ampli- Voltage
within 10 V
fier)
5 Defective blower amplifier
Between (blue/black) and (black) of connec- Resis- 4.7 kz
tor [10] tance ±5%
Between (blue) (+) and (black) (–) of con- There is no continuity
nector [10] *Diode range
Between (blue) (–) and (black) (+) of con- There is continuity
nector [10] *Diode range
Between (30) on controller side of connector
6 Defective control amplifier Voltage Max. 1 V
[2] – ground
Between (14) on controller side of connector Approx.
Voltage
[2] – ground 10 V
52 HM300-2R
Trouble (3) Air is not cooled (Cooling performance is insufficient).

Related
information

Between (male) (2) (+) – (1) (–) of connector
1 Defective diode There is continuity
DIO
Between (male) (1) (+) – (2) (–) of connector
There is no continuity
DIO
Between [17] on air conditioner compressor
Resis- Approx.
side of connector COMP – ground (Air con-
Defective air conditioner tance 15 z
2 ditioner compressor coil resistance)
compressor
Between connector COMP (female) ([16])
Voltage 20 – 30 V
(1) – ground
Between (2) – (9) of [12] on machine wiring Resis-
Min. 1 Mz
harness side of connector AC1 tance
Possible causes
and standard Between (2) of [11] on air conditioner wiring
Resis-
value in normal harness of connector AC1 – (9) of [12] on Min. 1 Mz
Ground fault in wiring har- tance
state machine wiring harness side
3 ness
(Contact with GND circuit) Between (11) of [11] on air conditioner wir-
Resis-
ing harness of connector AC1 – (9) of [12] Min. 1 Mz
tance
on machine wiring harness side
Between (11) – (9) of [12] on machine wiring Resis-
Min. 1 Mz
harness side of connector AC1 tance
Between (2) of [15] on wiring harness side Resis-
Min. 1 Mz
of connector ACRD – ground tance
4 Defective pressure switch
Between (1) – (2) on pressure switch side of Resis-
Max. 1 z
connector ACRD tance
Disconnection in wiring har-
5 Between (14) or (15) of connector [1] –
ness Resis- Approx.
ground (Air conditioner compressor coil
tance 15 z
resistance)
6 Defective control amplifier
Between connector CM (female) (1) –
Voltage 20 – 30 V
ground
HM300-2R 53
54 HM300-2R
HM300-2R 55

© 2009 KOMATSU
All Rights Reserved
56 HM300-2R
SEN03430-00

HM300-2R

Troubleshooting of hydraulic and
mechanical system (H-mode)
Contents of troubleshooting table ................................................................................................................... 3
H-1 Machine does not start............................................................................................................................. 4
H-2 Machine does not travel smoothly (machine jerks) .................................................................................. 6
H-3 Lockup cannot be cancelled..................................................................................................................... 6
H-4 Excessive shock when starting or shifting................................................................................................ 7
H-5 Transmission does not shift up................................................................................................................. 8
H-6 Machine lacks power or speed when traveling ........................................................................................ 9
H-7 Time lag is excessive when starting or shifting gear ...............................................................................11
H-8 Torque converter oil temperature is high................................................................................................ 12
H-9 Torque converter oil pressure is low....................................................................................................... 13
H-10 Front brake is ineffective ...................................................................................................................... 14
H-11 Center brake is ineffective .................................................................................................................... 15
H-12 Steering wheel is heavy ....................................................................................................................... 16
H-13 Steering wheel does not work .............................................................................................................. 17
HM300-2R 1
H-14 Steering wheel vibrates ........................................................................................................................ 18

H-15 Dump body lifting speed is slow ........................................................................................................... 19
H-16 Dump body does not work.................................................................................................................... 20
H-17 Excessive hydraulic drift of dump body ................................................................................................ 21
2 HM300-2R
Contents of troubleshooting table 1

a Troubleshooting Table and Related Circuit Diagram collectively carry the following information. Carry out
troubleshooting work after fully grasping their contents.
Trouble Phenomenon occurring on machine

Related
Information on the failure occurred as well as the troubleshooting
information
2
Possible causes Cause for presumed failure <Contents>
and standard (The attached No. is for fil-
value in normal • The standard values in normalcy by which to judge “Good“
3 ing and reference purpose
state or “No Good“ about presumed causes.
only. It does not stand for
any priority.) • References for making judgement of “good“ or “No Good“
4
HM300-2R 3
H-1 Machine does not start 1
Trouble Machine does not start at any gear speed.

• Check that the transmission oil level is correct.
• If a failure code related to the input shaft speed sensor circuit or related to the machine is displayed,
Related
firstly troubleshooting the displayed code.
information
• Check that there is no defect in the drive shaft, etc.
• Check that the parking brake is completely released.

Defective power train pump The power train pump strainer is suspected to be clogged, check it
1
strainer directly.
Air sucked in at the suction Since the air can be suspected to be sucked in from the suction
2
side of the power train pump piping of the power train pump, check it directly.
a Prepare with the engine stopped and troubleshooting with engine
running at low idle and high idle.
Defective power train pump 2.55 ± 0.2 MPa
3 Low idle
main relief valve Relief oil {26.0 ± 2.0 kg/cm²}
pressure 2.55 ± 0.2 MPa
High idle
{26.0 ± 2.0 kg/cm²}
a Prepare with the engine stopped and troubleshooting with the
Defective torque converter engine running at high idle.
4 oil pressure Torque converter inlet pressure 0.91 ± 0.1 MPa {9.3 ± 1.0 kg/cm²}
(relief valve) Torque converter outlet
0.54 ± 0.1 MPa {5.5 ± 1.0 kg/cm²}
pressure
5 Defective torque converter engine running at high idle.
Possible causes Stall speed (power mode) 1,940 ± 100 rpm
and standard a Prepare with the engine stopped and troubleshooting with the
value in normal engine running at high idle.
state
Lo clutch ECMV output 2.45 ± 0.15 MPa
pressure {25.0 ± 1.5 kg/cm²}
Hi clutch ECMV output 2.45 ± 0.15 MPa
Defective gear speed clutch pressure {25.0 ± 1.5 kg/cm²}
6
ECMV 1st clutch ECMV output 2.45 ± 0.15 MPa
2.45 ± 0.15 MPa
R clutch ECMV output pressure
{25.0 ± 1.5 kg/cm²}
* A gear speed clutch operates using a combined operations of
two clutches; check the combination referring to Table 1.
• If the oil pressure is low in the item 6, leaks from the clutch seal
ring can be suspected.
7 Defective gear speed clutch
• If the oil pressures are within the ranges in the item 6, a slip of
the clutch can be suspected.
• If a defect is found in the item 3, disconnect the power train pump
8 Defective power train pump outlet hose, crank the engine, and check if the oil comes out.
• Judge by checking for presence of foreign materials.
Internally defective Since the transmission can be suspected to be internally defective,
9
transmission inspect the transmission directly.
4 HM300-2R
Table 1
Operated clutches
Hi Lo 1st 2nd 3rd R
R2 q q
R1 q q
N
Gear speed
F1 q q
F2 q q
F3 q q
F4 q q
F5 q q
F6 q q
HM300-2R 5
H-2 Machine does not travel smoothly (machine jerks) 1
Trouble Machine does not travel smoothly (hunting).

Related • Check that the transmission oil level is correct.
information • If a failure code related to the machine is displayed, firstly troubleshooting the displayed code.

Defective power train pump Since the power train pump strainer can be suspected to be
1
strainer clogged, check it directly.
Air sucked in at the suction Since the air is potentially sucked in from the suction piping of the
2
side of the power train pump power train pump; visually check it.
Possible causes running at low idle and high idle.
and standard Defective power train pump 2.55 ± 0.2 MPa
value in normal 3 Low idle
state
High idle
{26.0 ± 2.0 kg/cm²}
• If the oil pressure is low in the item 3, wear of the gear speed
clutch piston seal ring or wear of the ring groove can be sus-
4 Defective gear speed clutch pected.
the clutch can be suspected.
H-3 Lockup cannot be cancelled 1
Trouble Torque converter lockup cannot be cancelled.


Possible causes engine running at high idle.
Defective lockup solenoid
and standard 1
valve Lockup solenoid valve output 2.16 ± 0.15 MPa
value in normal
state pressure {22.0 ± 1.5 kg/cm²}
If the oil pressure is within the range in the item 1, a seizure of the
2 Defective lockup clutch
lockup clutch can be suspected.
6 HM300-2R
H-4 Excessive shock when starting or shifting 1
Trouble Shock when starting or shifting is excessive.

Related
• If a failure code related to the machine is displayed, firstly troubleshooting the displayed code.
information

* There is some shock, but it is difficult to judge if the shock is
excessive or not, so judge that it is excessive in the following
Possible causes cases.
and standard • When it is apparent that the shock suddenly became severer
value in normal Defective gear speed clutch than before.
1
state ECMV
• The shock is severer compared with other machines of the same
class.
Since the operation of the gear speed clutch ECMV can be
suspected to be defective, check it directly.
HM300-2R 7
H-5 Transmission does not shift up 1
Trouble Transmission does not shift up.

Related
information

1 Low idle
High idle
{26.0 ± 2.0 kg/cm²}
Defective lockup solenoid engine running at high idle.
2
If the shit up operations take place when traveling down a slope,
3 Defective lockup clutch
a slip of the lockup clutch can be suspected.
engine running at high idle.
Possible causes
and standard Hi clutch ECMV output 2.45 ± 0.15 MPa
value in normal pressure {25.0 ± 1.5 kg/cm²}
state Lo clutch ECMV output 2.45 ± 0.15 MPa
1st clutch ECMV output 2.45 ± 0.15 MPa
Defective gear speed clutch pressure {25.0 ± 1.5 kg/cm²}
4
ECMV 2nd clutch ECMV output 2.35 ± 0.15 MPa
3rd clutch ECMV output 2.45 ± 0.15 MPa
2.45 ± 0.15 MPa
{25.0 ± 1.5 kg/cm²}
• If the oil pressure is low in the item 4, wear of the gear speed clutch
Defective gear speed clutch piston seal ring or wear of the ring groove can be suspected.
5
piston • If the oil pressure is within the range in the item 4, a slip of the
gear speed clutch piston can be suspected.
Table 1
Operated clutches
Hi Lo 1st 2nd 3rd R
R2 q q
R1 q q
N
Gear speed
F1 q q
F2 q q
F3 q q
F4 q q
F5 q q
F6 q q
8 HM300-2R
H-6 Machine lacks power or speed when traveling 1
Trouble (1) When abnormality is present at all gear speeds (when traveling in lockup range).
Related • If a failure code related to the machine is displayed, firstly troubleshooting the displayed code.
information • Check that the parking brake is completely released and also check for dragging of the retarder brake.
• Check that the tire inflation pressure is proper.

1
strainer directly.
2
Defective power train pump running at low idle and high idle.
3
main relief valve Relief oil Low idle 2.55 ± 0.2 MPa {26.0 ± 2.0 kg/cm²}
pressure High idle 2.55 ± 0.2 MPa {26.0 ± 2.0 kg/cm²}
Defective lockup solenoid
and standard 4
value in normal
• If the oil pressure is low in the item 4, wear of the lockup clutch
piston seal ring or wear of the ring groove can be suspected.
5 Slip of lockup clutch
the lockup clutch piston can be suspected.
If a defect is found in the item 3, the power train pump can be
6 Defective power train pump suspected to be defective.
Check for aluminum worn powder etc. residing on the line filter.
If no problem is found in item 1 through 6, measure the torque
converter stall speed (in the power mode: 1,940 ± 100 rpm). If it is
7 Decrease of engine output
below the standard value, the deterioration of the engine unit per-
formance can be suspected.
Trouble (2) When machine lacks power or speed while traveling in torque converter range.
information • Check for oil leaking from the piping to the outside.
• Check that the parking brake is completely released and also check for dragging of the retarder brake.

Defective power train pump running at low idle and high idle.
1
main relief valve Relief oil Low idle 2.55 ± 0.2 MPa {26.0 ± 2.0 kg/cm²}
pressure High idle 2.55 ± 0.2 MPa {26.0 ± 2.0 kg/cm²}
Possible causes
and standard a Prepare with the engine stopped and troubleshooting with the
value in normal Defective torque converter engine running at high idle.
state 2
oil pressure Torque converter inlet pressure 0.91 ± 0.1 MPa {9.3 ± 1.0 kg/cm²}
Torque converter outlet pressure 0.54 ± 0.1 MPa {5.5 ± 1.0 kg/cm²}
3 Defective torque converter engine running at high idle.
Stall speed (power mode) 1,940 ± 100 rpm
HM300-2R 9
Trouble (3) Machine lacks speed or power when traveling in certain gear speeds.

Defective gear speed clutch 2nd clutch ECMV output 2.35 ± 0.15 MPa
1
Possible causes ECMV pressure {24.0 ± 1.5 kg/cm²}
and standard
value in normal 3rd clutch ECMV output 2.45 ± 0.15 MPa
2.45 ± 0.15 MPa
{25.0 ± 1.5 kg/cm²}
• It can be also diagnosed by replacing the ECMV.
• If the oil pressure is low in the item 1, wear of the gear speed
clutch piston seal ring or wear of the ring groove can be sus-
2 Defective gear speed clutch pected.
• If the oil pressure is within the range in the item 1, a slip of the
gear speed clutch can be suspected.
Table 1
Operated clutches
Hi Lo 1st 2nd 3rd R
R2 q q
R1 q q
N
Gear speed
F1 q q
F2 q q
F3 q q
F4 q q
F5 q q
F6 q q
10 HM300-2R
H-7 Time lag is excessive when starting or shifting gear 1

Trouble Time lag is excessive when starting or shifting gear.
Related
• Check for oil leaking from the piping to the outside.

Defective power train pump Since the power train pump strainer can be suspected to be
1
strainer clogged, check it directly.
Air sucked in at the suction Since the air is potentially sucked in from the suction piping of the
2
side of the power train pump power train pump; visually check it.
3 Low idle
High idle
{26.0 ± 2.0 kg/cm²}
Possible causes pressure {25.0 ± 1.5 kg/cm²}
and standard
value in normal
state Defective gear speed clutch
4 2nd clutch ECMV output 2.35 ± 0.15 MPa
ECMV pressure {24.0 ± 1.5 kg/cm²}
3rd clutch ECMV output 2.45 ± 0.15 MPa
2.45 ± 0.15 MPa
{25.0 ± 1.5 kg/cm²}
• It can be also diagnosed by replacing the ECMV.
• If the oil pressure is low in the item 4, wear of the gear speed clutch
piston seal ring or wear of the ring groove can be suspected.
5 Defective gear speed clutch
• If the oil pressure is within the range in the item 4, a slip of the
gear speed clutch can be suspected.
• If a defect is found in the item 3, the power train pump can be
Table 1
Operated clutches
Hi Lo 1st 2nd 3rd R
R2 q q
R1 q q
N
Gear speed
F1 q q
F2 q q
F3 q q
F4 q q
F5 q q
F6 q q
HM300-2R 11
H-8 Torque converter oil temperature is high 1
Trouble Torque converter oil temperature is high.

Related
information • If the oil temperature goes up when the torque converter is stalled and goes down when the trans-
mission is returned to the neutral position, the machine is normal and overload operation is a cause
of the problem.

1
strainer directly.
2
Defective power train pump
3 The filter can be suspected to be clogged; visually check it.
line filter
4 Low idle
Possible causes
and standard pressure 2.55 ± 0.2 MPa
High idle
value in normal {26.0 ± 2.0 kg/cm²}
state
• If a defect is found in the item 4, the power train pump can be
6
relief valve
Torque converter inlet pressure 0.91 ± 0.1 MPa {9.3 ± 1.0 kg/cm²}
7 Defective torque converter Torque converter inlet pressure 0.91 ± 0.1 MPa {9.3 ± 1.0 kg/cm²}
Torque converter outlet
0.54 ± 0.1 MPa {5.5 ± 1.0 kg/cm²}
pressure
12 HM300-2R
H-9 Torque converter oil pressure is low 1
Trouble Torque converter oil pressure is low.

Related
information
• Check for oil leaking from the piping to the outside.

1
strainer directly.
2
3 Low idle
Possible causes High idle
and standard {26.0 ± 2.0 kg/cm²}
value in normal • If a defect is found in the item 3, the power train pump can be
state 4 Defective power train pump suspected to be defective.
5
relief valve
Torque converter inlet pressure 0.91 ± 0.1 MPa {9.3 ± 1.0 kg/cm²}
6 Defective torque converter Torque converter inlet pressure 0.91 ± 0.1 MPa {9.3 ± 1.0 kg/cm²}
Torque converter outlet
0.54 ± 0.1 MPa {5.5 ± 1.0 kg/cm²}
pressure
HM300-2R 13
H-10 Front brake is ineffective 1
Trouble Front brake is ineffective.

Related
information

Air sucked in at the suction
Since the air can be suspected to be sucked in from the suction
1 side of the brake control
piping of the brake control pump, check it directly.
pump
a Prepare with the engine stopped and measure with the engine
running at high idle.
Defective accumulator 11.77 (+0.29/0) MPa
2 Charge valve cut-in pressure
charge valve {120 (+3.0/0) kg/cm²}
20.59 (+0.98/–0.49) MPa
Charge valve cut-out pressure
{210 (+10/–5) kg/cm²}
• If the brake becomes ineffective as soon as the engine is
Defective accumulator for stopped, the gas charged in the accumulator is insufficient.
3
front brake * [Reference] Charged gas pressure: 4.4 ± 0.15 MPa {45 ± 1.5 kg/
Possible causes cm²}
and standard
value in normal a Prepare with the engine stopped and measure with the engine
state running at high idle.
4 Defective front brake valve
Brake actuat- Brake pedal
4.9 ± 0.49 MPa {50 ± 5.0 kg/cm²}
ing pressure operated
Defective front brake running at high idle.
5 retarder pressure reducing
valve Brake actuat- Retarder lever
4.9 ± 0.49 MPa {50 ± 5.0 kg/cm²}
When the initial response time of brake system is excessively long
Defective front brake slack
6 or excess pedal effort is required to obtain the specific braking
adjuster
force, the slack adjuster can be suspected to be defective.
• If the oil pressure is low in the item 4 or 5, a seal ring or ring
groove can be suspected to be defective.
7 Defective front wheel brake
• If the oil pressures are within the range in the item 4 and 5, a slip
of the brake disc is suspected.
14 HM300-2R
H-11 Center brake is ineffective 1
Trouble Center brake is ineffective.

Related
information

1 side of the brake control
piping of the brake control pump, check it directly.
pump
running at high idle.
Defective accumulator 11.77 (+0.29/0) MPa
2 Charge valve cut-in pressure
charge valve {120 (+3.0/0) kg/cm²}
20.59 (+0.98/–0.49) MPa
Charge valve cut-out pressure
{210 (+10/–5) kg/cm²}
• If the brake becomes ineffective as soon as the engine is
Defective accumulator for stopped, the gas charged in the accumulator is insufficient.
3
center brake * [Reference] Charged gas pressure: 4.4 ± 0.15 MPa {45 ± 1.5 kg/
Possible causes cm²}
and standard
value in normal a Prepare with the engine stopped and measure with the engine
state running at high idle.
4 Defective center brake valve
Brake actuat- Brake pedal
4.9 ± 0.49 MPa {50 ± 5 .0 kg/cm²}
Defective center brake running at high idle.
5 retarder pressure reducing
valve Brake actuat- Retarder lever
4.9 ± 0.49 MPa {50 ± 5.0 kg/cm²}
When the initial response time of brake system is excessively long
Defective center brake slack
6 or excess pedal effort is required to obtain the specific braking
adjuster
force, the slack adjuster can be suspected to be defective.
• If the oil pressure is low in the item 4 or 5, a seal ring or ring
groove can be suspected to be defective.
7 Defective center wheel brake
• If the oil pressures are within the range in the item 4 and 5, a slip
of the brake disc is suspected.
HM300-2R 15
H-12 Steering wheel is heavy 1
Trouble Steering wheel is heavy.

• Check that the oil level in the hydraulic tank is correct.
• Check that the steering wheel play is correct (less than 150 mm).
Related
information • Check tha the hinge pin, etc. are greased sufficiently.
• Adjust the tire inflation pressure to the proper value before troubleshooting.
[Standard tire] 750-65 R25 (30-65 R25) × 2
(Front: 0.343 MPa {3.50 kg/cm²}) (Rear: 0.402 MPa {4.1 kg/cm²})

1 side of the steering and work
side of the steering and work equipment pump, check it directly.
equipment pump
Defective steering and work Since the steering and work equipment pump strainer is potentially
2
equipment pump strainer clogged, visually check it.
Defective relief valve of flow engine running at high idle.
3
amplifier valve Relief oil pressure (cylinder 20.59 (+0.98/0) MPa
stroke end) {210 (+10/0) kg/cm²}
4 Defective steering valve
Possible causes Relief oil pressure (cylinder 20.59 (+0.98/0) MPa
and standard stroke end) {210 (+10/0) kg/cm²}
value in normal
If the oil pressure is within the range, the operation of the flow
state Defective operation of flow
5 amplifier valve spool can be suspected to be defective: check it
amplifier valve spool
directly.
Relief oil pressure (cylinder 20.59 (+0.98/0) MPa
6 Defective steering cylinder
When the oil pressure is low, disconnect the hydraulic hose in the
steering cylinder head side and relieve the pressure at the stroke
end. If the oil comes out from the cylinder side, the cylinder piston
ring is defective.
If the oil pressure is low in the item 3 or 4, the steering and work
Defective steering and work
7 equipment pump can be suspected to be defective.
equipment pump
16 HM300-2R
H-13 Steering wheel does not work 1
Trouble Steering wheel does not work.

information • Check that the steering wheel play is correct (less than 150 mm).
• Check that the hinge pin, etc. are greased sufficiently.

If the dump body also does not work, the PTO can be suspected to
1 Defective PTO
be defective.
2 side of the steering and work
equipment pump
Defective steering and work Since the steering and work equipment pump strainer is potentially
3
equipment pump strainer clogged, visually check it.
4
amplifier valve Relief oil pressure (cylinder 20.59 (+0.98/0) MPa
and standard 5 Defective steering valve
value in normal stroke end) {210 (+10/0) kg/cm²}
state
If the oil pressure is within the range, the operation of the flow
Defective operation of flow
6 amplifier valve spool can be suspected to be defective: check it
amplifier valve spool
directly.
7 Defective steering cylinder
ring is defective.
If the oil pressure is low in the item 4 or 5, the steering and work
Defective steering and work
8 equipment pump can be suspected to be defective.
equipment pump
HM300-2R 17
H-14 Steering wheel vibrates 1
Trouble Steering wheel vibrates.

Related • Check that the oil level in the hydraulic tank is correct.

1 Defective oil Check for deterioration of oil.
and standard Relief oil pressure (cylinder 20.59 (+0.98/0) MPa
value in normal stroke end) {210 (+10/0) kg/cm²}
state 2 Defective steering cylinder
ring is defective.
18 HM300-2R
H-15 Dump body lifting speed is slow 1
Trouble When lifting dump body, the speed is slow and the power is insufficient.
Related
information
• Check that the dump lever moves smoothly.

1 side of the work equipment
and steering pump
Defective work equipment The work equipment and steering pump strainer is potentially
2
and steering pump strainer clogged, visually check it.
3
amplifier valve Relief oil pressure (steering 20.59 (+0.98/0) MPa
cylinder stroke end) {210 (+10/0) kg/cm²}
Defective dump EPC valve engine running at high idle.
4 relief valve (dump pilot pres- 3.4 ± 0.49 MPa {35 ± 5 kg/cm²}
sure) Operate dump lever to
“raise“ or “lower“ position. (Reference: low idle)
2.6 ± 0.49 MPa {27 ± 5 kg/cm²}
Possible causes If the oil pressure is low in the item 4, the operation of the dump
Defective operation of dump
and standard 5 EPC valve can be suspected to be defective; visually check the
EPC valve
value in normal valve.
state Defective pilot pump for If the oil pressure is low in the item 4, the pilot pump for the dump
6
dump EPC valve EPC valve circuit can be suspected to be defective; check it directly.
Defective hoist valve relief engine running at high idle.
7
valve Relief oil pressure (dump 20.59 (+0.98/0) MPa
cylinder raise stroke end) {210 (+10/0) kg/cm²}
If the oil pressure does not reach the standard value in the item 7,
Defective operation of the
8 the operation of the hoist valve main spool can be suspected to be
hoist valve main spool
defective. (Visually check the spool.)
9 Defective dump cylinder
dump cylinder head side and relieve the pressure at the raise stroke
ring is defective.
HM300-2R 19
H-16 Dump body does not work 1
Trouble Dump body does not work.

Related
information
• Check that the dump lever moves smoothly.

If the steering also does not work, the PTO can be suspected to be
1 Defective PTO
defective.
2 side of the work equipment
and steering pump
Defective work equipment The work equipment and steering pump strainer is potentially
3
and steering pump strainer clogged, visually check it.
4
amplifier valve Relief oil pressure (steering 20.59 (+0.98/0) MPa
cylinder stroke end) {210 (+10/0) kg/cm²}
Defective dump EPC valve engine running at high idle.
5 relief valve (dump pilot pres- 3.4 ± 0.49 MPa {35 ± 5 kg/cm²}
sure) Operate dump lever to
“raise“ or “lower“ position. (Reference: low idle)
2.6 ± 0.49 MPa {27 ± 5 kg/cm²}
Possible causes
and standard If the oil pressure is low in the item 5, the operation of the dump
Defective operation of dump
value in normal 6 EPC valve can be suspected to be defective; visually check the
EPC valve
state valve.
Defective pilot pump for If the oil pressure is low in the item 5, the pilot pump for the dump
7
dump EPC valve EPC valve circuit can be suspected to be defective; check it directly.
Defective hoist valve relief engine running at high idle.
8
valve Relief oil pressure (dump 20.59 (+0.98/0) MPa
cylinder raise stroke end) {210 (+10/0) kg/cm²}
If the oil pressure does not reach the standard value in the item 8,
Defective operation of the
9 the operation of the hoist valve main spool can be suspected to be
hoist valve main spool
defective. (Visually check the spool.)
dump cylinder head side.
If the oil comes out from the cylinder side at the raise stroke end,
the cylinder piston ring is defective.
20 HM300-2R
H-17 Excessive hydraulic drift of dump body 1
Trouble Hydraulic drift of dump body is excessive.

Related
information

a Raise the dump body and troubleshooting with the engine
stopped.
Defective oil tightness of Raise the dump body and disconnect the hydraulic hose in the
Possible causes 1
hoist valve main spool dump cylinder head side.
and standard
value in normal If the oil flows out from the cylinder side, the oil tightness of the
state spool is defective.
Raise the dump body and disconnect the hydraulic hose in the
dump cylinder head side.
If the oil does not flow out from the cylinder side, the cylinder piston
ring is defective.
HM300-2R 21

© 2007 KOMATSU
All Rights Reserved
22 HM300-2R
SEN03431-01

HM300-2R
1SHOP MANUAL

Troubleshooting of engine (S-mode)
How to use a troubleshooting chart ................................................................................................................ 3
S-1 Engine is hard to start .............................................................................................................................. 6
S-2 Engine does not start ............................................................................................................................... 7
S-3 Engine does not pick up smoothly.......................................................................................................... 10
S-4 Engine stops during operations ...............................................................................................................11
S-5 Engine does not rotate smoothly ............................................................................................................ 12
S-6 Engine lacks output (or lacks power) ..................................................................................................... 13
S-7 Exhaust gas color is black (incomplete combustion).............................................................................. 14
S-8 Oil consumption is excessive (or exhaust gas color is blue) .................................................................. 15
S-9 Oil gets contaminated prematurely......................................................................................................... 16
S-10 Fuel consumption is excessive............................................................................................................. 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 18
S-12 Oil pressure drops ................................................................................................................................ 19
S-13 Oil level rises (coolant or fuel mixes).................................................................................................... 20
S-14 Coolant temperature rises too high (overheat)..................................................................................... 21
S-15 Abnormal noise comes out................................................................................................................... 22
HM300-2R 1
S-16 Vibration is excessive ........................................................................................................................... 23

S-17 Air cannot be bled from fuel circuit ....................................................................................................... 24
2 HM300-2R
How to use a troubleshooting chart 1

The troubleshooting chart consists of "questions",
"check items", "causes", and "troubleshooting"
blocks.
The "questions" and "check items" narrow down the
causes to highly probable "causes" by simple
inspection or from symptoms without using a diag-
nostic tool.
Then, the final verifications of "causes" are carried
out by checking the narrowed down "causes" in the
order of their probability with diagnostic tools or by
direct inspection following the "troubleshooting"
procedure.
[Questions]
Information to be obtained by questioning the
user or operator, and which corresponds to the
sections A and B in the right chart.
Section A includes basic information, and sec-
tion B contains items which can be obtained
depending on the level of the user or operator.
[Check items]
Items checked by the serviceman in order to
narrow down the causes, section C of the right
chart is corresponding to them.
[Causes]
Items to be narrowed down by the questions
and check items.
The serviceman narrows down the causes to
highly probable causes according to the infor-
mation from A, B and C.
[Troubleshooting]
Items to be verified at the end in order to check if the narrowed down causes are the true factors caus-
ing the failure. The verification is carried out by applying diagnostic tools or implementing direct inspec-
tion in the order of probability.
This troubleshooting chart marks the content of the questions and check items with E, Q or w according to
their closer relationship with the causes.
E: A cause that can be referred to in relation to the question or check item.
Q : A cause that is related the question or check item.
w : A cause particularly probable among those marked with Q above.
a Count the priority level of each marking as w > Q when determining the cause.
Don't count E when determining the cause. The item with this marking may be counted, however, if no
difference is present than this and the cause cannot be determined.
HM300-2R 3
<Example of troubleshooting> Exhaust gas color is black (incomplete combustion)

Let us assume that a trouble of “Exhaust gas color is black” occurred and we checked the [Questions] and
[Check items] and found the following 3 items to be the causal symptoms; [Exhaust gas color slowly became
black], [Power slowly became weaker], and [Dust indicator is lighting red].
4 HM300-2R
There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 6 items in
the [Causes] sections.
The method of pinpointing the [cause] from the causal relationship and approaching the [troubleshooting] is
explained according to Step 1 — Step 3 shown below.
HM300-2R 5
S-1 Engine is hard to start 1

General causes why engine is hard to start: Causes
q Defective electrical system
Leaking or clogged fuel piping, entry of air

Clogged air breather hole in fuel tank cap
Defective contact of valve and valve seat
Insufficient supply of fuel
Defective alternator (generator section)

q
Defective alternator (regulator section)

Stuck or seized supply pump plunger
q Insufficient intake of air
Defective intake air heater system

Improper selection of fuel
Defective or deteriorated battery

q
Clogged feed pump gauze filter

q Coolant in exhaust pipe
Clogged air cleaner element
Worn piston ring or cylinder

a The common rail fuel injection system (CRI) recognizes
Clogged fuel filter element

the fuel injection timing electrically. Accordingly, even if
the starting operation is carried out, the engine may not
Defective injector
start until the crankshaft revolves 2 turns at maximum.
This symptom does not indicate a trouble, however.
Confirm recent repair history

Degree of use of machine Operated for long period E E E E
Became worse gradually Q w w Q Q
Startability
Engine starts easily when warm w w
Questions
Non-specified fuel is being used Q Q Q Q

Replacement of filters has not been carried out according to Operation and Mainte-
nance Manual w w w Q Q
More engine oil is required for refill than before w
When engine is preheated or when temperature is low, preheating monitor does not
indicate properly. (if monitor is installed) w
During operation, charge level monitor indicates abnormal charge
(if monitor is installed) w w
Dust indicator is red (if indicator is installed) w
Air breather hole in fuel tank cap is clogged w
Fuel is leaking from fuel piping w Q
When priming pump is operated, it makes no reaction or it is heavy w Q Q
Starting motor cranks engine slowly w
If air bleeding plug of fuel filter is removed, fuel does not
flow out w w
While engine is cranked
with starting motor, When spill hose from injector is disconnected,
w
Check items
little fuel spills

When exhaust manifold is touched immediately after starting engine, temperature
of some cylinders is low w
Engine does not pick up smoothly and combustion is irregular Q Q w
Engine hunts (rotation is irregular) Q w Q Q
Blow-by gas is excessive w
Inspect air cleaner directly q

When compression pressure is measured, it is found to be low q q
When air is bled from fuel system, air comes out q
Inspect fuel filter and strainer directly q
q
Troubleshooting
Inspect feed pump gauze filter directly

Carry out troubleshooting by failure code "Loss of pressure feed from supply pump
(*1)" q
When a specific cylinder is cut out for reduced cylinder mode operation, engine
speed does not change q
Intake air heater mount does not become warm during operation of preheating q
Is voltage 20 – 30 V between alternator terminal B and terminal E with Yes q
engine at low idle ? No q
When electrolyte specific gravity and voltage of battery are measured, they are too
low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
*1: Failure code [CA559] and failure code [CA2249]
6 HM300-2R
S-2 Engine does not start 1

a) Engine does not crank Causes
General causes why engine does not crank:
Defective starting motor (safety relay section)

q Internal parts of engine seized
Defective connection of battery terminal

o See "S-4 Engine stops during operations"
Defective starting motor (motor section)

q Water hammer caused by coolant which entered cylinder
Defective PTO or hydraulic pump

Defective electrical system

q
Defective starting circuit wiring

q Defective PTO or hydraulic pump
Broken flywheel ring gear
Defective starting switch

Defective battery relay
Questions
Degree of use of machine Operated for long period E E

Condition of horn with Horn does not sound Q Q w
starting switch ON Horn volume is too low w
Battery electrolyte level is too low w
Battery terminal is loose w
When starting switch is turned ON, there is no operating noise from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q w
Check items
Speed of rotation is too low w

When starting switch is
turned to START, starting Makes grating noise w w
pinion moves out, how- Soon disengages again w
ever
Makes rattling noise and does not turn Q Q w
Inspect flywheel ring gear directly q
Carry out troubleshooting in E mode.

Carry out troubleshooting in H mode
When electrolyte specific gravity and voltage of battery are measured, they are too low q
The voltage (20 – 30 V) is not supplied between battery relay terminal q
B and terminal E
Troubleshooting
When terminal B and terminal C of starting switch are connected,

q
engine starts
Turn starting switch OFF
to connect cord, then turn
ON to diagnose When terminal B and terminal C at safety relay outlet are connected, q
engine starts
Even if terminal B and terminal C at safety relay outlet are connected, q

engine does not start
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
—
—
HM300-2R 7
b) Engine cranks but no exhaust smoke comes out Causes

General causes why engine cranks but no exhaust smoke
Defective operation of overflow valve (does not close)

comes out:
q Fuel is not being supplied
q Supply of fuel is extremely small

q Improper selection of fuel (particularly in winter)
Wrong connection of supply pump PCV

Seized or abnormally worn feed pump
Defective operation of flow damper

Broken supply pump shaft or key
Defective supply pump PCV

Clogged fuel filter element
Insufficient fuel in tank
Defective fuel injector

Use of improper fuel
Questions
Degree of use of machine Operated for long period E E E

Exhaust smoke suddenly stopped coming out (when restarting) w Q w w w E E
Replacement of filters has not been carried out according to Operation and
w w E Q
Maintenance Manual
When fuel tank is inspected, it is found to be empty w
Air breather hole in fuel tank cap is clogged Q w
Rust or water are observed when fuel tank is drained Q Q Q Q Q
When fuel filter is removed, there is no fuel in filter w w
Fuel is leaking from fuel piping w
Check items

If air bleeding plug of fuel filter is removed, fuel does
Q Q w Q
While engine is cranked not flow out
with starting motor, When spill hose from injector is disconnected, little
Q w w w w Q
fuel spills

Inspect fuel filter directly q
Inspect feed pump gauze filter directly q
Troubleshooting
Check feed pump directly q

Carry out troubleshooting by failure code "Loss of pressure feed from supply
q q q q
pump (*1)"
Carry out troubleshooting by failure code "Abnormal PCV1 (*2) or Abnormal
q
PCV2 (*3)"
Inspect overflow valve directly q
Engine can be started in reduced cylinder mode q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Clean
Refill

8 HM300-2R
c) Exhaust smoke comes out but engine does not start Causes
(fuel is being injected)
Defective coolant temperature sensor or wiring harness

General causes why exhaust smoke comes out but engine
does not start:
q Lack of rotating force due to defective electrical system
Worn valve system (valve, rocker lever, etc.)
Leaking or clogged fuel system, entry of air

q Insufficient supply of fuel


q Improper selection of fuel
Defective intake air heater system

Clogged injector, defective spray
Worn piston ring or cylinder liner

Clogged fuel filter or strainer
Use of improper fuel

Degree of use of
machine
Operated for long period E E E E
Suddenly failed to start w w Q
Questions
Non-specified fuel is being used Q Q

nance Manual w w w
When engine is preheated or when temperature is low, preheating monitor does not
indicate properly (if monitor is installed) w
Air breather hole in fuel tank cap is clogged Q
Rust or water are observed when fuel tank is drained w w
When fuel filter is removed, there is no fuel in filter w
Starting motor cranks engine slowly w
When engine is cranked, abnormal noise comes out around cylinder head w
Check items
While engine is If air bleeding plug of fuel filter is removed, fuel does not flow
Q w w
cranked with starting out
motor, When spill hose from injector is disconnected, little fuel spills w
When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low w

Inspect valve system directly q
When compression pressure is measured, it is found to be low q
Troubleshooting

Carry out troubleshooting by failure code "Loss of pressure feed from supply pump
(*1)" q
When injector unit is tested, spray condition is bad q
When electrolyte specific gravity and voltage of battery are measured, they are too
low q
Coolant temperature gauge does not indicate properly (if coolant temperature
gauge is installed) q
Intake air heater mount does not become warm during operation of preheating q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
HM300-2R 9
S-3 Engine does not pick up smoothly 1

General causes why engine does not pick up smoothly: Causes
Seized turbocharger or interference of turbocharger

q Defective condition of fuel injection
Improper selection of fuel

q

q Controller is controlling in derate mode

(limiting injection rate (output) because of an error in elec-
Defective operation of flow damper

(Excessive leakage from injector)
Clogged injector, defective spray
trical system)

Improper valve clearance

Degree of use of machine Operated for long period E E E E E
Questions
Engine pick-up suddenly becomes worse w Q Q Q

Non-specified fuel is being used w w w w
nance Manual w w w
Rust and water are observed when fuel tank is drained w w
some cylinders is low Q w
Blue under light load w
Color of exhaust gas is
Black w Q w w
Check items
When engine is running, interference noise comes out around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is
applied Q w w
Engine hunts (rotation is irregular) Q Q w Q

Inspect valve clearance directly q
Troubleshooting
When turbocharger is rotated by hand, it is found to be heavy q

Carry out troubleshooting by failure code "Loss of pressure feed from supply pump q
(*1)"
When a specific cylinder is cut out for reduced cylinder mode operation, engine speed q q
does not change
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
10 HM300-2R
S-4 Engine stops during operations 1

General causes why engine stops during operations: Causes
q Seized parts inside engine
Broken valve system (valve, rocker lever, etc.)

Broken or seized piston or connecting rod

q Engine is overheating

q
Broken or seized crankshaft bearing

Broken supply pump shaft or key
Leaking or clogged fuel piping
Broken or seized feed pump

Broken or seized gear train
Abnormal noise was heard and engine stopped sud- w w w w Q w Q w
denly
Condition when engine w Q
Questions
Engine overheated and stopped

stopped
Engine stopped slowly w Q Q
There was hunting and engine stopped w Q Q Q Q
Non-specified fuel is being used Q Q Q Q
Replacement of filters has not been carried out according to Operation and Mainte- w w
nance Manual
Fuel level monitor indicates low level (if monitor is installed) w
Rust or water are observed when fuel tank is drained w w
Metal particles are observed when oil in oil pan is drained w w Q Q
Check items
Does not turn at all w w

When engine is cranked Turns in opposite direction w
by hand Moves by amount of gear backlash w
Supply pump shaft does not turn w
Engine turns, but stops when load is applied to machine w

Inspect piston and connecting rod directly q
Inspect crankshaft bearing directly q

Troubleshooting
Inspect gear train directly q
Check feed pump directly q

Carry out troubleshooting by failure code "Loss of pressure feed from supply pump q q
(*1)"
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
Clean
Clean
Clean
—
Refill
HM300-2R 11
S-5 Engine does not rotate smoothly 1

General causes why engine does not rotate smoothly: Causes
q Air in fuel system
Defective operation of flow damper (Excessive leakage from injector)

q Defective speed sensor (Error at degree that it is not indi-
cated)
q Defective EGR valve
q Defective bypass valve
Clogged injector, defective spray (dirt in injector)
Defective Bkup speed sensor or wiring harness

Defective Ne speed sensor or wiring harness
Defective operation of bypass valve

Low idle speed is set too low

Occurs at a certain speed range Q Q Q Q
Questions
Occurs at low idle w Q Q Q Q Q Q Q

Condition of hunting
Occurs even when speed is raised Q Q Q Q
Occurs on slopes w Q Q
Replacement of filters has not been carried out according to Operation and Maintenance
Manual w w
Check items
Rust or water are observed when fuel tank is drained Q Q

Carry out troubleshooting by failure code "Abnormal bypass valve servo (*1)" q
Troubleshooting

When a specific cylinder is cut out for reduced cylinder mode operation, engine speed
does not change q q
Carry out troubleshooting by failure code "Abnormal engine Ne speed sensor (*2)" q
Carry out troubleshooting by failure code "Abnormal engine Bkup speed sensor (*3)" q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Remedy
Clean
Refill

*2: Failure code [CA689]
*3: Failure code [CA778]
12 HM300-2R
S-6 Engine lacks output (or lacks power) 1

General causes why engine lacks output: Causes
Defective fuel temperature sensor or wiring harness

Defective charge pressure sensor or wiring harness
Clogged injector, defective spray (dirt in injector)
Defective installation of charge pressure sensor

Defective drive of injector (signal, solenoid)



o See "S-14 Coolant temperature becomes
Air leakage from air intake piping

too high (overheating)"

Leaking or clogged fuel piping
q Controller is controlling in derate mode

(limiting injection rate (output) because of an

error in electrical system)
(air leakage)
Degree of use of machine Operated for long period E E E E E
Suddenly Q Q Q Q
Questions
Power was lost

Gradually Q Q Q Q Q Q Q
Replacement of filters has not been carried out according to Operation
and Maintenance Manual w
More engine oil is required for refill than before Q Q Q
Output becomes insufficient after short stop of operation w
Black w w
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low w
When engine is cranked, interference noise comes out around turbocharger w
Check items
High idle speed is too low Q
High idle speed under no load is normal, but speed suddenly drops
when load is applied w w Q
Engine does not pick up smoothly and combustion is irregular w Q Q w
Engine hunts (rotation is irregular) Q Q Q Q

Inspect air intake piping directly q
When boost pressure is measured, it is found to be low q q q
Troubleshooting

Carry out troubleshooting by failure code "Loss of pressure feed from
supply pump (*1)" q
When a specific cylinder is cut out for reduced cylinder mode operation,
engine speed does not change q q
Inspect boost pressure sensor mounting section directly q
Carry out troubleshooting by failure code "Abnormal charge pressure
sensor (*2)" q
Carry out troubleshooting by failure code "Abnormal fuel temperature
sensor (*3)" q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Clean
Remedy
HM300-2R 13
S-7 Exhaust gas color is black (incomplete combustion) 1

General causes why exhaust gas color is black: Causes

Leakage of air between turbocharger and cylinder head
q Excessive fuel is supplied

Clogged fuel spill piping (on cylinder head side)


o See "S-14 Coolant temperature becomes too high

(overheating)"
Controller is controlling in derate mode

q
Improper fuel injection pressure

(limiting injection rate (output) because of an error in
Improper fuel injection timing

Crushed or clogged muffler

electrical system)
Clogged or seized injector

Abnormally worn injector

Suddenly became black w Q Q
Questions
Color of exhaust gas is Gradually became black w Q Q Q

More oil is required for refill than before w
Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Leakage of air between turbocharger and cylinder head or loose clamp w
Engine is running in low-temperature mode at normal temperature Q Q Q
When exhaust manifold is touched immediately after starting engine, tempera-
ture of some cylinders is low Q w
Check items
When engine is running, abnormal noise comes out around cylinder head w
Torque converter stall speed or pump relief speed is too high
(Excessive fuel is injected) Q Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q w
When spill hose from injector is disconnected, abnormally much fuel spills w

q
Troubleshooting
Inspect valve clearance directly

When muffler is removed, exhaust gas color improves q
Carry out troubleshooting by failure code "Loss of pressure feed from supply
pump (*1)" q q
When a specific cylinder is cut out for reduced cylinder mode operation, engine
speed does not change q
Inspect fuel spill piping (on cylinder head side) visually q
Carry out troubleshooting by failure code "Abnormal coolant temperature sensor
(*2)" q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Adjust
Clean
Remedy

*2: Failure code [CA144] and [CA145]
14 HM300-2R
S-8 Oil consumption is excessive (or exhaust gas color is blue) 1

General causes why oil consumption is excessive: Causes
q Abnormal combustion of oil
Turbocharger
Worn or damaged valve (stem, guide or seal)
Long-time operation of engine at low idle or high idle
Oil leakage from oil pan, cylinder head, etc

q
(Do not run engine at idle for more than 20 minutes
Dust sucked in from air intake system

continuously)
Clogged breather or breather hose

External leakage of oil

q
Worn or damaged rear oil seal
Oil leakage from oil drain plug

q Wear of parts in lubrication system
Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal at turbine end
Worn seal at blower end
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

E E E E
Questions
Degree of use of machine Operated for long period

Oil consumption suddenly increased w Q
More oil is required for refill than before w Q
Oil gets contaminated prematurely Q Q w
Smear of oil is observed on the outside of engine w w w w w
There are loose piping clamps in air intake system w
Inside of turbocharger intake air outlet pipe has been smeared with oil w
Inside of turbocharger exhaust gas outlet pipe has been smeared with oil Q w
Check items
Oil has been mixed into the coolant w

Oil level in damper chamber has risen w
Exhaust gas color is blue under light load w w
Excessive Q Q w w
Amount of blow-by gas
None w
When intake manifold is removed, dust is observed inside q

When intake manifold is removed, excessive dirt is observed on the inside q
Troubleshooting
Excessive play of turbocharger shaft q q

Inspect breather and breather hose visually q
Inspect rear oil seal visually q
A leakage has been detected during a pressure tightness test of the oil cooler q q
Oil is leaking to the outside of the engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
HM300-2R 15
S-9 Oil gets contaminated prematurely 1

General causes why oil gets contaminated prematurely: Causes
q Entry of exhaust gas into oil due to internal wear
Clogged turbocharger lubrication drain tube

Defective seal at turbocharger turbine end
q Clogging of lubrication passage
q Use of improper fuel
Clogged breather or breather hose

q Use of improper oil

q Operation under excessive load
Defective oil filter safety valve

Worn valve or valve guide
Exhaust gas color is bad

Clogged oil cooler
Clogged oil filter
Questions
Non-specified fuel is being used Q

Even when engine oil temperature rises, oil filter clogging monitor displays clogging
(if monitor is installed) w Q
Metal particles are observed when oil in oil filter is drained Q Q w
Inside of exhaust pipe has been smeared with oil w
Engine oil temperature rises quickly w
Check items

Black w
Excessive Q Q w Q
Amount of blow-by gas
No w
Excessive play of turbocharger shaft q

Troubleshooting
Inspect breather and breather hose visually q
See S-7
Inspect oil cooler visually q
Inspect oil filter visually q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube visually q
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
—
16 HM300-2R
S-10 Fuel consumption is excessive 1

General causes why fuel consumption is excessive: Causes
q Leakage of fuel

q Defective condition of fuel injection (fuel pressure, injection timing)
q Excessive injection of fuel
Fuel leakage from fuel filter, piping, etc.
Defective common rail fuel pressure

Fuel leakage inside head cover
Defective supply pump plunger
Defective operation of injector

Defective feed pump oil seal
Defective spray by injector

E E E
Questions
Degree of use of machine Operated for long period

Is excessive when compared with others of same model Q Q Q Q
Fuel consumption Gradually increased Q Q
Suddenly increased Q Q
Fuel is leaking to the outside of the engine w
Combustion is irregular w
Oil level rises and oil smells of diesel fuel w w
When exhaust manifold is touched immediately after starting engine, temperature of some cylin-
ders are low w
Check items
Low idle speed is too high Q

Torque converter stall speed or pump relief speed is too high Q
Black Q Q Q Q
White Q
Remove head cover and inspect visually q

Inspect feed pump oil seal visually q
Troubleshooting
Carry out troubleshooting by failure code "Loss of pressure feed from supply pump (*1)" q
When a specific cylinder is cut out for reduced cylinder mode operation, engine speed does not
change q
When spill hose from injector is disconnected, the spill measures too much q
Carry out troubleshooting by failure code "Abnormal coolant temperature sensor (*2)" q
Confirm with monitoring function of machine monitor q q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Remedy

HM300-2R 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
General causes why oil is in coolant: Causes
q Internal leakage in lubrication system
Damaged cylinder liner O-ring or holes caused by pitting

q Internal leakage in cooling system
Broken hydraulic oil cooler or power train oil cooler

Insufficient protrusion of cylinder liner
Broken cylinder head or head gasket
Broken oil cooler core or O-ring

Cracks inside of cylinder block
Questions
Suddenly Q Q Q
Oil level rose
Gradually Q Q
Hard water is being used as coolant Q Q
Oil level has risen and oil is milky Q Q w
w w
Check items
Excessive air bubbles are trapped in the radiator and coolant spurts back
Hydraulic oil or power train oil is milky w
When hydraulic oil or power train oil is drained, water comes out with the oil w
A leakage has been detected during a pressure tightness test of the cylinder head q
Troubleshooting
troubleshooting
Inspect cylinder block and liner visually q q
in H mode.
Carry out
Inspect cylinder liner visually q
A leakage has been detected during a pressure tightness test of the oil cooler q
Replace
Replace
Replace
Replace
Replace
Remedy
—
18 HM300-2R
S-12 Oil pressure drops 1

General causes why oil pressure drops: Causes
q Leakage, clogging or worn part in lubrication system
Defective oil pressure sensor or wiring harness

q Defective oil pressure control
Defective oil level sensor or wiring harness

Leaking, crushed, clogged hydraulic piping
q Selection of oil by the temperature etc. specified in the Opera-
tion and Maintenance Manual is not observed
q Deterioration of oil due to overheat
Clogged or broken pipe in oil pan
Defective oil pump relief valve

Clogged strainer in oil pan
Worn bearing journal
Coolant or fuel in oil

Lack of oil in oil pan
Defective oil pump
Clogged oil filter

Questions
Oil pressure monitor indicates oil pressure is too low (if monitor is installed) Q w
Non-specified oil is used Q Q
Replacement of filters has not been carried out according to Operation and Maintenance
Manual w
Indicates pressure drop at low idle w Q
Oil pressure monitor Indicates pressure drop at low and high idle Q w w w Q
(if monitor is installed) Indicates pressure drop on slopes w
Sometimes indicates pressure drop w Q Q
Oil level monitor indicates oil level drop (if monitor is installed) w w
Oil level in oil pan is low w
External hydraulic piping is leaking or crushed w
Check items
Oil is milky or smells of diesel oil w

Metal particles are observed when oil pan is drained w
Metal particles are observed when oil filter is drained w Q
Metal particles are observed in oil filter q

Inspect oil pan strainer and pipe visually q q
Troubleshooting
Oil pump rotation is heavy, or there is excessive play in oil pump q

See S-13
Valve or spring of oil pump relief valve is fatigued or damaged q

Inspect oil filter visually q
Carry out troubleshooting by failure code "Abnormal oil pressure sensor (*1)" q
If oil level sensor is replaced, oil pressure monitor indicates properly q
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Remedy
Refill
—
HM300-2R 19
S-13 Oil level rises (coolant or fuel mixes) 1

General causes why oil level rises: Causes
q Coolant in oil (milky)
Clogged water pump drain hole (breather hole) or defective seal

q Fuel in oil (smells of diluted diesel fuel)
a If oil is in coolant, carry out troubleshooting for

"S-11 Oil is in coolant".
Internally defective supply pump

Broken oil cooler core or O-ring
Fuel leakage inside head cover
Cracks inside of cylinder block
Worn or damaged rear oil seal
Defective thermostat seat

Questions

Fuel consumption has increased w w
More coolant is required for refill than before Q w
Oil has been mixed into the coolant Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q w
After engine is started, drops of water come from muffler Q
When engine is running at low idle with the radiator cap removed, excessive bubbles come out or
coolant spurts back w Q
Check items
Exhaust gas color is white Q Q

Water pump drain hole (breather hole) is clogged w
When water pump drain hole (breather hole) is cleaned, coolant comes out w
Oil level in clutch or damper chamber of machine has lowered w
Oil level in hydraulic tank of machine has lowered

Remove head cover and inspect visually q
Troubleshooting
Inspect cylinder block and liner visually q q

Inspect rear oil seal visually q
A leakage has been detected during a pressure tightness test of the oil cooler q
Remove water pump and inspect visually q
Remove thermostat cover and inspect visually q
Remove supply pump and inspect visually q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
20 HM300-2R
S-14 Coolant temperature rises too high (overheat) 1

General causes why coolant temperature rises too high: Causes
q Lack of cooling air (deformation or damage of fan)

q Drop in heat radiation efficiency
q Problem in coolant circulation system
q Rise in oil temperature in power train
Defective radiator cap (pressure valve)
Defective coolant temperature gauge

Slipping fan belt or worn fan pulley
Rise in power train oil temperature

Defective operation of thermostat
Clogged, crushed radiator fins
Clogged or broken oil cooler
Clogged radiator core

Broken water pump
Lack of coolant
Q w Q
Questions
Suddenly occurred
Overheating
Always tends to overheat Q w w Q
Coolant temperature Rises quickly Q w
gauge
(if coolant temperature Does not go down from red range w
gauge is installed)
Radiator coolant level monitor indicates drop of coolant level (if monitor is installed) w
Engine oil level has risen and oil is milky w Q
Fan belt tension is too low w
Fan pulley has excessive play when it is turned w
Milky oil is floating on the coolant w
Excessive air bubbles are trapped in the radiator and coolant spurts back w
Check items
When light bulb is held behind radiator core, no light passes through w
Radiator shroud and inside of undercover are clogged with dirt or mud w w
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Power train oil temperature enters red range faster than engine coolant temperature (if
oil temperature gauge and coolant temperature gauge are installed) w

Inspect cylinder liner visually q

Inspect oil cooler visually q
Temperature difference between upper and lower tanks of radiator is too large q
Troubleshooting
When operation test of thermostat is carried out, it does not open at valve cracking tem-
perature q
Temperature difference between upper and lower tanks of radiator is too small q
Inspect radiator core visually q
When operation test for radiator cap is carried out, valve cracking pressure is too low q
Inspect fan belt and pulley visually q
When coolant temperature is measured, it is found to be normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
—
Refill
HM300-2R 21
S-15 Abnormal noise comes out 1

General causes why abnormal noise comes out: Causes
q Abnormality due to defective parts
Improper fuel injection timing (abnormal coolant temperature sensor)

q Abnormal combustion
q Air sucked in from air intake system
a Judge if the noise is an internal noise or an external noise,
Internally defective muffler (partition plate out of position)

before starting troubleshooting.
Leakage of air between turbocharger and cylinder head
Deformed fan, loose fan belt or interference of fan belt

a The engine is operated in the low-temperature mode while
Interference of turbocharger or seized turbocharger

it is not warmed up sufficiently.
Accordingly, the engine sound becomes a little larger.
Excessive wear of piston ring or cylinder liner

This does not indicate abnormality, however.
Broken valve system (valve, rocker lever)

a When the engine is accelerated, it is operated in the accel-
Removed or seized gear train bushing

eration mode and its sound becomes a little larger for up to
about 5 seconds. This does not indicate abnormality, how-
ever.
Improper gear train backlash
Clogged or seized injector

Dirt caught in injector

Degree of use of machine Operated for long period E
Questions
Gradually Q Q
Abnormal noise appeared
Suddenly Q Q Q
Non-specified fuel is being used Q
More oil is required for refill than before w
Metal particles are observed when oil in oil filter is drained w w
Air leaks between turbocharger and cylinder head w
When engine is running, abnormal noise comes out around cylinder head w w
When engine is running, beating noise comes out around muffler w
Check items

some cylinders is low w Q
Black Q w Q
Engine does not pick up smoothly and combustion is irregular w
Abnormal noise is loud during acceleration Q Q Q Q

When muffler is removed, abnormal noise disappears q
Troubleshooting

Inspect gear train directly q q
Inspect fan and fan belt visually q
When a specific cylinder is cut out for reduced cylinder mode operation, engine speed
does not change q q
Abnormal noise comes out only when engine is started q
Confirm with monitoring function of machine monitor q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Adjust
Remedy
22 HM300-2R
S-16 Vibration is excessive 1

General causes why vibration is excessive: Causes
q Defective parts (abnormal wear, breakage, etc.)
Misalignment between engine and devices on machine side

q Misalignment with chassis side
q Abnormal combustion
a If abnormal noise comes out and vibration is excessive, also carry out
Worn main bearings or connecting rod bearings

troubleshooting for "S-15 Abnormal noise comes out".
Loose engine mounting bolts, broken cushions

Stuck valve system (valve, rocker lever, etc.)
Broken output shaft or parts in damper

Improper gear train backlash
Worn camshaft bushing
Questions
Suddenly increased Q Q
Condition of vibration
Gradually increased Q Q Q
Metal particles are observed when oil in oil filter is drained w w
Metal particles are observed when oil pan is drained w w
Oil pressure is low when running at low idle Q Q
Check items
Vibration occurs when running at a medium speed Q Q

Vibration follows engine speed Q Q Q Q
Exhaust gas color is black w

Inspect main bearings and connecting rod bearings visually q
Troubleshooting
Inspect gear train directly q

Inspect camshaft bushing visually q
Confirm with monitoring function of machine monitor q
Inspect engine mounting bolts and cushions visually q
When alignment is checked, radial runout or facial runout is detected q
Inspect output shaft or inside of damper visually q
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Remedy
HM300-2R 23
S-17 Air cannot be bled from fuel circuit 1

(After filter is replaced or fuel is used up and then air is bled, engine does not start
or it starts but stalls.)
General causes why air cannot be bled Causes
q Electric priming pump does not operate.
Defective wiring harness of electric priming pump

Fuel is not supplied or is supplied very little.
Improper setting of air bleeding valve (Closed)

q
Fuel valve or air bleeding valve is not set properly.
Malfunction of electric priming pump switch

q
Air bleeding piping is clogged.
Leaking or clogged fuel piping or air in it

q
Improper setting of fuel valve (Closed)

Fuel return piping is clogged.
Malfunction of electric priming pump

q
Clogged fuel tank cap breather hole
Clogged water separator screen

Clogged air bleeding piping
Low battery charge level

Clogged fuel filter
Low fuel level
Questions
Degree of use of
machine Operated for long period EE
Non-specified fuel is used Q Q
Fuel tank is empty w
Fuel tank cap breather hole is clogged Q w
Switch lamp does not blink w w Q
Check items
When electric prim- Lamp blinks but pump operation sound is not heard w w
ing pump switch is
operated Pump operation sound is heard but fuel does not flow out of
hose soon Q Q w w w Q Q
Air bleeding valve is closed q

Fuel valve (supply side) is closed q
Fuel valve (return side) is closed q
Water drain valve and air intake plug of water separator are loosened q
Troubleshooting
Water drain valve of fuel prefilter is loosened q

There is flaw or dirt on sealing face of fuel prefilter or main filter q
Check air bleeding piping and orifice directly (See Note 1) q
Check fuel piping (supply side and return side) directly (for clogging and breakage) q
Check electric priming pump directly q
Check electric priming system directly (See E-33 in E-mode) q q
Check water separator screen directly q
Check fuel filter for clogging (Failure code CA559, Note 2) q
Replace
Replace
Replace
Replace
Charge
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
Add
24 HM300-2R
Note 1: Check of air bleeding piping for clogging
q Remove joint bolt (1) and blow clean compressed air into hole [b] of the orifice to check for clogging.
HM300-2R 25

© 2009 KOMATSU
All Rights Reserved
26 HM300-2R
SEN04028-01
HM300-2R

50 Disassembly and assembly1

General information on disassembly and
assembly
How to read this manual ................................................................................................................................. 2
Coating materials list....................................................................................................................................... 4
Special tool list ................................................................................................................................................ 7
Sketches of special tools .............................................................................................................................. 12
HM300-2R 1
SEN04028-01 50 Disassembly and assembly
How to read this manual 1

(Rev. 2009.01)
1. Removal and installation of assemblies
Special tools Removal

q Special tools which are necessary for q In "Removal" section, the work procedures,
r e m o v a l o r i n s ta l l a t i o n o f pa r ts a r e precautions and know-how to do the work, and
described as A1,•••X1 etc. and their parts the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for removal
q Also the following information is described are described as [1], [2] ••• etc. and their part
in the special tool list. numbers, part names and quantities are not
1) Necessity described.
t : Special tools that cannot be substituted q Various symbols used in "Removal" section are
and should always be used explained and listed below.
k
q : Special tools that will be useful if avail-
: Precautions related to work safety
able and are substitutable with tools
available on the market a: Guidance or precautions for the work
2) Distinction of new and existing special tools [*1] : This mark shows that instructions or precau-
N: Tools newly developed for this tions for parts installation work are given in
model. They have a new part num- "Installation" section.
ber respectively.
R: Tools made available by redesign- 6 : Amount of oil or coolant to be drained
ing the existing tools which were 4 : Weight of part or component
developed for other models. Each
of them has a new part number
assigned by setting forward the part Installation
number of the existing tool. q Unless otherwise instructed, installation of parts
Blank: Tools already available for other is to be done in the reverse order to removal.
models. They can be used without q Instructions and precautions for parts installation
any modification. is shown with the mark ([*1], [*2]...) which corre-
3) Circle mark Q in sketch column: sponds to the mark in "Removal" section.
q The sketch of the special tool is pre- q Common tools that are necessary for installation
sented in the section of "Sketches of are described as [1], [2] ••• etc. and their part
special tools". numbers, part names and quantities are not
q Part No. of special tools starting with described.
79*T-***-****: q Marks shown in the "Installation" section stand
means that they are not available from for the following.
k
Komatsu Ltd. (i.e. tools to be made
locally).
a: Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
5 : Amount of oil or coolant to be replenished
Sketches of special tools

q Various special tools are illustrated for the local
manufacture.
2 HM300-2R
2. Disassembly and assembly of assemblies
Special tools Disassembly

q Special tools which are necessary for dis- q In "Disassembly" section, the work procedures,
assembly and assembly of parts are precautions and know-how to do the work, and
described as A1,•••X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for disas-
q Also the following information is described sembly are described as [1], [2] ••• etc. and
in the special tool list. their part numbers, part names and quantities
1) Necessity are not described.
t : Special tools that cannot be substituted q The meanings of the symbols used in "Disas-
and should always be used. sembly" section are as follows.
k
q : Special tools that will be useful if avail-
able and are substitutable with tools
available on the market. a: Guidance or precautions for the work
2) Distinction of new and existing special tools 6: Amount of oil or coolant drained
N : Tools newly developed for this
model. They have a new part num-
ber respectively. Assembly
R : Tools made available by redesign- q In "Assembly" section, the work procedures,
ing the existing tools which were precautions and know-how to do the work, and
developed for other models. Each the amount of oil and coolant to be replenished
of them has a new part number are described.
assigned by setting forward the q Common tools that are necessary for assembly
part number of the existing tool. are described as [1], [2] ••• etc. and their part
Blank : Tools already available for other numbers, part names and quantities are not
models. They can be used without described.
any modification. q The meanings of the symbols used in "Assem-
3) Circle mark Q in sketch column: bly" section are as follows.
k
q The sketch of the special tool is pre- : Precautions related to work safety
sented in the section of "Sketches of
special tools". a: Guidance or precautions for the work
2
q Part No. of special tools starting with : Type of coating material
79*T-***-****:
means that they are not available from 3 : Tightening torque
5
Komatsu Ltd. (i.e. tools to be made : Amount of oil or coolant to be replenished
locally).
Sketches of special tools

q Various special tools are illustrated for the local
manufacture.
HM300-2R 3
Coating materials list 1

(Rev. 2009.08)
a The recommended coating materials such as adhesives, liquid gaskets, and greases used for disassembly
and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part No. Capacity Container Main features and applications
gory code
q Use to prevent rubber gaskets, rubber cushions,

LT-1A 790-129-9030 150 g Tube
and cork plugs from coming out.
q Use for plastic (except polyethylene, polypropy-
20 g Polyethylene lene, tetrafluoroethylene and vinyl chloride), rub-
LT-1B 790-129-9050
(2 pcs.) container ber, metal, and non-metal parts which require
immediate and strong adhesion.
Polyethylene q Features: Resistance to heat and chemicals.
LT-2 790-129-9040 50 g
container q Use to fix and seal bolts and plugs.
790-129-9060 Adhesive:
(Set of adhe- 1 kg
LT-3 Can q Use to bond and seal metal, glass and plastics.
sive and hard- Hardener:
ener) 500 g
Adhesive
Polyethylene
LT-4 790-129-9040 250 g q Use to seal plugs for blank holes
container
Holtz
790-129-9120 75 g Tube q Heat-resistant seal used to repair engines.
MH 705
q Instanetaneous adhesive.
ThreeBond Polyethylene q Curing time: From 5 sec. to 3 min.
790-129-9140 50 g
1735 container q Use mainly to bond metals, rubbers, plastics, and
woods.
q Instanetaneous adhesive.
Aron-alpha Polyethylene q Quick-curing type (max. strength is obtained after
790-129-9130 2g
201 container 30 minutes)
q Use mainly to bond rubbers, plastics, and metals.
q Features: Resistance to heat and chemicals.
Loctite 648- Polyethylene
79A-129-9110 50 cc q Use for fitted portions subjected to high tempera-
50 container
ture.
q Use to seal various threaded portions, pipejoints,
Polyethylene and flanges.
LG-5 790-129-9080 1 kg
container q Use to seal taper plugs, elbows, and nipples for
hydraulic piping.
q Features: Silicon-based heat and cold-resistant
sealant.
LG-6 790-129-9160 200 g Tube q Use to seal flange surfaces and threaded por-
tions.
Liquid gasket
q Use to seal oil pan, final drive case, etc.

q Features: Silicon-based quick-curing sealant.
LG-7 790-129-9170 1 kg Tube q Use to seal flywheel housing, intake manifold,
thermostat old, oil pan, thermostat housing, etc.
LG-8 q Features: Silicon-based, heat and cold-resistant,
ThreeBond 419-15-18131 100 g Tube vibration-resistant, impact-resistant sealant.
1207B q Use to seal transfer case, etc.
q Use for rough surfaces such as the circle gear top
LG-9
seal which is not clamped by bolts, gaps in the
ThreeBond 790-129-9310 200 g Tube
weld which must be caulked, etc.
1206D
q Can be coated with paint.
4 HM300-2R
Cate- Komatsu
gory code
LG-10 q Use as lubricant/sealant when installing the radia-
ThreeBond 790-129-9320 200 g Tube tor hoses to the water tubes.
Liquid gasket
1206E q Can be coated with paint.

LG-11 q Feature: Can be used together with solid gaskets.
ThreeBond 790-129-9330 200 g Tube q Use for covers of the transmission case and steer-
1121 ing case etc.
ThreeBond
790-129-9090 100 g Tube q Liquid gasket used to repair engine.
1211
q Use to prevent galling and seizure of press-fitted
Molybdenum disulfide
portions, shrinkage-fitted portions, and threaded

LM-P 09940-00040 200 g Tube
portions.
lubricant
q Use to lubricate linkages, bearings, etc.

q Spray type
q Thin molybdenum disulphide films are made on
— 09995-00250 190 g Can metal surfaces to prevent the metals from galling.
q Use for the drive shaft splines, needle bearings,
various link pins, bolts, etc.
prevention compound
q Feature: Seizure and galling prevention com-

LC-G pound with metallic super-fine-grain, etc.
Seizure
NEVER- — — Can q Use for the mounting bolt in the high temperature
SEEZ area of the exhaust manifold and the turbocharg-
er, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI
G0-LI (*) q Feature: Lithium grease with extreme pressure lu-
SYGA-160CNLI Various Various
*: For cold brication performance, general purpose type.
SYG0-400LI-A
district
(*)
SYG0-160CNLI
(*)
q Use for parts under heavy load.
Molybde- Caution:
Bellows-type
num disul- SYG2-400M 400 g × 10 q Do not use this grease for rolling bearings like
container
fide grease SYG2-400M-A 400 g × 20 swing circle bearings, etc. and spline.
LM-G (G2- SYGA-16CNM 16 kg q Use this grease for work equipment pins only
Can
M) when installing them, but do not use it after-
ward.
SYG2-400T-A
Grease
Hyper White
SYG0-400T-A q Seizure resistance, heat resistance and water re-
G2-T, Bellows-type
(*) 400 g sistance higher than molybdenum disulfide
G0-T (*) container
SYG2-16CNT 16 kg grease.
*: For cold Can
SYG0-16CNT q Not conspicuous on machine since color is white.
district
(*)
Biogrease
G2-B SYG2-400B
G2-BT (*) SYG2-400BT
Bellows-type q Since this grease is biodegradable in short period,
*: For use at (*) 400 g
container it has less impact on microorganisms, animals,
high temper- SYGA-16CNB 16 kg
Can and plants.
ature and SYGA-16CNBT
under high (*)
load
q Feature: Silicone grease with wide usable temper-
G2-S ature range, high resistance to thermal-oxidative
ThreeBond — 200 g Tube degradation and performance to prevent deterio-
1855 ration of rubber and plastic parts.
q Use for oil seals of the transmission, etc.
HM300-2R 5
Cate- Komatsu
gory code
q Feature: Urea (organic system) grease with heat
resistance and long life, can be packed into the
Grease
G2-U-S
427-12-11871 2 kg Can confined space and left intact until next overhaul.
ENS grease
q Use for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
q Use as primer for painted cab sheet metal
SUNSTAR
Glass con- surface.
PAINT 20 ml
tainer (Effective period: four months after date of
PRIMER580
manufacture)
SUPER 417-926-3910
SUNSTAR
q Use as primer for glass.
GLASS Glass con-
For adhered window glass

20 ml (Effective period: four months after date of
PRIMER tainer
manufacture)
580 SUPER
SUNSTAR q Use as primer for painted cab sheet metal
Primer
PAINT Glass con- surface.

22M-54-27230 20 ml
PRIMER tainer (Effective period: four months after date of
435-95 manufacture)
q Use as primer for black ceramic-coated
SUNSTAR
glass surface and for hard polycarbonate-
GLASS
22M-54-27240 150 ml Can coated surface.
PRIMER
(Effective period: four months after date of
435-41
manufacture)
SUNSTAR q Use as primer for sash (anodized aluminum
SASH Glass con- surface).
22M-54-27250 20 ml
PRIMER tainer (Effective period: four months after date of
GP-402 manufacture)
SUNSTAR q Use "S" in high-temperature season and
PENGUINE "W" in low-temperature season as adhesive
Polyethylene
SEAL580 417-926-3910 320 ml for glass.
container
SUPER "S" (Effective period: four months after date of
Adhesive
or "W" manufacture)
Sika Japan, q Use as adhesive for glass.
Polyethylene
Sikaflex 20Y-54-39850 310 ml (Effective period: six months after date of
container
For adhered window glass
256HV manufacture)
SUNSTAR q Use as adhesive for glass.
Ecocart (Spe-
PENGUINE 22M-54-27210 320 ml (Effective period: six months after date of
cial container)
SUPER 560 manufacture)
SUNSTAR
q Use to seal glass-to-glass joints.
PENGUINE Polyethylene
417-926-3920 320 ml (Effective period: four months after date of
SEAL No. container
manufacture)
Caulking material
2505
SEKISUI q Use to seal front window.
Polyethylene
SILICONE 20Y-54-55130 333 ml (Effective period: six months after date of
container
SEALANT manufacture)
GE
q Use to seal glass-to-glass joint. Translu-
TOSHIBA
cent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Effective period: 12 months after date of
TOSSEAL3
manufacture)
81
6 HM300-2R
Special tool list 1

(Rev. 2009.01)
a Tools with part number 79*T-***-**** means that they are not available from Komatsu Ltd. (i.e. tools to be
made locally).
a Necessity : t . . . . . Special tools that cannot be substituted and should always be used
: q . . . . . Special tools that will be useful if available and are substitutable with tools avail-
able on the market
a New/Remodel: N . . . . . Tools newly developed for this model. They have a new part number respectively.
: R. . . . . . Tools made available by redesigning the existing tools which were developed for
other models. Each of them has a new part number assigned by setting forward
the part number of the existing tool.
: Blank . . Tools already available for other models. They can be used without any modification.
a Tools marked with Q in the sketch column are presented in the sketches of the special tools (See "Sketches
of special tools")
New/Remodel
Sym-
Necessity
Work item Part No. Part name Nature of work and remarks
bol
Sketch
Q'ty
795-630-5500 Standard puller t 1
Removal and installation of fuel
1 01010-81090 Bolt t 2
supply pump
01643-31032 Washer t 2
2 790-331-1110 Wrench (Angle) q 1 Tightening of cylinder head bolt
3 795-931-1100 Seal puller assembly t 1 Removal of engine seal
795-931-1210 Push tool t 1
4 01050-31625 Bolt t 3
01050-31645 Bolt t 3 Press fitting of engine rear seal
Engine assembly A
795-931-1220 Push tool t 1
5
01050-31645 Bolt t 3
795T-521-1140 Push tool t 1 Q
790-101-5221 Grip t 1 Press fitting of engine front
6
01010-81225 Bolt t 1 seal
01050-31640 Bolt t 3
792T-220-1310 Centering tool t 2 N Q Centering of engine assembly
7
01050-61225 Bolt t 8 and transmission assembly
790-501-5000 Unit repair stand q 1
Disassembly and assembly of
1 790-901-2110 Bracket q 1
Torque converter torque converter assembly
C 792T-213-1210 Plate q 1 Q
assembly
2 792-213-1110 Wrench t 1
pump bearing nut
1 790-102-1871 Nut wrench t 1
PTO bearing nut
Press fitting of lower shaft
2 796-465-1120 Push tool t 1
bearing (3rd side)
Press fitting of lower shaft
3 792T-423-1110 Push tool t 1 Q
bearing (2nd side)
792T-213-1220 Push tool t 1 Q
Transmission assembly D Press fitting of input coupling
4 790-101-5421 Grip t 1
dust seal
01010-81240 Bolt t 1
792T-213-1230 Push tool t 1 Q
Press fitting of input coupling
5 790-101-5421 Grip t 1
oil seal
01010-81240 Bolt t 1
6 790-201-2730 Spacer t 1 Press fitting of PTO bearing
HM300-2R 7
New/Remodel
Necessity
Sym-
bol
Sketch
Q'ty
Press fitting of idler gear bear-
7 792T-413-1120 Push tool t 1 Q
ing
Press fitting of output coupling
Transmission assembly D 8 792T-215-1120 Push tool t 1 Q
cover
Operation test of clutch assem-
9 799-301-1500 Oil leak tester kit t 1
bly
Press fitting of output shaft
1 792T-227-1110 Push tool t 1 Q
bearing
792T-423-1130 Push tool t 1 Q
Front differential Press fitting of side carrier oil
2 790-101-5421 Grip t 1
assembly seal
01010-51240 Bolt t 1
Press fitting of bevel pinion
3 790-201-2840 Spacer t 1
bearing
792T-423-1130 Push tool t 1 Q
Press fitting of transfer input
2 790-101-5421 Grip t 1
shaft cage oil seal
01010-51240 Bolt t 1
790-101-5401 Push tool kit t 1
790-101-5441 • Plate 1 Press fitting of bearing cage oil
4
790-101-5421 • Grip 1 seal
01010-51240 • Bolt 1
Press fitting of bearing cage
5 790-201-2770 Spacer t 1
side seal
Unit repair stand
790-501-5000 t 1
(AC 100 V)
Center differential Unit repair stand Disassembly and assembly of
assembly 6 790-501-5200 t 1
(AC 100 V, AC 220 V) center differential assembly
H 790-901-2110 Bracket t 1
792T-222-1210 Plate t 1 Q
Adjustment of pre-load on side
7 792-103-0901 Wrench t 1
bearing
8 792T-223-1120 Push tool t 1 Q
shaft bearing
792T-423-1140 Push tool t 1 Q
9 790-101-542 Grip t 1
shaft cage oil seal
01010-51240 Bolt t 1
10 792T-223-1110 Push tool t 1 Q
bearing
Unit repair stand
790-501-5000 t 1
(AC 100 V)
Unit repair stand Disassembly and assembly of
6 790-501-5200 t 1
(AC 100 V, AC 220 V) rear differential assembly
Rear differential 790-901-2110 Bracket t 1
assembly 792T-222-1210 Plate t 1 Q
Adjustment of pre-load on side
7 792-103-0901 Wrench t 1
bearing
10 792T-223-1110 Push tool t 1 Q
bearing
8 HM300-2R
New/Remodel
Sym-
Necessity
bol
Sketch
Q'ty
792T-227-1120 Fixture t 3 Q
792T-223-1140 Plate t 3 Q
01010-61240 Bolt t 3
1 01643-31232 Washer t 3
brake assembly
01580-01210 Nut t 3
01010-61245 Bolt t 3
01010-62440 Bolt t 3
2 792T-222-1220 Push tool t 1 Q Press fitting of shaft bearing
Front final drive and 792T-227-1130 Push tool t 1 Q
brake assembly 3 790-101-5221 Grip t 1 Press fitting of shaft oil seal
01010-81225 Bolt t 1
4 791-580-1520 Installer t 1
Installation of floating seal
5 791-580-1510 Installer t 1
793T-622-1110 Push tool t 1 Q
Press fitting of outer gear oil
6 790-101-5421 Grip t 1
seal
01010-81240 Bolt t 1
Press fitting of inner hub bear-
7 797T-622-1240 Push tool t 1 Q
ing
J 2 792T-222-1220 Push tool t 1 Q Press fitting of shaft bearing
4 791-580-1520 Installer t 1
Installation of floating seal
5 791-580-1510 Installer t 1
793T-622-1110 Push tool t 1 Q
Press fitting of outer gear oil
6 790-101-5421 Grip t 1
seal
01010-81240 Bolt t 1
Press fitting of inner hub bear-
Center final drive and 7 797T-622-1240 Push tool t 1 Q
ing
brake assembly
792T-227-1130 Fixture t 3 Q
792T-223-1140 Plate t 3 Q
01010-61240 Bolt t 3
8 01643-31232 Washer t 3
brake assembly
01580-01210 Nut t 3
01010-61245 Bolt t 3
01010-62440 Bolt t 3
Press fitting of wheel hub bear-
2 792T-222-1220 Push tool t 1 Q
Rear final drive ing
assembly Press fitting of inner hub bear-
7 797T-622-1240 Push tool t 1 Q
ing
1 792T-246-1130 Plate t 1 Q
Press fitting of dust seal
Hitch frame assembly K 2 792T-246-1140 Plate t 1 Q
3 792T-246-1110 Push tool t 1 Q Press fitting of bearing
HM300-2R 9
New/Remodel
Sym-
Necessity
bol
Sketch
Q'ty
790-101-5201 Push tool kit t 1 Press fitting of dust seal
790-101-5341 • Plate 1 (For center shaft)
4 790-101-5331 • Plate 1 (For upper hinge pin)
790-101-5221 • Grip 1
01010-51225 • Bolt 1
790-201-1640 • Plate 1 Press fitting of dust seal for
5
790-101-5021 • Grip 1 lower hinge pin
Hitch frame assembly K 01010-50816 • Bolt 1
792T-446-1120 Push tool t 1 Q
790-101-2310 Block t 2
790-101-2390 Leg t 2
790-101-2420 Adapter (16 mm) t 2
6
790-101-2360 Plate t 2
02215-11622 Nut t 2
790-101-2102 Puller 300 kN {30 ton} t 1
790-101-1102 Pump t 1
Suspension cylinder Filling suspension cylinder with
Q 792-610-1000 Suspension tool assembly t 1
and equalizer bar oil and nitrogen gas
790-502-1003 Cylinder repair stand t 1 Disassembly and assembly of
1
790-101-1102 Hydraulic pump t 1 cylinder assembly
Removal and installation of cyl-
2 790-102-3802 Wrench assembly t 1
inder head
Socket (Width across flats:
3 790-102-1480 t 1 Removal and installation of nut
80 mm)
790-720-1000 Expander t 1
4 796-720-1660 Ring t 1 Installation of piston ring
Steering cylinder 07281-01159 Clamp t 1
assembly
790-101-5021 • Grip 1
5 Press fitting of bushing
01010-50816 • Bolt 1
U
790-202-1811 • Push tool 1
790-101-5021 • Grip 1
6 Press fitting of dust seal
01010-50816 • Bolt 1
790-201-1620 • Plate 1
790-502-1003 Cylinder repair stand t 1 Disassembly and assembly of
1
790-101-1102 Hydraulic pump t 1 cylinder assembly
Removal and installation of cyl-
Hoist cylinder assembly inder head
790-720-1000 Expander t 1
4 796-720-1660 Ring t 1 Installation of piston ring
07281-01159 Clamp t 1
10 HM300-2R
New/Remodel
Sym-
Necessity
bol
Sketch
Q'ty
790-101-5021 • Grip 1
5 01010-50816 • Bolt 1 Press fitting of bushing
790-201-1831 • Push tool 1
790-201-1871 • Push tool 1
Hoist cylinder assembly U
790-101-5021 • Grip 1
6 01010-50816 • Bolt 1 Press fitting of dust seal
790-201-1640 • Plate 1
790-201-1680 • Plate 1
790-102-4300 Wrench assembly t 1
7 Tightening of piston assembly
790-102-4310 Pin t 1
Operator's cab 1 792-454-1100 Pump assembly q 1 N Tilting up by tilt cylinder
X 2 793-498-1210 Lifter (Suction cup) t 2 Installation of operator's cab
Operator's cab glass
3 20Y-54-13180 Stopper rubber t 2 glass
HM300-2R 11
Sketches of special tools 1

Note: Komatsu cannot accept any responsibility for special
tools manufactured according to these sketches.
A6 Push tool
A7 Centering tool
12 HM300-2R

C1 Plate
D3 Push tool
HM300-2R 13

D4 Push tool
D5 Push tool
14 HM300-2R

D7 Push tool
D8 Push tool
HM300-2R 15

H1 Push tool
H2 Push tool
16 HM300-2R

H6 Plate
H8 Push tool
HM300-2R 17

H9 Push tool
H10 Push tool
18 HM300-2R

J1 Fixture
J1 Plate
HM300-2R 19

J2 Push tool
J3 Push tool
20 HM300-2R

J6 Push tool
J7 Push tool
HM300-2R 21

J8 Fixture
J8 Plate
22 HM300-2R

K1 Plate
K2 Plate
HM300-2R 23

K3 Push tool
PUSH TOOL
K6 Push tool (For bearing of rear side hitch frame)
24 HM300-2R
HM300-2R 25

© 2009 KOMATSU
All Rights Reserved
26 HM300-2R
SEN04029-01
HM300-2R


Engine and cooling system
(SAA6D125E-5)
Removal and installation of fuel supply pump assembly ................................................................................ 2
Removal and installation of fuel injector assembly ......................................................................................... 7
Removal and installation of cylinder head assembly .................................................................................... 12
Removal and installation of engine front seal ............................................................................................... 24
Removal and installation of engine rear seal ................................................................................................ 26
Removal and installation of engine assembly ............................................................................................... 30
Removal and installation of radiator assembly ............................................................................................. 38
Removal and installation of cooling assembly .............................................................................................. 40
Removal and installation of output shaft assembly ....................................................................................... 43
Disassembly and assembly of output shaft assembly .................................................................................. 48
HM300-2R 1

supply pump assembly 1
Special tools
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
795-630-5500 Standard puller t 1
A 1 01010-81090 Bolt t 2
01643-31032 Washer t 2
Removal
k Stop the machine on level ground. 6. Disconnect connector COMP (6).
k Turn the parking brake switch ON and stop
7. Disconnect wiring harness clamp (7).
the engine.
k Chock the wheels. 8. Disconnect connector CM (8).
k Set the lock bar to the frame.
k Disconnect the cable from the negative (–) 9. Loosen adjustment nut (9) of the air conditioner
terminal of the battery. compressor.
1. Open engine undercover (1). 10. Loosen the mounting bolts of air conditioner
compressor (10).
11. Remove air conditioner compressor belt (11).

[*1]
12. Remove rod and plate assembly (12).
13. Remove air conditioner compressor (10) from

the bracket.
a Do not disconnect air conditioner compres-
sor hoses but place them on this side.
14. Remove air conditioner compressor bracket

(13).
a D: Damper
2. Open the engine hood.
3. Disconnect fuel hoses (2).
4. Remove prefilter (4).

a Remove the prefilter and bracket together.
5. Remove fan guard (5).
2 HM300-2R
15. Disconnect fuel return hose (14). [*2]
16. Disconnect connectors PCV1 (15), PCV2 (16),

and G (17).
17. Disconnect bracket (18). [*3]
18. Remove fuel filter (19).

a Use a filter wrench, etc. to remove the filter.
24. Disconnect clamps (26) and (27).
25. Disconnect bracket (28).
26. Remove right and left bellows (29).
27. Remove high-pressure pipe assembly (30).
19. Remove fuel tubes (21) and (22). [*4]
20. Disconnect fuel hose (23). [*5]
21. Remove fuel tubes (24), (24-1) and clamp

assembly. [*6]
22. Remove over flow tube (24-2). [*7]
23. Remove lubrication tube (25).
HM300-2R 3
28. Remove cover (31). 31. Install tool A1 and tighten bolt (B) to pull the fuel
supply pump shaft out of the drive gear.
29. Rotate the crankshaft forward and set interme- a Keep tool A1 installed until the gear is
diate point "a" between the stamps of 2•5 TOP installed again.
and 3•4 TOP on damper (D) to pointer (P) (The
stamp of 1•6 TOP is set near the bottom at this
time).
a At this time, check that the forcing tap of the
drive gear is aligned with the bolt hole of
cover (31). (If not, rotate the crankshaft 1
more turn.)
a At this point, the key of the pump shaft is
turned clockwise by 15° from the top.
32. Remove bracket (34).
33. Remove 4 bolts (35) and fuel supply pump

assembly (36).
30. Remove nut (32) and washer (33). [*8]

a Using driver [1] and magnet [2], prevent
washer (33) from falling in the case.
4 HM300-2R
Installation 3 Common rail side:

39.2 – 58.8 Nm {4 – 6 kgm}
• Fuel supply pump and high-pressure pipe Pump side: 39.2 – 49 Nm {4 – 5 kgm}
assembly
1. Install fuel supply pump assembly (36) with 4 5. Permanently tighten mounting bolts (35) of fuel
bolts (35) and finger tighten them. supply pump assembly (36).
2 Mounting bolts: Liquid adhesive (LT-2)
6. Permanently tighten the cylinder block side of

2. Finger tighten bracket (34). bracket (34) and then permanently tighten the
fuel supply pump side.
3 Fuel supply pump side:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
7. Install bellows (29) to each high-pressure pipe.

a When installing, take care of the direction of
the slit.
• Pump side: To be directed to the block.
• Common rail side: To be directed down.
8. Finger tighten lubrication tube (25).
9. Finger tighten clamp (27-2) and then perma-

nently tighten it.
k Do not bend the high-pressure pipe to cor-
rect before installing. 10. Finger tighten bracket (37) and clamp (38) and
k Be sure to use the genuine high-pressure then permanently tighten them.
pipe clamps and observe the tightening
torque. 11. Finger tighten brackets (39) and (28) and clamp
(27-1) and then permanently tighten them.
a When installing each high-pressure pipe, check
the taper seal of its joint (Part "a": Part of 2 mm 12. Finger tighten clamp (27-3) and then perma-
from the end) for visible lengthwise slit "b" and nently tighten it.
spot "c" and check part "d" (End of taper seal:
Part at 2 mm from the end) for stepped-type 13. Permanently tighten lubrication tube (25).
wear caused by fatigue which your nail can feel. 3 Lubrication tube (25) joint bolt:
If there is any of those defects, it can cause fuel 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
leakage. In this case, replace the high-pressure
pipe. 14. Finger tighten clamp (26) and then permanently
tighten it.
3 Clamp mounting bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
3. Finger tighten high-pressure pipe assembly

(30).
4. Permanently tighten the sleeve nuts of high-

pressure pipe assembly (30).
HM300-2R 5
[*5]
3 Joint bolt on fuel supply pump side of fuel
hose (23):
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
3 Sleeve nut on fuel cooler side of fuel
hose (23):
84 – 132 Nm {8.5 – 13.5 kgm}
[*6]
3 Joint bolt on fuel filter side of fuel tubes
(24), (24-1):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
3 Joint bolt on fuel supply pump side of fuel
tube (24):
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
3 Joint bolt on fuel cooler side of fuel tube
(24-1): 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
3 Clamp of tubes (24), (24-1):
27 – 34 Nm {2.8 – 3.5 kgm}
[*7]
3 Joint bolt on air vent (upper) side of over
flow tube (24-2):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
3 Joint bolt on over flow valve (lower) side
of over flow tube (24-2):
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
• Carry out the rest of installation in the reverse

order to removal.
[*1]
Adjust the air conditioner compressor belt ten-
sion. For details, see Testing and adjusting,
"Testing and adjusting air conditioner compres-
sor belt tension".
[*2]
3 Return hose joint bolt:
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
[*3] [*8]
3 Fuel filler clamp: 3 Gear mounting nut:
10.8 – 26.5 Nm {1.1 – 2.7 kgm} 127 – 147 Nm {13 – 15 kgm}
[*4] k Check that each high-pressure pipe and

3 Joint bolt on fuel supply pump side of fuel wiring harness are at least 10 mm apart
tube (22): from each other.
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
3 Joint bolt on block side of fuel tube (22):
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
6 HM300-2R

injector assembly 1
Removal
k Stop the machine on level ground.
the engine.
k Chock the wheels.
k Disconnect the cable from the negative (–)
terminal of the battery.
1. Open engine hood (1).

6. Remove cover (6-1) and 2 tubes (6-2). [*1]
7. Remove tubes (6-3) and (6-4). [*2]
2. Disconnect connector M01 (2) from the rear of

the reservoir tank.
8. Disconnect fuel hose (7).
9. Remove fuel hose (8) between the filters. [*3]
10. Remove 2 tubes (9) and clamp assembly. [*4]
11. Remove 2 filter and bracket assemblies (10).
12. Disconnect 2 tubes (11). [*5]
13. Remove filter and bracket assembly (12). [*5]
3. Disconnect reservoir tank hoses (3).
4. Remove bar (4).
5. Disconnect hose and bracket assemblies (5)

and (6).
HM300-2R 7
14. Disconnect wiring harness and plate assembly 21. Remove the air conditioner compressor. For
(14). details, see "Removal of fuel supply pump
assembly". (Do not disconnect the air condi-
15. Remove diffuser and pump assembly (17). tioner hoses.)
4 Diffuser and pump assembly: 25 kg
22. Using the side hole of the fan pulley, set
stamped line L of 1•6 TOP of damper (D) to
pointer P.
a Rotate the crankshaft. For details, see Test-
ing and adjusting, Testing and adjusting
valve clearance.
16. Remove cover (18). [*6]
23. Remove blow-by hose (24).
24. Remove cylinder head cover (25). [*7]
17. Remove 6 clamps (19). [*6]
18. Remove 6 bellows (20) and 6 bellows (21). [*6]
19. Remove high-pressure pipe assemblies (22). [*6]
20. Remove 2 clamps (23).
8 HM300-2R
25. Disconnect 2 capture nuts (26). Installation

a The capture nuts are so installed that they
will not fall. • Fuel injector assembly
1. Install gasket (34) and O-rings (35) and (36) to
26. Loosen locknut (27) and adjustment screw (28). fuel injector assembly (33).
2 O-ring: Engine oil (EO30-DH)
27. Remove mounting bolts (29) and rocker arm

and shaft assembly (30).
2. Insert holder (32) in fuel injector assembly (33)

and insert inlet connector (37) in the rocker
28. Remove holder mounting bolts (31) and then housing, directing it to the hole to insert the
remove holder (32) and fuel injector assembly high-pressure pipe.
(33) together.
a Never hold the solenoid valve unit at the top 3. Install spherical washer (38) to bolt (31) and
of the injector with pliers, etc. temporarily tighten holder (32).
a Check that the holder is inserted firmly to
the end.
Engine oil (EO30-DH)
4. Permanently tighten bolt (31) of holder (32).

58.8 – 73.5 Nm {6.0 – 7.5 kgm}
HM300-2R 9
• Rocker arm and shaft assembly

1. Set rocker arm and shaft assembly (30).
a When installing the rocker arm shaft, direct
its larger mounting hole end down and its
ball plug (43) end forward.
2. Check that the ball of adjustment screw (28) is

fitted in push rod socket (42) and tighten mount-
ing bolts (29).
a Before installing, clean the oil holes.
3 Mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
3. Adjust the valve clearance. For details, see

Testing and adjusting, "Testing and adjusting
valve clearance". [*3]
3
3 Locknut (27):
Joint bolt of fuel hose (8):
58.8 – 73.5 Nm {6 – 7.5 kgm} 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
• Fuel injector wiring harness [*4]

3 Joint bolt on filter (upper) side of tube (9):
4. Tighten 2 capture nuts (26) of the wiring har-
ness into injector assembly (33). 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
3
3 Capture nut:
Joint bolt on fuel supply pump (lower)
2.0 – 2.4 Nm {0.2 – 0.24 kgm} side of tube (9):
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
3 Joint bolt on fuel cooler (lower) side of
tube (9):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
3 Clamp of tube (9):
27 – 34 Nm {2.8 – 3.5 kgm}
[*5]
Filter and bracket assembly (12) and tube (11)
1. Finger tighten filter and bracket assembly
(12).
2. Finger tighten tube (11).
3. Permanently tighten tube (11).
4. Permanently tighten filter and bracket
assembly (12).
order to removal.
[*1]
3 Joint bolt of tube (6-2):
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
[*2]
3 Sleeve nut on air vent (upper) side of
tube (6-3): 60 – 68 Nm {6.1 – 6.8 kgm}
3 Joint bolt on block (lower) side of tube
(6-3): 44.1 – 53.9 Nm {4.5 – 5.5 kgm}
3 Joint bolt on air vent (upper) side of tube
(6-4): 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
of tube (6-4):
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
10 HM300-2R
[*6] 4. Installation procedure for clamps and brackets

• High-pressure pipe assembly 3 Mounting bolt of clamp and bracket (Per-
k Do not bend the high-pressure pipe to cor- manently tightening):
rect before installing. 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
k Be sure to use the genuine high-pressure
pipe clamps and observe the tightening 1) Finger tighten 6 clamps (39) and 6 brackets
torque. (19).
2) Permanently tighten clamps (39) and brack-
a When installing each high-pressure pipe, check ets (19) in order.
the taper seal of its joint (Part "a": Part of 2 mm 3) Finger tighten 4 hollow clamps (40).
from the end) for visible lengthwise slit "b" and 4) Finger tighten clamp (41) to bracket (18)
spot "c" and check part "d" (End of taper seal: and then permanently tighten it.
Part at 2 mm from the end) for stepped-type 5) Permanently tighten bracket (18).
wear caused by fatigue which your nail can feel. 6) Permanently tighten 4 hollow clamps (40).
If there is any of those defects, it can cause fuel
leakage. In this case, replace the high-pressure
pipe.

(22).
a Loosen all of the high-pressure pipe clamps.
2. Permanently tighten high-pressure pipe assem-

bly (22).
3 Sleeve nut of high-pressure pipe assem-
bly (22) (on both sides):
39.2 – 49 Nm {4 – 5 kgm}
3. Install 6 bellows (20) and 6 bellows (21) each to

each high-pressure pipe. [*7]
a When each bellows, take care of the direc- • Cylinder head cover
tion of the slit. a Check that the O-ring is installed without
• Fuel injector side: To be directed down. being twisted.
• Common rail side: To be directed to cyl- 3 Mounting bolt:
inder block (upper) side. 9.8 ± 1 Nm {1.0 ± 0.1 kgm}
a The bellows are installed so that fuel will not
spout over the hot parts of the engine and k Check that each high-pressure pipe and
catch fire when it leaks for some reason. wiring harness are at least 10 mm apart
from each other.
HM300-2R 11
Removal and installation of 1. Open engine undercover (1).

cylinder head assembly 1
Special tool
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
A2 790-331-1110 Wrench (Angle) q 1
X1 792-454-1100 Pump assembly q 1 N
Removal
precautions to prevent a serious injury or 2. Open engine hood (2).
straight ahead position and stop the
lock knob.
chock the wheels.
k Set the lock bar to the frame and lock front
and rear frame.
• Precautions in tilting cab

lever is fixed securely. 3. Drain the coolant.
k Do not start the engine while the cab is 6 Coolant: 59 l
tilted.
under the cab.
lever.

k If the coolant temperature in the radiator is
high, you may be scalded. In this case,
wait until the coolant temperature lowers
and then drain the coolant.
12 HM300-2R
4. Sling operator's cab assembly (3) and tilt it up. 7. Remove air tube-hose-bracket assemblies (5)
a Use 2 shackles (S) so that hook (F) of the and (6). [*1]
sling will not hit glass (G) of the cab assem-
bly. 8. Disconnect air vent hose (7).
5. Pull lock lever (2-1) and set lock bar (B) with the 9. Disconnect reservoir tank hose (8).
care the direction of the lock bar (B).
k Check that the lock lever (2-1) closes and 10. Remove fan guard (9).
the operator cab assembly (3) is held
securely in position by the lock bar (B). 11. Remove air tube and hose assembly (10). [*2]
For details, see Testing and adjusting, Method
of tilting up cab.
a Pump assembly X1 is necessary for tilting
up by tilt cylinder.

the reservoir tank.
13. Disconnect reservoir tank hose (13).
6. Remove cover (4). 14. Remove bars (14) and (15).
HM300-2R 13
15. Loosen the mounting bolts of bracket (16). 21. Remove cover (30-1) and 2 tubes (30-2). [*4]
16. Remove exhaust tube (17). 22. Remove tubes (30-3) and (30-4). [*5]
17. Remove covers (18) – (22). 23. Remove fuel hose (31) between the filters. [*6]
24. Remove 2 tubes (32) and clamp assembly. [*7]
25. Remove 2 filter and bracket assemblies (33).
26. Disconnect 2 tubes (34). [*8]
27. Remove filter and bracket assembly (35). [*8]
18. Disconnect fuel hoses (27) and (28).
19. Remove filter and bracket assembly (29).
20. Disconnect heater terminal (30). [*3]
14 HM300-2R
28. Disconnect blow-by hose (36). 34. Disconnect turbocharger lubrication oil outlet
tube (46).
29. Remove pipe (37).
35. Temporarily sling turbocharger and exhaust
30. Remove turbocharger lubrication oil inlet tube manifold assembly (47).
(38). [*9]
31. Disconnect wiring harness and plate assembly

(40).
36. Lift off turbocharger and exhaust manifold

assembly (47). [*10]
4 Turbocharger and exhaust manifold
assembly: 40 kg
32. Disconnect connectors TIM (41) and PIM (42).
a While lowering lock (L), pull out connector
(41).
33. Disconnect wiring harness and plate assembly

(40).
37. Disconnect wiring harness (54).
HM300-2R 15
39. Remove bracket (62). 43. Disconnect 6 injector connectors (71).
40. Remove diffuser and pump assembly (63). 44. Disconnect wiring harness and bracket assem-
4 Diffuser and pump assembly: 25 kg bly (72).
41. Remove air housing (69). 45. Disconnect 6 clamps (73). [*11]
46. Remove 6 bellows (74) and 6 bellows (75). [*11]
47. Remove high-pressure pipe assembly (76). [*11]
48. Disconnect clamp (77).
49. Disconnect bracket (78).
16 HM300-2R
50. Lift off air intake24 manifold (79). 53. Remove spill tube (80).
4 Air intake manifold: 25 kg
54. Remove air vent tube (81).
55. Remove cylinder head cover (82).
51. Remove the air conditioner compressor. For

details, see Removal of fuel supply pump
assembly. (Do not disconnect the air condi-
tioner hoses.) 56. Disconnect 2 capture nuts (83).
a The capture nuts are so installed that they
52. Using the side hole of the fan pulley, set will not fall.
stamped line L of 1•6 TOP of damper (D) to
pointer P. 57. Loosen locknut (84) and adjustment screw (85).
a Rotate the crankshaft. For details, see Test-
ing and adjusting, Testing and adjusting 58. Remove mounting bolts (86) and rocker arm
valve clearance. and shaft assembly (87).
59. Remove 12 push rods (88).
HM300-2R 17
60. Remove holder mounting bolts (89) and then Installation

remove holder (90) and fuel injector assembly
(91) together. • Cylinder head assembly
a Never hold the solenoid valve unit at the top 1. Check that the cylinder head mounting surface
of the injector with pliers, etc. and the inside of the cylinder are free from dirt
and foreign matter and then set cylinder head
gasket (100).
a When installing the gasket, check that the
grommet is fitted normally.
61. Remove 12 crossheads (92).
62. Remove rocker arm housing (93).
63. Remove cylinder head assembly (94). 2. Check the following items of the cylinder head
mounting bolts. If any bolt is out of the stan-
dard, do not use it but replace it.
1) The number of tightening times of the bolt
(indicated by the number of punch marks)
must be 5 or less.
2) Using limit of stem length "a" of bolt: Below
171.4 mm.
18 HM300-2R
3. Using slings [1], lift up cylinder head assembly a When not using tool A2, make marks "b" on
(94) and set it on the cylinder block. the cylinder head and bolt with paint and
4 Cylinder head assembly: 20 kg then tighten the bolt by 90 – 120° (Target:
120°).
1] Make a punch mark "c" on the mounting
bolt head to indicate the number of tight-
ening times.
a When a new bolt is used, do not
make a punch mark on its head.
4. Tighten the cylinder head mounting bolts in the

order of 1 – 6 and then tighten auxiliary bolt 7.
2 Mounting bolt (1 – 6 in following figure):
Molybdenum disulfide grease (LM-P)
or engine oil (EO30-DH).
3 Mounting bolt (1 – 6 in following figure)
1st time: 98.1 ± 9.8 Nm {10 ± 1 kgm} 5. Fit the gasket to cylinder head assembly (94)
2nd time: and install rocker arm housing (93).
166.6 – 176.4 Nm {17 – 18 kgm} 3 Mounting bolt:
(Target: 176.4 Nm {18 kgm}) 58.8 – 73.5 Nm {6 – 7.5 kgm}

3rd time: Using tool A2, tighten by 90 –
120° (Target: 120°). • Crosshead
3 Auxiliary bolt (7 in following figure): 1) Set crosshead (92), loosen locknut (101),
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm} and return adjustment screw (102).
2) Hold the rocker arm contacting surface of
crossheads (92) lightly with the finger to
keep crosshead (92) in contact with the
valve stem on the push rod side.
3) Tighten adjustment screw (102) until cross-
heads (92) touches the other valve stem.
4) After adjustment screw (102) touches the
valve stem, tighten it further by 20° and
tighten locknut (101) under this condition.
2 Crosshead guide and top of crosshead:
3 Locknut: 58.7 ± 5.9 Nm {6.0 ± 0.6 kgm}
HM300-2R 19
• Fuel injector assembly • Rocker arm and shaft assembly

6. Install gasket (103) and O-rings (104) and (105) 11. Set rocker arm and shaft assembly (87).
to fuel injector assembly (91). a When installing the rocker arm shaft, direct
2 O-ring: Engine oil (EO30-DH) its larger mounting hole end down and its
ball plug (108) end forward.
12. Check that the ball of adjustment screw (85) is

fitted in push rod socket (109) and tighten
mounting bolts (86).
a Before installing, clean the oil holes.
3 Mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
13. Adjust the valve clearance. For details, see

Testing and adjusting, Testing and adjusting
valve clearance.
3 Locknut (84):
58.8 – 73.5 Nm {6 – 7.5 kgm}
7. Insert holder (90) in fuel injector assembly (91)
and insert inlet connector (106) in the rocker • Fuel injector wiring harness
housing, directing it to the hole to insert the 14. Tighten 2 capture nuts (83) of the wiring har-
high-pressure pipe. ness into injector assembly (91).
3 Capture nut:
8. Install spherical washer (107) to bolt (89) and 2.0 – 2.4 Nm {0.2 – 0.24 kgm}
temporarily tighten holder (90).
a Check that the holder is inserted firmly to
the end.
9. Permanently tighten bolt (89) of holder (90).

58.8 – 73.5 Nm {6.0 – 7.5 kgm}
10. Install the 12 push rods.
20 HM300-2R
15. Fit the O-ring and install cylinder head cover • Carry out the rest of installation in the reverse
(82). order to removal.
a When installing the O-ring, do not twist it. a For the photos corresponding to the Nos., see
3 Mounting bolt: Removal.
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
[*1]
16. Fit the gaskets to both sides, install air vent tube a Set the tightening portions of the 2 clamps
(81). on the exactly opposite side to each other
3 Joint bolt: so that they can be tightened from the same
9.8 – 12.7 Nm {1.0 – 1.3 kgm} direction.
3 Clamp on aftercooler side:
17. Fit the gaskets to both sides, install spill tube 8.8 ± 0.5 Nm {0.90 ± 0.05 kgm}
(80). 3 Clamp on engine side:
3 Joint bolt: 9.8 ± 0.5 Nm {1.0 ± 0.05 kgm}
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
[*2]
a Set the tightening portions of the 2 clamps
on the exactly opposite side to each other
so that they can be tightened from the same
direction.
3 Clamp: 8.8 ± 0.5 Nm {0.90 ± 0.05 kgm}
[*3]
3 Heater terminal:
5.88 – 7.48 Nm {0.6 – 0.8 kgm}
[*4]
3 Joint bolt of tube (30-2):
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
• Intake manifold
18. Tighten the mounting bolts in the numeric order [*5]
shown below. 3 Sleeve nut on air vent (upper) side of
3 Mounting bolt: tube (30-3): 60 – 68 Nm {6.1 – 6.8 kgm}
59 – 74 Nm {6 – 7.5 kgm} 3 Joint bolt on block (lower) side of tube
(30-3): 44.1 – 53.9 Nm {4.5 – 5.5 kgm}
3 Joint bolt on air vent (upper) side of tube
(30-4): 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
of tube (30-4):
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
[*6]
3 Joint bolt of fuel hose (31):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*7]
3 Joint bolt on filter (upper) side of tube
(32): 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
3 Joint bolt on fuel supply pump (lower)
side of tube (32):
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
3 Joint bolt on fuel cooler (lower) side of
tube (32):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
3 Clamp of tube (32):
27 – 34 Nm {2.8 – 3.5 kgm}
HM300-2R 21
[*8] [*11]
Filter and bracket assembly (35) and tube (34) • High-pressure pipe assembly
k Do not bend the high-pressure pipe to cor-
1. Finger tighten filter and bracket assembly (35). rect before installing.
k Be sure to use the genuine high-pressure
2. Finger tighten tube (34). pipe clamps and observe the tightening
torque.
3. Permanently tighten (34).
a When installing each high-pressure pipe, check
4. Permanently tighten filter and bracket assembly the taper seal of its joint (Part "a": Part of 2 mm
(35). from the end) for visible lengthwise slit "b" and
spot "c" and check part "d" (End of taper seal:
[*9] Part at 2 mm from the end) for stepped-type
3 Sleeve nut: 40 – 44 Nm {4.1 – 4.5 kgm} wear caused by fatigue which your nail can feel.
If there is any of those defects, it can cause fuel
[*10] leakage. In this case, replace the high-pressure
• Exhaust manifold pipe.
Tighten bolts [1], [2], and [3] first and then
tighten the other bolts.
3 Mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}

(76).
a Loosen all of the high-pressure pipe clamps.
2. Permanently tighten high-pressure pipe assem-

bly (76).
3 Sleeve nut (on both sides):
39.2 – 49 Nm {4 – 5 kgm}
3. Install 6 bellows (74) and 6 bellows (75) each to

each high-pressure pipe.
a When each bellows, take care of the direc-
tion of the slit.
• Fuel injector side: To be directed down.
• Common rail side:
To be directed to cylinder block (upper) side.
a The bellows are installed so that fuel will not
spout over the hot parts of the engine and
catch fire when it leaks for some reason.
22 HM300-2R
4. Installation procedure for clamps and brack-

ets
3 Mounting bolt of clamp and bracket
(Permanently tightening):
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
1) Finger tighten 6 clamps (110) and 6 brack-
ets (73).
2) Permanently tighten clamps (110) and
brackets (73) in order.
3) Finger tighten 4 hollow clamps (111).
4) Finger tighten clamp (112) to bracket (70)
and then permanently tighten it.
5) Permanently tighten bracket (70).
6) Permanently tighten 4 hollow clamps (111).
k Check that each high-pressure pipe and

wiring harness are at least 10 mm apart
from each other.
• Refilling with coolant

Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
5 Coolant: Approx. 59 l
HM300-2R 23

engine front seal 1
Special tools
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
3 795-931-1100 Seal puller assembly t 1
795T-521-1140 Push tool t 1 Q
A 790-101-5221 Grip t 1
6
01010-81225 Bolt t 1
01050-31640 Bolt t 3
Removal 6. Remove front seal (7) according to the following

procedure.
1. Remove the cooling assembly. For details, see
1) Make several holes about 3 mm in diameter
"Removal of cooling assembly".
with a drill on front seal (7).
2) Set tool A3 to the drilled holes. (Tip: Drill
2. Loosen alternator (1) and remove alternator belt
type)
(2). [*1]
3) Remove the front seal with impacts of slide
hammer (SH).
3. Loosen air conditioner compressor (3) and
a Remove all the chips.
remove air conditioner compressor belt (4). [*2]
• Tool A3
4. There is a stamped line of 1•6TOP on damper
(D). Make a matchmark (A) on damper (D) and
front cover (FC).
5. Remove 6 mounting bolts (5) and pulley and

damper assembly (6). [*3]
4 Pulley and damper assembly: 30 kg
24 HM300-2R
Installation • Carry out the rest of installation in the reverse

order to removal.
1. Clean, degrease, and dry the contacting surface
against the front cover. [*1]
Adjust the alternator belt tension. For details,
2. Remove the matter sticking to the crankshaft see Testing and adjusting, Testing and adjusting
flange with clean cloth. alternator belt tension.
a Clean, degrease, and dry the seal lip sur-
face (peripheral surface of the crankshaft). [*2]
a Check that the end corner and lip sliding Adjust the air conditioner compressor belt ten-
surface of the crankshaft are free from flaw, sion. For details, see Testing and adjusting,
burr, sharp fin, rust, etc. Testing and adjusting air conditioner compres-
sor belt tension.
[*3]
a There are 2 kinds in the pulley and damp
assembly mounting bolts. Take care.
3 M14 (1 piece):
157 – 196 Nm {16 – 20 kgm}
3 M16 (5 pieces):
245 – 309 Nm {25 – 31.5 kgm}
3. Evenly tighten the bolts to press fit front seal (7)

until the end of tool A6 touches the end of cover
(10).
a Take care not to mistake the installing direc-
tion.
2 Front seal lip (50 – 80% full of hollow part
of lip): Grease (G2-LI)
a When press fitting the front seal, take care
extremely not to damage the lip on this side
with the tool set.
a Installed dimension of front oil seal (7) from
end of cover (10).
a: 16 – 17 (mm)
HM300-2R 25
Removal and installation of a If real seal (2) cannot be removed from the
engine rear seal 1 crankshaft easily, remove it according to the
Special tools 1) Change the tip of tool A3 to the hook type.
2) Hitch the hook to the metal ring of seal (2).
New/Remodel
3) Remove the rear seal with impacts of slide
Sym- hammer (SH).
Necessity
Part No. Part name
bol a Before pulling out the seal, drive in it a little to
Sketch
Q'ty
separate.
3 795-931-1100 Seal puller assembly t 1 a If the seal is sleeved, cut and remove sleeve (5)
795-931-1210 Push tool t 1 with a chisel and a hammer.
4 01050-31625 Bolt t 3 a Take care not to damage crankshaft (4).
A
01050-31645 Bolt t 3
795-931-1220 Push tool t 1 • Tool A3
5
01050-31645 Bolt t 3
Removal
1. Remove the output shaft assembly. For details,
see "Removal and installation of output shaft
assembly".
2. Install sling [1] to flywheel (1) and lift up the fly-

wheel temporarily.
3. Remove the 6 mounting bolts and remove fly-

wheel (1) from the dowel pin and lift it off. [*1]
4 Flywheel: 25 kg
4. Remove rear seal (2).

a Take care not to damage the seal mounting
section of the flywheel housing and the seal
contacting surface of the crankshaft.
26 HM300-2R
Installation • Procedure for installing standard seal

a Do not apply grease, oil, etc. to the seal lip sur-
a Check the Teflon seal (Laydown lip seal) by face.
checking the wear of the shaft and replace it 1) Set the large inside diameter side "b" of
with the "standard seal" or "sleeved seal". plastic inside cylinder (3) of rear seal (2) to
a If the shaft is worn to the degree of luster (If the end of crankshaft (4).
wear which you feel with your finger is less than a Take care not to mistake the direction of
10 m) and does not have any flaw, install the the plastic inside cylinder.
standard seal A. In other cases, install the
sleeved seal B.
a (3): Plastic inside cylinder which is also used as
installation guide
a (5): Sleeve
a Do not remove installation guide (3) from rear
seal (2) before installing it.
a Handle rear seal (2) and sleeve (5) as an
assembly and never separate them from each
other.
2) Hold the metal ring of rear seal (2) with both

hands and push it in firmly.
3) After pushing in the rear seal, remove plas-
tic inside cylinder (3).
a When removing the inside cylinder, take
care not to damage the seal lip.
a Clean, degrease, and dry the contacting surface

against the flywheel housing.
a Clean, degrease, and dry the seal lip surface
(peripheral surface of the crankshaft).
a Check that the end corner and lip sliding surface
of the crankshaft are free from flaw, burr, sharp
fin, rust, etc.
HM300-2R 27
4) Tighten the bolts evenly to press fit rear seal 2) Set the sleeve of the rear seal to the end of
(2) until the end of tool A4 reaches the end the crankshaft, and then tighten the bolts
of crankshaft (4). evenly to press fit sleeve and rear seal
a Driving depth of rear seal: assembly (6) until the end of tool A5
10 ± 0.2 (mm) from end of crankshaft reaches the end of crankshaft (4).
a First, tighten tool A4 until the bolt (Stem
length: 45 mm) stops, then tighten the
bolt (Stem length: 25 mm).
a When press fitting the seal, take care
not to damage the lip on this side with
the tool set, etc.
a After press fitting the seal, remove the
red sealant layer from its periphery.
3) Remove tool A5 and install tool A4.

4) Tighten the bolts evenly to press fit sleeve
and rear seal assembly (6) until the end of
tool A4 reaches the end of crankshaft (4).
a After press fitting the rear seal, remove
the red sealant layer from its periphery.
a Driving depth of rear seal:
10 ± 0.2 (mm) from end of crankshaft
• Procedure for installing sleeved seal
a Do not apply grease, oil, etc. to the seal lip sur-
face.
1) Set sleeve and rear seal assembly (6) to
tool A5.
2 Inside surface (C) of sleeve:

order to removal.
28 HM300-2R
[*1]
Flywheel
1. Tighten the mounting bolts twice in the numeric
order shown below.
2 Mounting bolt: Engine oil (EO30-DH)
3 Mounting bolt
1st time: 147 ± 19.6 Nm {15 ± 2.0 kgm}
2nd time: 289.1 ± 19.6 Nm {29.5 ± 2.0 kgm}
2. Using dial gauge [3], measure the facial runout

and radial runout.
a Facial runout: Max. 0.20 mm
a Radial runout: Max. 0.15 mm
HM300-2R 29
Removal and installation of 1. Open engine undercover (1).

engine assembly 1
Special tool
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
792T-220-1310 Centering tool t 2 N Q
A 7
01050-61225 Bolt t 8
X 1 792-454-1100 Pump assembly q 1 N
Removal
k When tilting the cab, observe the following 2. Open engine hood (2).
lock knob.
chock the wheels.
and rear frame.

k When tilting the cab, check that the lock 3. Remove radiator cap and then drain the cool-
lever is fixed securely. ant.
k Do not start the engine while the cab is a Location of drain valves
tilted. • Lower tank – 2 pcs
k When it is obliged to start the engine for • Oil cooler – 1 pc
testing etc., check that there is nobody 6 Coolant: 59l
under the cab.
lever.

30 HM300-2R
4. Sling operator's cab assembly (3) and tilt it up. 7. Remove air tube-hose-bracket assemblies (5)
a Use 2 shackles (S) so that hook (F) of the and (6). [*1]
bly. 8. Disconnect air vent hose (7).
5. Pull lock lever (2-1) and set lock bar (B) with the 9. Disconnect reservoir tank hose (8).
care the direction of the lock bar (B).
k Check that the lock lever (2-1) closes and 10. Remove fan guard (9).
securely in position by the lock bar (B). 11. Disconnect radiator inlet hose (10). [*2]
For details, see Testing and adjusting, Method
of tilting up cab. 12. Remove air tube and hose assembly (11). [*3]

the reservoir tank.
6. Remove cover (4).
HM300-2R 31
14. Disconnect reservoir tank hose (13). 20. Disconnect drive shaft (19). [*4]
a Socket size: 3/4 in.
15. Remove bars (14) and (15).
21. Disconnect clamps (20) and (21).

16. Loosen the mounting bolts of bracket (16).
17. Remove exhaust tube (17).
22. Disconnect terminals 80 (22), E1 black (23),

and E1 red (24) from the alternator. [*5]
18. Disconnect clamp (18). 23. Disconnect heater hose (25).
19. Remove bracket (16). 24. Disconnect clamp (26).
32 HM300-2R
25. Disconnect clamp (27). 31. Disconnect fuel hose (36).
26. Disconnect 2 terminals (28) from the starting

motor. [*6]
27. Disconnect heater hose (29) from the top of the

starting motor.
32. Disconnect connectors J3P (39) and J2P (40)

from the engine controller.
a Disconnect clamps, too.
28. Disconnect connector 78 (30), ground terminals

(31) and (32), and connector OL (33) from the
right of the starting motor.
33. Disconnect fuel return hose (41) from the com-

mon rail (at the left rear of the engine unit).
34. Disconnect clamp (42) of fuel return hose (41).
35. Disconnect ground terminal GS (43).

29. Disconnect hose (34).
30. Disconnect water tube (35).

a Replace the gasket (G).
a If hose (H) is disconnected, the work will
take more than 1 hour.
HM300-2R 33
36. Disconnect connector COMP (44). 47. Remove fan assembly (54).
37. Disconnect wiring harness clamp (45).
38. Disconnect connector CM (46).
39. Loosen adjustment nut (47) of the air condi-

tioner compressor.
40. Loosen the mounting bolts of air conditioner

compressor (48).
41. Remove air conditioner compressor belt (49).

[*7]
42. Remove rod and plate assembly (50). 48. Remove engine mounting bolts (55). [*9]
a The nut plate (NP) comes off the reverse
43. Remove air conditioner compressor (48) from side.
bracket (51).
a Do not disconnect air conditioner compres-
sor hoses but place the air conditioner com-
pressor on this side.
44. Remove air conditioner compressor bracket

(51).
49. Disconnect air hose (56). [*10]
50. Remove air cleaner (57).
45. Disconnect fuel return hose (52).
46. Disconnect heater terminal (53). [*8]
34 HM300-2R
51. Loosen alternator locknut (58). 59. Disconnect clamps (66).
52. Remove alternator belt (59). 60. Disconnect bracket (67).
53. Remove alternator (60). [*11]
54. Remove engine mounting bolts (61). [*12]
61. Disconnect emergency steering motor ground

terminal (68).
62. Loosen engine mounting bolts (69). [*14]

55. Disconnect blow-by hose (62).
63. Remove mounting bolts (70) of the engine
56. Disconnect aeration tube (63). mounting bracket (MB).
57. Remove cylinder head cover (64). [*13]

a P: Plate to hitch sling
64. Disconnect engine assembly (65) from the

engine mounting bracket (MB).
a NP: Dowel pin
58. Temporarily sling engine assembly (65).
HM300-2R 35
65. Lift off engine assembly (65). Installation

4 Engine assembly: 1,400 kg
• Carry out installation in the reverse order to
removal.
[*1]
direction.
3 Clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*2]
3 Radiator hose clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
direction.
Positions of hose clamps
• B: Bulge
• C: Clamp
• H: Hose
• T: Tube
a Between bulge and inside clamp:
Max. 5 mm
a Between hose end and outside clamp:
5 – 10 mm
[*3]
direction.
3 Clamp: 8.8 ± 0.5 Nm {0.90 ± 0.05 kgm}
[*4]
a If the engine assembly, transmission and
torque converter assembly, drive shaft was
removed, align them in the lateral direction
with tools A7 according to the following pro-
cedure.
1) Install tools A7 to the coupling on the engine
side and the coupling on the torque con-
verter side.
36 HM300-2R
2) Apply rules [1] to both sides of tools A7. [*5]

3) Measure respective clearances "a" and "b" a Alternator terminal
between rules [1] and tools A7 on both 3 Size M5:
sides. 1.9 – 2.5 Nm {0.19 – 0.25 kgm}
a Check that the clearances at the widest 3 Size M6:
position are 3 mm or less on both sides. 3.2 – 4.4 Nm {0.33 – 0.45 kgm}
(If the clearances are not even, check
that the widest clearance is 3 mm or [*6]
less.) 3 Starting motor terminal (M10):
a If the level difference is larger than 3 19.6 – 25.5 Nm {2 – 2.6 kgm}
mm, reduce them by moving the engine
assembly. [*7]
Adjust the air conditioner compressor belt ten-
sion. For details, see Testing and adjusting,
"Testing and adjusting air conditioner compres-
sor belt tension".
[*8]
3 Heater terminal:
5.88 – 7.48 Nm {0.6 – 0.8 kgm}
[*9], [*12], [*14]

3 Engine mounting bolt (4 places):
662 – 829 Nm {67.5 – 84.5 kgm}
[*10]
a When installing the drive shaft, check 3 Clamp: 8.8 ± 0.5 Nm {0.90 ± 0.05 kgm}
that the convex section on the spider
cap is fitted in the groove of the mating [*11]
yoke, and then tighten the mounting Adjust the alternator belt tension. For details,
bolts. see Testing and adjusting, "Testing and adjust-
2 Mounting bolt: Liquid adhesive (LT-2) ing alternator belt tension".
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm} [*13]
Target: 113 Nm {11.5 kgm} • Cylinder head cover
a After the drive shaft between the engine and a Check that the O-ring is installed without
transmission is installed, measure distance being twisted.
"a" between the flywheel housing and cou- 3 Mounting bolt:
pling end. If distance "a" is out of the follow- 9.8 ± 1 Nm {1.0 ± 0.1 kgm}
ing range, adjust it into the standard range
by moving the engine assembly. • Refilling with coolant
• Distance between flywheel housing and Add coolant through the coolant filler to the
coupling end specified level. Run the engine to circulate the
a: 153.2 – 156.2 mm coolant through the system. Then, check the
5 Coolant: 59 l
• Bleeding air
See Testing and adjusting, "Bleeding air from
each part".
HM300-2R 37
Removal and installation of 4. Disconnect aeration hose (3).

radiator assembly 1
5. Disconnect reservoir tank hoses (4) and (5).
Removal
the engine.
k Chock the wheels.
1. Open engine undercover (1).
7. Disconnect cover (7).
8. Remove plate (8).
9. Disconnect radiator inlet hose (9). [*1]
10. Remove radiator hose (10). [*2]
3. Remove radiator cap and then drain the cool-

ant.
a Location of drain valves
• Lower tank – 2 pcs
• Oil cooler – 1 pc
6 Coolant: 59l
38 HM300-2R
12. Remove fan assembly (12). 18. Remove radiator assemblies (18) and (19). [*5]
13. Disconnect shroud (13).
Installation
14. Disconnect the clamp of wiring harness (14) removal.
from underside.
[*1] – [*4]
15. Remove radiator tube clamp (15). 3 Radiator hose clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
16. Disconnect radiator hose (16). [*3] a If there are 2 clamps, set their tightening
portions on the exactly opposite side to
each other so that they can be tightened
from the same direction.
• B: Bulge
• C: Clamp
• H: Hose
• T: Tube
Max. 5 mm
5 – 10 mm
17. Remove radiator hose (17). [*4]
[*5]
If the seal (sponge) is damaged, replace it.

5 Coolant: 59 l
HM300-2R 39
Removal and installation of 4. Remove cover (4).

cooling assembly 1
Removal
the engine.
k Chock the wheels.
and then drain the coolant. 5. Remove air tube-hose-bracket assemblies (5)
and (6). [*1]
1. Open engine undercover (1).
6. Disconnect aeration hose (7).
7. Disconnect reservoir tank hose (8).
8. Disconnect radiator inlet hose (9). [*2]
10. Remove fan assembly (11).
3. Remove radiator cap and then drain the cool-

ant.
a Location of drain valves
• Lower tank – 2 pcs
• Oil cooler – 1 pc
6 Coolant: 59 l
40 HM300-2R
11. Disconnect the clamp of wiring harness (12) 15. Remove nut (15).
from underside.
16. Loosen nut (16) and disconnect rod (17).
12. Remove radiator tube clamp (13). a Since there is not sufficient space on the
right side, make tool [2] by cutting a spanner
13. Disconnect radiator hose (14). [*3] of 24 mm and install an extension [3] to it for
the ease of work
17. Temporarily sling cooling assembly (18).

a Use mounting bracket (P) as a fulcrum.
18. Remove mounting bolts (19).
14. Secure air conditioner condenser (AC) with line

[1] and disconnect air conditioner condenser
(AC).
a For the EU specification model, fix line [1]
to sound absorbing blade (B).
19. Lift off cooling assembly (18).

a Tool [4] is used to lock the sling.
4 Cooling assembly: 160 kg
a View after cooling assembly is removed
a For models other than EU specification

model, fix line [1] to the grille, etc.
HM300-2R 41
Installation
removal.
[*1]
direction.
3 Clamp : 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*2], [*3]
3 Radiator hose clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
a If there are 2 clamps, set their tightening
portions on the exactly opposite side to
each other so that they can be tightened
from the same direction.
• B: Bulge
• C: Clamp
• H: Hose
• T: Tube
Max. 5 mm
5 – 10 mm

5 Coolant: 59 l
42 HM300-2R
Removal and installation of output 1. Drain the oil from the hydraulic tnak.
shaft assembly 1 6 Hydraulic tnak: 120 l
Special tool 2. Open engine hood (1).
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
A 7
01050-61225 Bolt t 8
X 1 792-454-1100 Pump assembly q 1 N
Removal
3. Remove 4 each mounting bolts from the right
and left mounts at the front of the cab.
a Check the thickness, quantity, and positions
of the inserted shims.
lock knob.
chock the wheels.
and rear frame.

lever is fixed securely.
tilted.
under the cab.
lever.

k Loosen the hydraulic oil filler cap to release
the internal pressure of the hydraulic tank.
HM300-2R 43
4. Sling opsserator's cab (3) and tilt it up. 6. Disconnect connector M01 (4) from the rear of
a Use 2 shackles (S) so that hook (F) of the the reservoir tank.
bly. 7. Disconnect reservoir tank hose (5).
5. Pull lock lever (2-1) and set lock bar (2) with the 8. Remove bars (6) and (7).
care the direction of the lock bar (2).
k Check that the lock lever (2-1) closes and
securely in position by the lock bar (2).
For details about cab tilt, see "Method of tilting
cab up" in chapter Testing and adjusting.
9. Disconnect the following piping from steering

and hoist pump (8).
• (9) – (11): Discharge hoses
• (13): Suction tube
44 HM300-2R
10. Lift off steering and hoist pump assembly (8). a When replacing oil seal (17), remove oil seal
4 Steering and hoist pump assembly: cage (16) with forcing screws [1] and re-
move oil seal (17) from the oil seal cage.[*3]
40 kg

11. Lift off drive shaft (14) between the engine and
transmission. [*1]
14. Remove plate (19) from cover (18). [*5]

a There is a seal between cover (18) and
12. Remove coupling (15). [*2] plate (19).
HM300-2R 45
15. Using guide bolts [2], lift off output shaft assem-
bly (20). [*6].
4 Output shaft assembly: 50 kg
46 HM300-2R
Installation [*4]
2 Between cover and flywheel housing (U):
• Carry out installation in the reverse order to Gasket sealant:
removal. ThreeBond 1207B or equivalent
3 Cover and plate assembly mounting bolt:
[*1] 58.8 – 73.5 Nm {6 – 7.5 kgm}
a For details, see Removal and installation of
engine assembly, Installation, [*4]. [*5]
2 Mounting bolt: Liquid adhesive (LT-2)
2 Contacting surfaces of seal cover and
3 Mounting bolt:
plate (V): Adhesive (ThreeBond No.
98 – 123 Nm {10 – 12.5 kgm} 1521 or equivalent)
2
Target: 113 Nm {11.5 kgm} Inside contacting surface of seal (W):
Grease (G2-LI)
3
[*2] Plate mounting bolt:
a Before installing the coupling, supply 20 cc 27.44 – 34.3 Nm {2.8 – 3.5 kgm}
of lithium molybdenum disulfide extreme
pressure grease to part S.
2 Lithium molybdenum disulfide extreme
pressure grease:
• Molylex No. 2 manufactured by
KHODO YUSHI or equivalent
• Retinax AM manufactured by
SHOWA SHELL SEKIYU or equiva-
lent
• Molytex No. 2 manufactured by
NIPPON OIL CORPORATION or
equivalent
a Before installing the coupling, apply molyb-

denum disulfide dry lubricant to its spline (R)
and dry in air for 2 - 3 minutes.
2 Molybdenum disulfide dry lubricant:
Rocol Dry Spray manufactured by
SUMICO LUBRICANT or equivalent
[*3]
a When installing the oil seal, fill space G
between the main lip and dust lip with G2-LI
or lithium molybdenum disulfide extreme
pressure grease.
a When installing the oil seal cage, supply 100
cc of lithium molybdenum disulfide extreme
pressure grease to part T.
2 Lithium molybdenum disulfide extreme [*6]
pressure grease: 2 Mounting bolt: Liquid adhesive (LT-2)
• Molylex No. 2 manufactured by 3 Output shaft assembly mounting bolt:
KHODO YUSHI or equivalent 58.8 – 73.5 Nm {6 – 7.5 kgm}
• Retinax AM manufactured by
SHOWA SHELL SEKIYU or equiva-
lent
• Molytex No. 2 manufactured by
NIPPON OIL CORPORATION or
equivalent
3 Oil seal cage mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
HM300-2R 47
Disassembly and assembly of 2. Outer body

output shaft assembly 1 1) Set outer body (5) on wooden blocks [2],
keeping it off the ground.
Disassembly 2) Separate outer body (5) from inner body (6),
hitting the inner body with push tool [3].
a Prepare for ENS grease (G2-U-S):
427-12-11871 (grease).
a In order not to lose the original balance of the
output shaft assembly due to disassembly, mark
a setting position on the flange and outer body
before disassembling.
1. Inner flange
1) Remove 12 flange mounting bolts (1).
2) Remove snap ring (2).
3. Rubber
Remove 4 large pieces of rubber (7) and 4 small
pieces of rubber (8).
3) Remove inside flange (3), using forcing

screws [1].
4. Outside flange and inner body

1) Reverse outside flange and inner body
assembly (9).
4) Remove bearing (4) from inside flange (3).
48 HM300-2R
3) Push inner body (11) out of outer flange (12) Assembly

with a press, using push tool [4]. 1. Outside flange and inner body
1) Press-fit bearing (13) into outside flange
(12).
a Fill the inside and outside of bearing
balls completely with lithium type
extreme-pressure grease containing
molybdenum disulfide.
2 Lithium type extreme-pressure grease
containing molybdenum sulfide:
• Molylex No. 2 of Kyodo Yushi or
equivalent
• Retinax AM of Showa Shell
Sekiyu or equivalent
• Molynoc No.2 of Nippon
Mitsubishi Oil or equivalent
2 Bearing outside contact face on out-
side flange and outside cylindrical
surface of bearing:
Loctite 601 or equivalent
4) Remove bearing (13) from outside flange

(12).
2) Set outside flange (12) on inner body (11),

and then press-fit, using push tool [5].
2 Bearing contact face on inner body
and intside cylindrical surface of
bearing: Loctite 601 or equivalent
HM300-2R 49
3) Install snap ring (10). 3. Rubber

Install 4 large pieces of rubber (7) and 4 small
pieces of rubber (8).
a Set the rubber pieces as shown in the photo
below.
2 When installing the rubber pieces, coat
all over the rubber, inner body periphery
and outer body periphery with ENS
grease (G2-U-S).
2 After installing the rubber pieces, fill each
"P" portion (4 points) between the rubber
and inner body evenly with 190 ml l of
ENS grease (G2-U-S).
a ENS grease (G2-U-S):
2. Outer body 427-12-11871
1) Reverse outside flange and inner body
assembly (9).
2) Press-fit outer body (5) into outside flange
and inner body assembly (9).
2 Mating face: Gasket sealant (LG-11)
50 HM300-2R
HM300-2R 51

© 2009 KOMATSU
All Rights Reserved
52 HM300-2R
SEN04031-00
HM300-2R


Power train, Part 1
Removal and installation of transmission and front differential assembly....................................................... 2
Disconnection and connection of front differential assembly and transmission assembly.............................. 8
Disassembly and assembly of front differential assembly............................................................................. 10
Disassembly and assembly of torque converter assembly ........................................................................... 25
HM300-2R 1
Removal and installation of 4. Disconnect clamp (2).

transmission and front differential 5. Sling vertical member (3) to remove.
assembly 1 4 Vertical member: 35 kg
Special tool
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
A 7
01050-61225 Bolt t 8
Removal
the engine.
6. Separate the following parts from the transmis-
k Chock the wheels.
sion upper front side.
k Set the lock bar to the frame. 1) Disconnect 3 discharging hoses (5) to (7)
k Disconnect the cable from the negative (–) from steering and hoist pump assembly (4).
terminal of the battery. 2) Remove suction tube (8).
1. Drain hydraulic oil.
6 Hydraulic tank: 120l
2. Drain oil from the transmission and brake oil
tank.
6 Transmission case and brake oil tank:
77.5l
3. Refer to the section of "removing and installing
the operator's cab assembly", sling operator's
cab assembly (1) to remove.
4 Operator's cab assembly: 1,200 kg 3) Sling steering and hoist pump assembly (4)
to remove.
4 Steering and hoist pump assembly
: 50 kg
2 HM300-2R
4) Remove upper and lower drive shaft guards 7. Disconnect grease hose (19) from the frame
(9), and then remove drive shaft (10) right side.
between the engine and transmission. [*1]
4 Drive shaft: 25 kg
5) Remove coupling (11) on the output shaft
side. [*2]
8. Disconnect grease hose (20) from frame left

side.
a HSTSC: Hydraulic tank suction tube
6) Disconnect transmission lubrication circuit

inlet hoses (12).
7) Disconnect front differential breather hose
(13).
8) Disconnect 3 discharging hoses (15), (16)
and (17) from the rear brake cooling and
brake actuating pump assembly (14).
9) Disconnect hose (18).
HM300-2R 3
9. Separate the following parts from the transmis-

sion upper rear side.
1) Disconnect clamp of the hose (21).
2) Disconnect torque converter outlet hoses
(22), (23) and (24) and return hose (25).
3) Disconnect hose (26).
6) Remove drive shaft (34) between the trans-

mission and hitch frame. [*3]
4 Drive shaft between transmission
and hitch frame: 30 kg
11. Disconnect left and right drive shafts (35) from

10. Separate the following parts from the rear left of the underside of the transmission. [*4]
the transmission. a Disconnect them at the front differential
1) Disconnect return hoses (29) to brake sub- side.
tank as well as breather hose (27) and (28)
from the oil supply piping.
2) Remove cover (30).
3) Remove tube (31) between the sub-tank
and oil supply piping.
4) Remove the mounting bolts of oil supply
hose (H) connector (32).
5) Disconnect oil supply piping (33).
4 HM300-2R
12. Remove the each mounting bolt. 13. Sling the transmission and front differential
Front differential mount (36) transmission assembly (39) slowly and remove it.
mounts front side (37) and rear side (38). a Make sure that no hose or wiring is left still
a Shims are installed, so check their thick- connected.
ness, number in use and installed location In particular, take good care to avoid inter-
beforehand. ference between the transmission lubrica-
tion inlet tube (return tube) on the front side
and the output shaft oil seal as well as inter-
ference between the rear left mount and the
hoist valve.
4 Transmission and front differential
assembly: 1,450 kg
HM300-2R 5
Installation a When measuring dimension "a" between

the flywheel housing and the coupling tip,
• Installation is carried out in the reverse order to
while drive shaft between the engine and
removal.
transmission is in place, and if this dimen-
sion "a" falls out of the value shown below,
[*1] make adjustment by shifting the position of
a When removing the engine assembly, trans- transmission and front differential assembly
mission and torque converter assembly or mount so that the dimension falls within the
drive shafts, carry out centering the engine specified value.
and transmission in the left and right direc- • Dimension "a" between flywheel housing
tion in the following manner, using tool A7. and coupling tip: 156.2 -30 mm
1) Install tool A7 to the coupling on the engine
side and the coupling on the torque con-
verter side.
2) Put scale [1] to the left and right sides of tool
A7.
3) Measure the clearance between scale [1]
and tool A7 on the left side (a) and on the
right side (b).
a Check that the max. clearance remains
below 3 mm both on the left and right
sides. (If both clearances are not in par-
allel, check that the clearance remains
less than 3 mm even at the widest point) [*2]
a If the clearance exceeds 3 mm, make a Coat the coupling spline area (S) with dry
adjustment by shifting the position of type lubricant of molybdenum disulfide, and
torque converter and transmission
install after it dries up in a few minutes.
assembly mount.
2 Dry type lubricant of molybdenum
disulfide:
Rocol Dry Spray of Sumico
Lubricant or equivalent
a When installing the drive shaft, check that

the convex section on the spider cap fully
engage with groove of the corresponding
yoke, and then tighten the mounting bolt.
3 Mounting bolt for drive shaft
between engine and transmission:
98 – 123 Nm {10 – 12.5 kgm}
[Target value: 113 Nm {11.5 kgm}]
6 HM300-2R
[*3] [*4] • Oil supply (hydraulic tank)

a When installing the drive shaft between the Refill with oil through the oil filler port up to the
transmission and hitch frame, turn it to face specified level, then start the engine to let oil cir-
in the same direction as the yoke of the culate in the piping and check the oil level
drive shaft between the hitch frame and again.
center differential. 5 Hydraulic tank: 120l (TO10)
a When installing drive shafts, check that the • Oil supply (transmission case and brake oil
convex section on spider cap fully engages tank)
with the groove of the counter yoke, and Refill with oil through the oil filler port up to the
then tighten the mounting bolts. specified level, then start the engine and run at
a Install the drive shaft between the transmis- low idle, and check the oil level again.
5
sion and hitch frame only after confirming Transmission and brake oil tank
that it faces in the same direction as the : 77.5l (TO10)
yoke of the drive shaft between the hitch
k
frame and center differential does. Air bleeding (brake)
2 Mounting bolt
After finishing the installation, bleed air from
: Liquid adhesive (LT-2) the brake circuit, referring to the section of
3 Mounting bolt for drive shaft between "Bleeding air from brake circuit" in Testing and
transmission and hitch frame and adjusting.
mounting bolt for left and right drive
shaft
: 98 – 123 Nm {10 – 12.5 kgm}
[*5]
a Install shims both for the front differential
mount and for the transmission rear mount.
Do not make a mistake about their right
location for installation.
• Standard shim thickness: 2 mm
• Kind of shim thickness:
0.5 mm (for front differential mount)
1.0 mm (for transmission rear mount)
3 Mounting bolt for front differential mount
: 1,150 – 1,440 Nm {118 – 147 kgm}
3 Mounting bolt for front transmission
mount: 157 – 196 Nm {16 – 20 kgm}
3 Mounting bolt for rear transmission
mount
: 235 – 285 Nm {23.5 – 29.5 kgm}
HM300-2R 7
Disconnection and connection of

front differential assembly and
transmission assembly 1
Disconnection
1. Remove pipes (1), (2).
2. Disconnect hose (3).
6. Remove mount bracket (7). [*1]

7. Sling transmission assembly (8) and front differ-
ential assembly (9) temporalily, and support
front differential assembly (9) with hydraulic jack
[1].
8. Remove the front differential assembly mount-
ing bolts, tighten left and right forcing screws [2]
3. Remove pipe (4). evenly and separate the front differential
assembly.
9. Pull out front differential assembly (9) with hoist
and a hydraulic jack [1] and remove. [*2]
4 Front differential assembly: 340 kg
4. Remove the rear brake cooling and brake actu-

ating pump (5).
4 Rear brake cooling and brake actuating
pump: 25 kg
5. Remove the torque converter, transmission and
front brake cooling pump (6).
4 Torque converter, transmission and front
brake cooling pump: 25 kg
8 HM300-2R
Connection
• Carry out connection in the reverse order to dis-
connection.
[*1]
2 Mount bracket mounting bolt
: Liquid adhesive (LT-2)
3 Mount bracket mounting bolt
: 455 – 565 Nm {46.5 – 58 kgm}
[*2]
2 Front differential mounting bolt
3 Front differential mounting bolt
: 245 – 309 Nm {25 – 31.5 kgm}
HM300-2R 9
Disassembly and assembly of 4. Coupling

front differential assembly 1 Remove holder (4) and coupling (5).
Special tools
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
1 792T-227-1110 Push tool t 1 Q
792T-423-1130 Push tool t 1 Q
H 2 790-101-5421 Grip t 1
01010-51240 Bolt t 1
3 790-201-2840 Spacer t 1
5. Removal of bevel pinion and cage assembly
Disassembly Remove bevel opinion and cage assembly (6),
using forcing screws [1].
1. Drive shaft cover a Shims are provided, so check their thick-
Remove drive shaft covers (1) at left and right. ness, number in use and installed locations
2. Upper cover beforehand.
Remove upper cover (2).
6. Further disassembly of bevel pinion and

3. Bevel gear fall-proof bolt cage assembly
Remove bevel gear fall-proof bolt (3). 1) Remove bevel pinion assembly (8) from
cage assembly (7), using push tool [2].
10 HM300-2R
2) Remove spacer (10) and bearing (11) from 8. Side carrier and shaft assembly and differ-
bevel pinion (9). ential gear assembly
1) Sling differential gear assembly (22), and
remove side carrier assemblies (23) and
(24), using forcing screws [3].
a Shims are provided, so check their
thickness, number in use and installed
locations beforehand.
2) Remove differential gear assembly (22)
from differential housing (25).
4 Differential gear assembly: 80 kg
3) Remove oil seals (13) and (14) from cage

(12).
4) Remove bearing (15) and outer races (16)
and (17).
9. Further disassembly of side carrier and

shaft assembly
1) Remove shaft and bearing assembly (27)
from side carrier assembly (26), using push
tool [4].
7. Left and right output shaft couplings

Remove holders (18) and then remove output
shaft couplings (19).
a Shims (56) are provided, so check their
thickness, number in use and installed loca-
tions beforehand.
HM300-2R 11
2) Remove bearing (29) from shaft (28). 2) Remove bearing (38) from case (37).
3) Remove oil seal (31) from carrier (30). 3) Remove washer (39).
4) Remove bearing (32) and outer races (33),
(34) and (35).
4) Remove 3 plates (40) and 2 discs (41).
10. Further disassembly of differential gear

assembly
1) Remove case and bearing assembly (36).
12 HM300-2R
5) Remove pressure ring (42). 8) Remove 4 pinion gears (46) and 4 bushings
a Put fingers into a hole on the case side (47) from shaft (45).
and lift.
9) Remove differential side gear (48).

10) Remove pressure ring (49).

7) Remove pinion gear assembly (44) in one
piece.
HM300-2R 13
11) Remove 3 plates (51) and 2 discs (50). Assembly

12) Remove washer (52).
a Clean each of the parts thoroughly and check
that it is free of dust or damage. Coat the sliding
surface with axle oil (AXO80) and then assem-
ble.
1. Subassembly of differential gear assembly
1) Shrink-fit bearing (55) to case (54).
• Shrink-fit temperature: For 30 minutes
at approx. 120°C.
a Drip axle oil (AXO80) on the bearing
after installing.
2) Install bevel gear (53) to case (54).
a Install according to the counter marks
which were left at the time of removing.
2 Mounting bolt
13) Reverse the case and bevel gear assembly. : Liquid adhesive (LT-2)
3 Mounting bolt
14) Remove bevel gear (53) from case (54).
a Leave a counter mark both on the bevel : 157 – 196 Nm {16 – 20kgm}
gear and on the case before removing.
15) Remove bearing (55).
3) Reverse the bevel gear and case assembly.

4) Put washers (52) in the case (54).
a Direct the lined face toward the gear.
5) Using the depth gauge, measure level dif-
ference C2 between case (54) and washer
(52) at 4 places equally spaced on the
periphery.
• Value C2 on drawing = 6.05 – 6.15 mm
Record the values measured at the 4 places in
the check sheet and obtain an average.
Average of level difference C2 = Total of values
measured at 4 places / 4
14 HM300-2R
6) Assemble 3 plates (51) and 2 discs (50). 9) Install bushings (47) and pinion gears (46) 4
a Immerse the discs and plates in the fol- pieces for each to shaft (45).
lowing oil before assembling.
2 Disc and plate: Axle oil (AXO80)
a Align the 4 toothless position of the
discs.
10) Install pinion gear assembly (44) in one

piece.
7) Install pressure ring (49) to the case.
11) Install differential side gear (43).
HM300-2R 15
12) Install pressure ring (42).
iv) Using the depth gauge, measure level

difference D2 between gear (43) and
13) Assemble 3 plates (40) and 2 discs (41).
plate (40) at 4 places equally spaced on
a Immerse the discs and plates in the fol-
the periphery.
lowing oil before assembling.
Record the values measured at the 4
places in the check sheet and obtain an
average.
Average of level difference D2 = Total of
values measured at 4 places / 4
14) Adjustment of clearance.

i) Using the depth gauge, measure level
difference A1 of case (37) at 4 places
equally spaced on the periphery. v) While pressing the disc and plate with a
Record the values measured at the 4 force of 686 N {70 kg}, perform steps vi)
places in the check sheet and obtain an and vii).
average. vi) Using the depth gauge, measure level
Average of level difference A1 = Total of difference A2 between case (54) and
values measured at 4 places / 4 plate (40) at 4 places equally spaced on
ii) Set washer (39) on case (37). the periphery. Record the values mea-
a Direct the lined face toward the sured at the 4 places in the check sheet
gear. and obtain an average.
iii) Using the depth gauge, measure level Average of level difference A2 = Total of
difference C1 between case (37) and values measured at 4 places / 4
washer (39) at 4 places equally spaced vii) Using the depth gauge, measure level
on the periphery. difference D1 between gear (43) and
Record the values measured at the 4 plate (40) at 4 places equally spaced on
places in the check sheet and obtain an the periphery. Record the values mea-
average. sured at the 4 places in the check sheet
Average of level difference C1 = Total of and obtain an average.
values measured at 4 places / 4 Average of level difference D1 = Total of
16 HM300-2R
15) Install washer (39).

viii) Calculation method for clearance A

between disc and plate.
Clearance A = Clearance A2 – Clear-
ance A1
a Check that clearance A is 0.2 – 0.75 • Bearing shrink fit temperature
mm. : For 30 minutes at 120°C
ix) If clearance A is out of the above range, a Drip axle oil (AXO80) on the bearing
replace plate (40) and measure dimen- after installing.
sion A2 again until a proper clearance is
obtained.
a The total thicknesses of the 3 plates
on the right and left sides must be
the same.
• Thicknesses of plates (40):
3.1 mm, 3.2 mm
x) Calculation method for side gear clear-
ances B1 and B2 in axial direction
Clearance B1 = Clearance C1 – Clear-
ance D1 + (Clearance A / 2)
a Use the clearance obtained in viii) 17) Install case and bearing assembly (36).
3 Mounting bolt
as clearance A.
a Check that both clearances B1 and : 98 – 123 Nm {10.0 – 12.5 kgm}
B2 are 0.15 – 0.35 mm.
xi) If either or both of clearances B1 and B2
are out of the above range, replace
washers (39) and (52) and measure
dimensions C1 and C2 again until
proper clearances are obtained.
• Thicknesses of washers:
4.0 mm, 4.1 mm
HM300-2R 17
2. Subassembly of side carrier and shaft 3. Adjustment of pre-load on shaft bearing

assembly 1) Drip axle oil (AXO80) on the bearing and
1) Install outer races (35), (34) and (33) to car- rotate it.
rier (30). 2) Measure dimension "b" between the end
surface of shaft (28) and the end surface of
output shaft coupling.
3) Select shims which attain the dimension of
b + (0 to 0.05 mm).
4) Assemble the selected shims (56) in and
then install output shaft coupling (19) and
holder (18).
3 Mounting bolt
: 490 – 608 Nm {50 – 62 kgm}
5) Hook a push-pull scale on to the bolt hole
(208 mm in dia.) on side carrier assembly
(28), and measure start torque.
• Standard value for start torque
2) Press-fit bearing (29) into shaft (28), using
: Min. 14.7 N {1.5 kg}
tool H1.
a If the start torque exceeds the above
standard value, increase or decrease
the number of shims for adjustment and
measure again.
6) Remove holder (18) and output shaft cou-
pling (19).
3) Put side carrier assembly (28) on shaft and

bearing assembly (27).
4) Assemble bearing (32) in.
5) Install output shaft coupling (19) and holder
(18), and then press-fit bearing (32), using
push tool [5]. 7) Press-fit oil seal (31) into carrier (30), using
tool H2.
a Keep press-fitting until distance "a"
between the oil seal periphery surface
and carrier end surface becomes 4.6 ±
0.2 mm.
2 Oil seal periphery surface
: Seal End 242 or equivalent
2 Oil seal lip face and oil seal inside
(100% full): Grease (G2-LI)
18 HM300-2R
5. Adjustment of pre-load on side bearing

a Drip axle oil (AXO80) on the bearing thor-
oughly.
1) Measure start torque of bevel gear (53) at
the addendums (in the tangential direction),
using push scale [5].
: 7.2 – 32.4 N {0.74 – 3.3 kg}
2) If the start torque exceeds the standard
value, decrease thickness of the shims and
measure again.
a Do not change the total thickness of left
and right shims, even if swapping them
between the left and right for adjusting
tooth contact or backlash.
a After adjusting the pre-load, be sure to
tighten the mounting bolts to the torque
specified in the step 2).
4. Differential gear assembly and side carrier

and shaft assembly
1) Sling differential gear assembly (22) and
keep the gear on the mounting position of
differential case (25).
4 Differential gear assembly: 80 kg 6. Left and right output shaft couplings
2) Assemble shims (57) whose thickness, 1) Assemble shims (56) selected in the step 3,
number in use and location were confirmed and install output shaft coupling (19) and
at the time of disassembling, and then install holder (18).
side carrier and shaft assemblies (23) and 2 Mounting bolt
(24). : Liquid adhesive (LT-2)

• Kind of shim thickness 3 Mounting bolt
: 0.05 mm, 0.2 mm, 0.3 mm and 0.8 mm : 490 – 608 Nm {50 – 62 kgm}
3 Mounting bolt
: 157 – 196 Nm {16 – 20 kgm}
HM300-2R 19
7. Subassembly of bevel pinion and cage 4) Put cage assembly (7) and bearing (11) on
assembly bevel pinion assembly (8), and press-fit
1) Install outer races (17) and (16) to cage bearing (11) into the cage assembly, while
(12). turning the cage assembly, using coupling
(5), holder (4) and push tool [6].
(11).
a Remove holder (4) and coupling (5)
after press-fitting.
2) Press-fit bearing (11) into bevel pinion (9),

using tool H3.
after assembling.
3) Install spacer (10).
5) Press-fit oil seal (14), using tool [7].
a Keep press-fitting until distance "d"
between periphery surface of the oil seal
and end surface of cage (12) is 26 ± 0.5
mm.
: Seal end 242 or equivalent
2 Oil seal lip face and between lips
: Grease (G2-LI)
20 HM300-2R
6) Press-fit oil seal (13), using tool [8]. 10. Adjustment of tooth contact and backlash
a Keep press-fitting until the oil seal • Adjust backlash and adjust tooth contact at
periphery surface is flush with the cage the same time.
(12) end surface. 1) Adjustment of backlash
2 Oil seal periphery surface i) To shift the bevel gear for the adjust-
: Seal end 242 or equivalent ment, change shims (57) between differ-
2 Oil seal lip face and between lips ential case (25) and side carrier
: Grease (G2-LI) assembly (23) or (24). In that case, do
not change the total thickness of left and
right shims (57) in order not to change
the pre-load given to the bearing.
8. Installation of bevel pinion and cage assem-

bly
Assemble the shims whose thickness, number ii) Apply the probe of dial gauge [9] per-
in use and location were confirmed at the time pendicularly to the tip of bevel gear.
disassembling, and then install bevel pinion iii) Read out the dial when moving the
cage assembly (6). bevel gear back and forth (in the direc-
a Tighten with 3 mounting bolts. tion of rotation), while fixing the bevel
a Tighten all the mounting bolts after adjusting pinion.
tooth contact. • Standard value for backlash
3 Mounting bolt In the circumferential direction of the
: 157 – 196 Nm {16 – 20 kgm} gear: 0.36 – 0.55 mm
9. Input shaft coupling and holder In the perpendicular direction to the gear
1) Install coupling (5) and holder (4). : 0.25 – 0.38 mm
2 Mounting bolt a Make this adjustment at 3 points and
: Liquid adhesive (LT-2) keep the fluctuation of backlash less
3 Mounting bolt
than 0.1 mm.
: 490 – 608 Nm {50 – 62 kgm} (The bevel gear in the photo below slightly
differs from the one for HM300-2)
HM300-2R 21
iv) If the backlash is found to fall out of the 2) Adjustment of tooth contact
standard value as a result of the mea- To shift the bevel pinion for the adjustment,
surement, make adjustment in the fol- increase or decrease shims (58) between
lowing manner. differential case (25) and cage (12).
• When there is a small backlash: • Kind of shim thickness
Decrease the shims on the right side of : 0.15 mm, 0.2 mm, 0.3 mm and 1.0 mm
chassis and add as many shims to the
left side (i.e. shifting the bevel gear in
direction A).
Inspection
i) Coat the bevel gear tooth surface thinly
with minium or red lead, then rotate the
• When there is a big backlash: bevel gear back and forth to check the
Decrease the shims on the left side of tooth contact pattern on the bevel gear.
chassis and add as many shims to the ii) The center of tooth contact must come
right side (i.e. shifting the bevel gear in in the middle of tooth height. Moreover,
direction B). it must be approx. 33% away from the
small end along the tooth length (x), and
the contact width must cover 45% to
55% of the tooth length (y). Meanwhile,
make sure that there is no excessively
strong tooth contact at any point of
addendum A, dedendum B, small end C
and big end D.
a If the adjustment is made this way,
right tooth contact is ensured, when
load is applied.
22 HM300-2R
ii) When the bevel pinion is too close to the

bevel gear centerline, a tooth contact
pattern shows the contact of the big end
tooth face of the bevel gear tooth face
curved outward with the small end tooth
face of the bevel gear tooth face curved
inward.
• Make adjustment in the following man-
ner.
Shift the bevel pinion in direction A by
adjusting the shims on the bevel pinion
side.
In addition, shift the bevel gear in direc-
Adjusting tion B and check the tooth contact pat-
• If no right pattern of tooth contact is
tern and backlash again.
obtained as a result of inspection, make
readjustment in the following manner.
a When adjusting shims for the side car-
rier assemblies, do not change the total
thickness of left and right shims in order
not to change the pre-load given to the
bearing.
i) When the bevel pinion is too far away
from the bevel gear centerline, a tooth
contact pattern shows the contact of the
small end tooth face of the bevel gear
tooth face curved outward with the big
end tooth face of the bevel gear tooth
face curved inward.
• Make adjustment in the following man- 3) After adjusting tooth contact, tighten the
ner. mounting bolts for the bevel pinion cage and
Shift the bevel pinion in direction A by side carriers to the specified torque.
adjusting the shims on the bevel pinion 3 Bevel pinion cage mounting bolt
side. : 157 – 196 Nm {16 – 20 kgm}

In addition, shift the bevel gear in direc- 3 Side carrier mounting bolt
tion B and check the tooth contact pat- : 157 – 196 Nm {16 – 20 kgm}
HM300-2R 23
11. Bevel gear fall-proof bolt

Install bevel gear fall-proof bolt (3).
a Screw the bolt in until it contacts the bevel
gear backside, then loosen the screw by a
3/4 turn and fasten with a lock nut.
2 Mounting bolt
: Gasket sealant (LG-5)
3 Lock nut
: 196 – 245 Nm {20 – 25 kgm}
12. Upper cover

Install upper cover (2).
a Pick out bolt A out of the 15 mounting bolts
and coat it with gasket sealant and install.
2 Cover mating surface
: Gasket sealant (Loctite LT-515
or equivalent)
2 Bolt A
: Gasket sealant (LG-5 or equivalent)
3 Mounting bolt
: 157 – 196 Nm {16 – 20 kgm}
13. Drive shaft cover
Install left and right drive shaft covers (1).
24 HM300-2R
Disassembly and assembly of 2) Turbine

torque converter assembly 1 Reverse the drive case, then remove the
mounting bolts, and remove turbine (7).
Special tools
New/Remodel
Sym-
Necessity
bol Part No. Part name
Sketch
Q'ty
790-501-5000 Unit repair stand q 1
1 790-901-2110 Bracket q 1
C
792T-213-1210 Plate q 1 Q
2 792-213-1110 Wrench t 1
Disassembly
1. Turbine and clutch disassembly 3) Drive case
1) Set the torque converter assembly on tool Remove the mounting bolts and then drive
C1. case (8) from clutch housing assembly (9).
2) Remove mounting bolt (1) at the pump side. 4) Disc
3) Remove turbine and clutch assembly (4), Remove disc (10) from clutch housing
using eyebolts [1]. assembly (9).
2. Further disassembly of turbine and clutch 5) Plate and snap ring

assembly Reverse the clutch housing, then remove
1) Input shaft snap ring (11), and remove plate (12).
i) Remove input shaft (5), using forcing
screws [2].
ii) Remove bearing (6), using puller [3].
HM300-2R 25
6) Shaft and piston 3. Stator assembly

Remove shaft (13) from clutch housing Pull up stator assembly (18) to remove.
assembly (9), using push tool [4], and then
remove piston (14).
4. Further disassembly of stator assembly

1) Stator
7) Seal ring Remove snap ring (40) and then remove
Remove seal rings (15) from piston (14). stator (41).
8) Bearing, seal ring and pin 2) Bushing

i) Remove bearing (16) from the clutch Remove bushings (20) and (21) from race
housing, using push tool [5]. (19).
ii) Remove seal ring (17). a Be careful not to lose ball (50).
3) Race and one-way clutch
Remove one-way clutch (23) from race (19).
26 HM300-2R
5. Further disassembly of pump and stator 4) Seal ring and bearing inner race
shaft assembly Remove seal ring (31) and bearing inner
1) Nut race (32) from stator shaft (30).
Remove nut (24), using tool C2.
5) Retainer
2) Remove the pump and stator shaft assem- Remove mounting bolts (33) and then
bly from tool C1. remove retainer (35) from pump (34).
3) Stator shaft assembly and bearing inner
race
Remove stator shaft assembly (28) and
bearing inner race (29) from pump assem-
bly (27) by pushing stator shaft assembly
(28).
6) Bearing and guide

i) Remove guide (37) from pump (34).
ii) Remove bearing (36) from guide (37).
HM300-2R 27
Assembly 3) Bearing inner race and seal ring

Press-fit bearing inner race (32) into stator
1. Subassembly of pump and stator shaft
shaft (30), using push tool [6], and install
assembly
1) Bearing and guide seal ring (31).
Install bearing (36) to guide (37), and then a Bearing inner race (32) is a set part, so
install the combination to pump (34). install it after checking that its manufac-
turing No. and counter mark (A) on the
a Bearing (36) is a set part, so install it
edge are the same as those of a counter
after checking that its manufacturing No.
bearing.
and counter mark (A) on the edge are
2 Seal ring periphery: Grease (G2-LI)
the same as those of a counter bearing.
2) Retainer 4) Stator shaft assembly and bearing inner

Install retainer (35) on pump (34) and fasten race
with mounting bolts (33). i) Press-fit stator shaft assembly (28) into
2 Retainer mounting bolt
pump assembly (27).
: 58.8 – 73.5 Nm {6 – 7.5 kgm}
ii) Press-fit bearing inner race (29) into sta-

tor shaft (30), using push tool [7].
a Bearing inner race (29) is a set part,
so install it after checking that its
manufacturing No. and counter
mark (A) on the edge are the same
as those of a counter bearing.
28 HM300-2R
2) Bushing
Expansion-fit bushings (20) and (21) with
ball (50) into race (19).
2 Sliding surface
: Powertrain oil (TO10 or TO30)
iii) Drip approx. 6 cc of powertrain oil

(TO10 or TO30) on the bearing and
rotate it by 10 turns.
5) Set pump and stator shaft assembly on tool
C1.
6) Nut
Install nut (24), using tool C2. 3) Stator
2 Nut thread portion
Install stator (41) with snap rings (40).
3 Nut
: 441.3 – 490.3 Nm {45 – 50 kgm}
3. Stator assembly
Install stator assembly (18).
2. Subassembly of stator assembly

1) One-way clutch and race
Install one-way clutch (23) to race (19).
a Install the one-way clutch so that an
arrow shown on the cage edge faces
the input side, and check the stator rota-
tion direction as viewed from the input
side.
Clockwise: No load
Counter-clockwise: Lock
2 Sliding surface
: Powertrain oil (TO10 or TO30)
HM300-2R 29
4. Subassembly of turbine and clutch assembly ii) Install piston (14) to the clutch housing
1) Bearing, seal ring and pin assembly.
i) Install bearing (16), using push tool [8] 2 Seal ring periphery: Grease (G2-LI)
ii) Install seal ring (17).
a Drip approx. 6 cc of powertrain oil
(TO10 or TO30) on the bearing (16) and
rotate it by 10 turns.
iii) Press-fit shaft (13) into clutch housing

assembly (9), using push tool [9].
2) Seal ring, piston and shaft

i) Install seal rings (15) to piston (14).
a Do not make a mistake about the direc-
tion of installation, referring to the figure
below.
3) Plate, snap ring

Install plate (12) to the shaft and then install
snap ring (11).
30 HM300-2R
4) Disc 7) Input shaft

Install disc (10) to clutch housing assembly i) Install bearing (6), using push tool [10].
(9). a Drip approx. 6 cc of powertrain oil
2 Sliding surface (TO10 or TO30) on the bearing (6) and
: Powertrain oil (TO10 or TO30) rotate it by 10 turns.
5) Drive case ii) Install input shaft assembly (5) to the
clutch housing.
Install drive case (8) to clutch housing
2 Mounting bolt
assembly (9).
2 Mounting bolt
3 Mounting bolt
: 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
3 Mounting bolt
: 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
5. Turbine and clutch assembly

6) Turbine 1) Install turbine and clutch assembly (4),
Install turbine (7). using eyebolts [1].
2 Mounting bolt 2) Tighten 40 mounting bolts (1).
: Liquid adhesive (LT-2) 2 Mounting bolt
3 Mounting bolt : Liquid adhesive (LT-2)
: 58.8 – 73.5 Nm {6.0 – 7.5 kgm} 3 Mounting bolt
: 27 – 34 Nm {2.8 – 3.5 kgm}
HM300-2R 31

© 2007 KOMATSU
All Rights Reserved
32 HM300-2R
SEN04032-00
HM300-2R


Power train, Part 2
Disassembly and assembly of transmission assembly ................................................................................... 2
HM300-2R 1
Disassembly and assembly of 2) Remove bushing (301) from trunnion (1).

transmission assembly 1
Special tools
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
1 790-102-1871 Nut wrench t 1
2 796-465-1120 Push tool t 1
3 792T-423-1110 Push tool t 1 Q
792T-213-1220 Push tool t 1 Q
4 790-101-5421 Grip t 1 2. Wiring harness, sensor and piping
01010-81240 Bolt t 1 1) Remove cover (4).
2) Disconnect connector B09 (4-1), (4-2) and
D 792T-213-1230 Push tool t 1 Q
(4-3).
5 790-101-5421 Grip t 1
01010-81240 Bolt t 1
6 790-201-2730 Spacer t 1
7 792T-413-1120 Push tool t 1 Q
8 792T-215-1120 Push tool t 1 Q
9 799-301-1500 Oil leak tester kit t 1
Disassembly
1. Trunnion
1) Remove plate (2) and then remove trun-
nions (1) and (3).
2 HM300-2R
3) Disconnect connector (4-4). 6) Output shaft R rotation sensor (7-1), output

4) Disconnect wiring harness assembly (5). shaft rotation sensor (differential input) (7).
5) Remove intermediate shaft rotation sensor 7) Tubes (8), (9) and (10).
(6).
3. Relief valve assembly

1) Remove lubrication oil temperature sensor
(LUB) (11) and then remove block (12).
2) Remove relief valve assembly (13) and dis-

connect piping (14).
HM300-2R 3
4. Strainer (left and right) 6. Main relief valve assembly, valve flow
Remove cover (15) and then remove strainer assembly and sensor
(16) and block (17). Remove main relief valve assembly (22), input
shaft rotation sensor (24), torque converter
intermediate pressure oil pressure sensor (25)
and torque converter outlet oil temperature sen-
sor (26).
a Seal the oil holes on the installing face with
tape or the like so that no foreign objects
enter them.
5. Transmission control valve assembly

a Seal the oil holes on the installing face with
tape or the like so that no foreign objects
enter them.
1) Disconnect tubes (18), (19) and (20).
2) Remove transmission control valve assem-
bly (21) and valve seat (302) together.
3) Remove each transmission control valve 7. Coupling
(21) and filter assembly (303) from the valve 1) Remove input coupling (27) and output cou-
seat (302). pling (28).
8. Cover and cage (R clutch and 2nd clutch

side)
1) Sling the transmission assembly and set it
on the block so that the transmission case
faces up.
4 HM300-2R
2) Remove cover (305). 3) Remove dust seal (34) and oil seal (35)
3) Remove cage (30), using forcing screws [1]. from retainer (32).
a Check the thickness of shims and their 4) Remove outer race (36) from cage (33).
number in use beforehand.
10. Rear transmission case assembly

4) Remove outer race (31) from cage (30). Separate rear transmission case assembly (29)
from the front side, using forcing screws [2] at 3
points.
k If the transmission is not placed with the
torque converter side down, it cannot be
disassembled. Be sure to set it with the
torque converter side down.
a If the transmission is disassembled with the
torque converter side up, its inside will be
broken. Accordingly, be sure to disassemble
the transmission with the torque converter
side down.
9. Retainer and cage (differential lock clutch

rear output side)
1) Screw forcing screws in holes A and remove
retainer (32).
2) Screw forcing screws in holes B and remove
cage (33).
HM300-2R 5
11. Further disassembly of rear transmission 13. Clutch assembly

case assembly Whole figure
1) Remove holder (37) to remove bearing (39), • (47): The FH and 1st clutch assembly
then remove gear (38), bearing (40) and col- • (48): The 2nd and 3rd clutch assembly
lar (41). • (400): Shroud
2) Remove outer races (320) and (321) from • (401): Differential clutch assembly
gear (38).
3) Remove bearings (42) and (43).
1) Remove snap ring (332) and spacer (333)

form the FH and 1st clutch assembly (47).
2) Take out idler gear (138) of FH and 1st

12. Seal ring clutch assembly together with inner race
Remove seal rings (44), (45) and (46). (137), using puller [18].
6 HM300-2R
3) Sling 2nd and 3rd clutch assembly (48) to 2) Reverse the case and remove cage (53),
remove. (Refer to whole figure) using forcing screws [3].
a For details on the further disassembly of
the 2nd and 3rd clutch assembly, refer
to the sections of 19 and 20.
a Sling tool [53] is shown just as an exam-
ple. (Refer to 6))
4) Sling differential clutch assembly (401)
together with shroud (400) to remove.
(Refer to whole figure)
a Shroud (400) cannot be removed inde-
pendently, when the differential lock
clutch assembly is still installed.
a For details on the further disassembly of
differential lock clutch assembly, refer to
the section of 18.
5) Sling FH and 1st clutch assembly (47) to 15. PTO case assembly
remove. (Refer to whole figure) Separate PTO case assembly (54) from the
a For details on the further disassembly of front transmission case to remove, using forcing
the FH and 1st clutch assembly, refer to screws [4].
the sections of 21 and 22. a Before removing, loosen nut (55) before-
6) Sling FL and R clutch assembly (49) to hand, using tool D1. (Refer to the section of
remove. 16.)
a For details on the further disassembly of a Use the input coupling as a rotation lock.
the FL and R clutch assembly, refer to
the sections of 23 and 24.
14. Further disassembly of front transmission

case assembly
1) Remove bearing (50) and (50-1) and outer
races (51) and (52).
HM300-2R 7
16. Further disassembly of PTO case assembly 4) Remove dust seal (65) and oil seal (66)
1) Disassemble PTO gears at 3 locations fur- from retainer (64).
ther in the following steps.
i) Remove nuts (55), using tool D1.
17. Torque converter assembly

Remove mounting bolts (67) connecting the
ii) Remove snap ring (56) and spacer (57). torque converter assembly with front transmis-
iii) Remove PTO gear (61) together with sion case, and then remove torque converter
spacer (59) and bearing (60) by pushing assembly (68).
the shaft portion. a For disassembly of the torque converter
a When the PTO gear is disengaged, assembly, refer to the section of "Disassem-
the bearing (58) goes off, too. bly and assembly of torque converter".
iv) Remove spacer (59) and bearing (60)
from PTO gear (61).
v) Remove outer races (62) and (63) as
well as spacer (330) from the PTO case.
2) Remove retainer (64), using forcing screws

[5].
3) Remove outer race (331) from the PTO
case.
8 HM300-2R
18. Further disassembly of differential lock ii) Remove spacer (73-2) from the rear out-
clutch assembly put shaft (72).
1) Remove gear (69). iii) Remove ring gear (74).
iv) Remove snap ring (75) from ring gear
(74).
v) Remove bearing (73-3).
2) Separate rear housing (70) from the output

gear, using forcing screws [6].
3) Sling rear housing (70) together with bear-
ing (71) and rear output shaft (72), using vi) Remove snap ring (76) and bearing (77)
tool [54] and remove. from the rear output shaft (72).
vii) Remove bearing (73-1) from rear hous-

4) Disassemble the rear output shaft (72), rear
ing (70).
housing (70) and ring gear (74) further in the
viii) Remove outer race (78) and (79).
following steps. ix) Remove bearing (71).
i) Using push tool [30] and [31], remove
the rear output shaft (72) together with
ring gear (74) assembly from rear hous-
ing (70) and bearing (73-1) assembly.
HM300-2R 9
5) Remove carrier assembly (80). 11) Remove 6 plates (87) and 5 discs (88).
a For further disassembly of the carrier
assembly, refer to the section 15).
12) Remove piston (90).

a Use the tapped holes for slinging.
6) Remove snap ring (81) and remove inner
race (83).
8) Remove sun gear (84).
13) Remove seal ring (91) from piston (90).
9) Remove clutch hub (85).

10) Compress the spring by pushing plate (87),
using tools [27], and remove snap ring (86).
10 HM300-2R
14) Disassemble the front output shaft, front v) Remove seal rings (306) from front out-
housing and output gear further in the fol- put shaft (95) and seal ring (307) from
lowing steps. front housing (96).
i) Separate front output shaft and housing
assembly (92) from output gear (93),
using forcing screws [10], and sling to
remove.
vi) Remove snap ring (97) and spacer (98),

and then remove bearing (99) from the
front output shaft.
ii) Remove seal rings (94).

iii) Remove snap ring (308).
vii) Remove bearing (101) from the front

housing.
iv) Reverse the front output shaft and hous-

ing assembly, and separate front output
shaft (95) from front housing (96), using
puller [11].
HM300-2R 11
15) Disassemble the carrier (102) assembly fur-

ther in the following steps.
i) Hammer pin (103) into shaft (104).
3) Remove bearing (113) from 2nd gear (112).
ii) Hammer out shaft (104) and remove

shaft (104), thrust washer (105), plane-
tary gear (106) and bearing (107).
iii) Remove pin (103) and plug (108) from
the shaft (104).
4) Compress the spring by pushing end plate

(114), using tool [14], and remove snap ring
(115).
a Fit the tool to the gear, using tapped
holes for slinging provided on the gear,
then insert a spacer of appropriate thick-
19. Further disassembly of 2nd and 3rd clutch ness in between the tool and end plate
assembly (2nd clutch side) (114), and compress the spring.
1) Set the clutch assembly to tool [12]. 5) Remove end plate (114).
2) Remove 2nd gear (112) together with bear-
ing (109), plate (110) and thrust washer
(111), using forcing screws [13].
12 HM300-2R
7) Remove thrust washer (119) and piston

(120).
a For removing the piston, use provided
tapped holes.
6) Remove 10 plates (116), 9 discs (117) and 9

springs (118).
8) Remove seal rings (121) and (122) from pis-

ton (120).
HM300-2R 13
20. Further disassembly of 2nd and 3rd clutch 6) Compress the spring by pushing end plate
assembly (3rd clutch side) (128) with C clamp, and remove snap ring
1) Set the clutch assembly to tool [15]. (129).
2) Hook the claw of puller [16] to the underside 7) Remove end plate (128), 10 plates (130), 9
of plate (123), and remove bearing (124) discs (131) and 9 springs (132).
together with plate (123). 8) Remove thrust washer (133) and piston
3) Remove thrust washer (125). (134).
4) Remove 3rd gear (126).

ton (134).
5) Remove bearing (127) from 3rd gear (126).

21. Further disassembly of FH and 1st clutch
assembly (1st clutch side)
1) Set the clutch assembly to a cylinder-like
tool.
2) Remove 2 spacers (139) and thrust washer
(140).
3) Remove 1st gear (141).
14 HM300-2R
4) Remove 2 bearings (142) from 1st gear 8) Remove thrust washer (148) and piston
(141). (149).
5) Compress the spring by pushing end plate 9) Remove seal rings (150) and (151) from pis-
(143), using tool [19], and remove snap ring ton (149).
(144).
6) Remove end plate (143).
7) Remove 13 plates (145), 12 discs (146) and

12 springs (147).
HM300-2R 15
22. Further disassembly of FH and 1st clutch

assembly (FH clutch side)
1) Set the clutch assembly to cylinder-like tool.
2) Remove FH gear (155) together with inner
race (152), plate (153) and thrust washer
(154), using forcing screws.

ton (162).
3) Remove bearing (156) from FH gear (155).
23. Further disassembly of FL and R clutch

assembly (R clutch side)
1) Set the clutch assembly to a cylinder-like
tool.
2) Hook the claw of puller [22] to the underside
4) Compress the spring by pushing end plate of plate (166), and remove inner race (165)
(157), using C clamp, and remove snap ring and plate (166).
(158). 3) Remove thrust washer (167) and then R
a The spring can also be compressed by gear (168).
fitting the tool to tapped holes A on the
FH and 1st cylinder and idler gear, and
then inserting a spacer of appropriate
thickness in between the tool and end
plate.
5) Remove end plate (157), 11 plates (159), 10
discs (160) and 10 springs (161).
6) Remove thrust washer (210) and piston
(162).
16 HM300-2R

ton (177).
4) Remove bearing (169) from R gear (168).
24. Further disassembly of FL and R clutch

assembly (FL clutch side)
1) Remove seal ring (335) and (336).

(170) with C clamp, and remove snap ring
(171).
6) Remove end plate (170), 11 plates (172), 10
discs (173) and 10 springs (174).
7) Remove thrust washer (175) and thrust
bearing (176).
HM300-2R 17
2) Set the clutch assembly to tool [23]. 5) Remove bearings (184) from FL gear (183).
3) Remove idler gear (181) together with inner
race (180), using puller [24].

(185), using tool [25], and remove snap ring
(186).
7) Remove end plate (185).
4) Remove thrust washer (182) and then FL

gear (183).
8) Remove 11 plates (187), 10 discs (188) and
10 springs (189).
18 HM300-2R
9) Remove thrust washers (190) and thrust Assembly

bearing (191).
a Clean each of the parts thoroughly and
check that it is free of dust, damage, etc.
before assembling.
a Coat the sliding surface of each of the parts
with engine oil before assembling.
a Immerse discs in clean powertrain oil
(TO10) for more than 2 minutes before
assembling.
a Assemble each seal ring (a) for pistons of
the clutch assembly with its pressure-
receiving side (b side) facing housing (c) as
shown in the figure below.

ton (192).
1. Subassembly of FL and R clutch assembly

(FL clutch side)
1) Install seal rings (193) and (194) to piston
(192).
a Install the seal ring with its pressure-
receiving side facing the housing side.
HM300-2R 19
2) Install piston (192). 6) Install bearings (184) to FL gear (183).

2 Seal ring periphery and sliding sur-
face: Powertrain oil (TO10)
3) Install thrust washers (190) and thrust bear-
ing (191).
7) Install FL gear (183) to the clutch assembly

temporarily, and match grooves of the discs.
a Turn the gear to the left and right, while
pressing it down, and push the gear in
4) Install each of 11 plates (187), 10 discs gradually, avoiding interfering with the
(188) and 10 springs (189) alternately from disc mountains.
the bottom to the top. 8) Remove FL gear (183) once.
a Immerse the discs in clean powertrain 9) Compress the spring by pushing end plate
oil (TO10) for more than 2 minutes (185), using tool [25], and install snap ring
before assembling. (186).
a Take care so that the plate will not get
caught in the snap ring groove.
a Make sure that the snap ring settles in
the groove completely.
5) Install end plate (185).
20 HM300-2R
10) Install FL gear (183) and thrust washer 2. Subassembly of FL and R clutch assembly
(182). (R clutch side)
a If it is found difficult to assemble the FL 1) Install seal rings (178) and (179) to piston
gear in, start the work all again from the (177).
step 7) above. a Install the seal ring with its pressure-
receiving side facing the housing.
11) Install idler gear (181) and shrink-fit inner

race (180). 2) Install bearing (169) to R gear (168).
• Shrink-fit temperature
: For 30 minutes at approx. 120°C
12) Apply a dial gauge to the edge surface of
idler gear (181), move the idler gear in the
thrust direction and check that clearance "a"
remains within the range of 0.28 and 1.10
mm.
HM300-2R 21
3) Install piston (177). 10) Install R gear (168) and thrust washer (167).
2 Seal ring periphery and sliding sur- a If it is found difficult to assemble the R
face: Powertrain oil (TO10) gear in, start the work all again from the
4) Install thrust washers (175) and thrust bear- step 7) above.
ing (176). 11) Install plate (166) and shrink-fit inner race
5) Install each of 11 plates (172), 10 discs (165).
(173) and 10 springs (174) alternately from • Shrink-fit temperature
the bottom to the top. : For 30 minutes at approx. 120°C
a Immerse the discs in clean powertrain 12) Apply a dial gauge to the edge surface of R
oil (TO10) for more than 2 minutes gear (168), move the R gear in the thrust
before assembling. direction and check that clearance "b"
6) Install end plate (170). remains within the range of 0.08 and 0.90
7) Install R gear (168) (above-mention) to the mm.
clutch assembly temporarily, and match disc
tooth.
gradually, avoiding interference with the
disc tooth.
8) Remove R gear (168) once.
(170) with C clamp, and then install snap
ring (171).
the groove completely. 3. Actuation test of FL and R clutch assembly
Blow air into the shaft oil hole, using tool D9,
and check that each clutch is actuated.
a If the gear on the air-blown side is fixed, the
clutch is in normal operation.
22 HM300-2R
4. Subassembly of FH and 1st clutch assembly 6) Install bearing (156) to FH gear (155).
(FH clutch side)
(162).
a Install the seal rings with their pressure-
7) Install FH gear (155) to the clutch assembly

temporarily, and match disc tooth.
2) Install piston (162). disc tooth.
2 Seal ring periphery and sliding sur- 8) Remove FH gear (155) once.
face: Powertrain oil (TO10) 9) Compress the spring by pushing end plate
3) Install thrust washer (210). (157) with C clamp, and install snap ring
4) Install each of 11 plates (159), 10 discs (158).
(160) and 10 springs (161) alternately from a Take care so that the plate will not get
the bottom to the top. caught in the snap ring groove.
a Immerse the discs in clean powertrain a Make sure that the snap ring settles in
oil (TO10) for more than 2 minutes the groove completely.
before assembling.
HM300-2R 23
10) Install FH gear (155). 2) Install piston (149).

a If it is found difficult to assemble the FH 2 Seal ring periphery and sliding sur-
gear in, start the work all again from the face: Powertrain oil (TO10)
step 7) above. 3) Install thrust washer (148).
11) Install thrust washer (154) and plate (153).
12) Shrink-fit inner race (152).
FH gear (155), move the FH gear in the
thrust direction and check that clearance "c"
remains within the range of 0.07 to 0.93
mm.
4) Install each of 13 plates (145), 12 discs

(146) and 12 springs (147) alternately from
the bottom to the top.
a Immerse the discs in clean powertrain
oil (TO10) for more than 2 minutes
before assembling.
5. Subassembly of FH and 1st clutch assembly

(1st clutch side)
(149).
a Install seal rings with their pressure-
24 HM300-2R
6) Install bearings (142) to 1st gear (141). 10) Install 1st gear (141).
a If it is found difficult to assemble in the
1st gear, start the work all again from
the step 7) above.
11) Install thrust washer (140) and 2 spacers
(139).
7) Install 1st gear (141) to the clutch assembly

temporarily, and match tooth of the discs.
disc tooth. 12) Install idler gear (138) and shrink-fit inner
8) Remove 1st gear (141) once. race (137).
9) Compress the spring by pushing end plate • Shrink fit temperature
(143), using tool [19], and install snap ring : For 30 minutes at approx. 120°C
(144).

1st gear (141), move the 1st gear in the
thrust direction and check that clearance "d"
remains within the range of 0.23 to 1.37
mm.
HM300-2R 25
6. Actuation test of FH and 1st clutch assembly 2) Install piston (134).

1) Blow air into the shaft oil hole, using tool D9,
and check that each clutch is actuated. face: Powertrain oil (TO10)
a If the gear on the air-blown side is fixed, 3) Install thrust washer (133).
the clutch is in normal operation. 4) Install each of 10 plates (130), 9 discs (131)
and 9 springs (132) alternately from the bot-
tom to the top.
before assembling.
2) Remove idler gear (138) and inner race

(137) once, referring to the step 13 section
2) of the "DISASSEMBLY".
a Installation is to be made in the step 15.
7. Subassembly of 2nd and 3rd clutch assem-
bly (3rd clutch side)
1) Install seal rings (135) and (136) to piston 6) Install bearing (127) to 3rd gear (126).
(134). 7) Install 3rd gear (126) to the clutch assembly
a Install the seal rings with their pressure- temporarily, and match tooth of the discs.
receiving side facing the housing. a Turn the gear to the left and right, while
disc tooth.
8) Remove 3rd gear (126) once.
26 HM300-2R
9) Compress the spring by pushing end plate 13) Apply a dial gauge to the edge surface of
(128) with C clamp, and then install snap 3rd gear (126), move the 3rd gear in the
ring (129). thrust direction and check that clearance "e"
a Take care so that the plate will not get remains within the range of 0.07 to 0.93
caught in the snap ring groove. mm.
10) Install 3rd gear (126).
a If it is found difficult to assemble in the
3rd gear, start the work all again from
the step 7) above.
11) Install thrust washer (125) and plate (123).
8. Subassembly of 2nd and 3rd clutch assem-

bly (2nd clutch side)
(120).
a Install the seal rings with their pressure-
12) Press-fit bearing (124), using tool D2. (Or

shrink-fit the bearing)
2) Install piston (120).

face: Powertrain oil (TO10)
3) Install thrust washer (119).
HM300-2R 27
4) Install each of 10 plates (116), 9 discs (117) 6) Install bearing (113) to 2nd gear (112).
and 9 springs (118) alternately from the bot-
tom to the top.
before assembling.
7) Install 2nd gear (112) to the clutch assembly

temporarily, and match tooth of the discs.
disc tooth.
8) Remove 2nd gear (112) once.
(114), using tool [14], and then install snap
ring (115).
28 HM300-2R
10) Install 2nd gear (112). 13) Apply a dial gauge to the edge surface of
a If it is found difficult to assemble the 2nd 2nd gear (112), move the 2nd gear in the
gear in, start the work all again from the thrust direction and check that clearance "f"
step 7) above. remains within the range of 0.07 to 0.93
11) Install thrust washer (111) and plate (110). mm.
12) Press-fit bearing (109), using tool D3. (Or 9. Actuation test of 2nd and 3rd clutch assem-
shrink-fit the bearing.) bly
• Shrink-fit temperature Blow air into the shaft oil hole, using tool D9,
: For 30 minutes at approx. 120°C and check that each clutch is actuated.
a If the gear on the air-blown side is fixed, the
clutch is in normal operation.
HM300-2R 29
10. Subassembly of differential lock clutch 2) Carry out subassembly of the front output
assembly shaft, front housing and output gear in the
1) Carry out subassembly of the carrier following steps.
assembly in the following steps. i) Shrink-fit bearing (101) to the front
i) Assemble bearings (107) in planetary housing.
gear (106). • Shrink-fit temperature
ii) Set planetary gear (106) to the carrier : For 30 minutes at approx. 120°C
with thrust washers (105) installed to the
top and bottom.
ii) Shrink-fit bearing (99) to the front output

shaft.
iii) Hammer shaft (104) to the halfway, then
check the hole, and hammer the shaft in
until it is flush with the carrier edge sur-
face. iii) Install spacer (98) and snap ring (97).
a Make the hole (h) of the shaft inside
and aligne the shaft pin hole and the
hole on the carrier side. Then ham-
mer the shaft.
iv) Install plug (108) and hammer the pin
(103).
iv) Install seal rings (306) to front output

shaft (95) and seal ring (307) to front
housing (96).
a Install seal ring (307) with its pres-
sure-receiving side facing the bear-
ing in the housing.
30 HM300-2R
v) Install front output shaft (95) to front vii) Sling front output shaft and housing
housing (96) with the shaft front facing assembly (92) and install output gear
up (the side of shorter shaft from the (93).
bearing), using tool [26]. 2 Housing mounting bolt
a Be careful not to damage the seal : Liquid adhesive (LT-2)
ring. 3 Housing mounting bolt
: 59 – 74 Nm {6 – 7.5 kgm}
3) Set the front output shaft-housing-output

gear assembly with the rear output shaft
connecting side facing up.
4) Install seal ring (91) to piston (90).
a Install the seal ring with its pressure-
vi) Install snap ring (308), and then install

seal rings (94) to the front output shaft.
5) Install piston (90).
HM300-2R 31
6) Install clutch hub (85). 9) Install sun gear (84), snap ring (82), inner
race (83) and snap ring (81).
7) Install each of 6 plates (87) and 5 discs (88)

alternately from the bottom to the top. 10) Install carrier assembly (80) to the front out-
a Immerse the discs in clean powertrain put shaft-housing-output gear assembly.
oil (TO10 or TO30) for more than 2 min-
utes before assembling.
11) Carry out subassembly of the rear output

shaft (72), rear housing (70) and ring gear
8) Compress the spring by pushing plate (87), (74) in the following steps.
using tool [27], and install snap ring (86). i) Shrink-fit bearing (71) to rear housing
(70).
ii) Install outer race (78) and (79).
32 HM300-2R
iii) Install bearing (77) and snap ring (76) to viii) Set shaft (72) and ring gear (74) assem-
the rear output shaft (72). bly on the block [33].
ix) Install rear housing (70).
x) Press fit bearing (73-1), using push tool
[31] and [32].
a Check that spacer (73-2) is installed.
iv) Press-fit bearing (73-3) to rear output

shaft (72), using tools [31] and [32].
a Bearing (73-3) and (73-1) and
spacer (73-2) are set parts.
12) Set the front output shaft and housing
assembly on a pair of blocks with the output
gear facing up.
13) Install rear output shaft-housing-ring gear
assembly (309), using tool [54].
2 Rear housing mounting bolt
3 Rear housing mounting bolt
: 59 – 74 Nm {6 – 7.5 kgm}
v) Install ring gear (74) to rear output shaft

(72) and bearing (73-3) assembly.
vi) Install snap ring (75).
vii) Install spacer (73-2).
14) Install coupling (69).
HM300-2R 33
11. Torque converter assembly 2) Install retainer (64) to the PTO case.
Install torque converter assembly (68) in the
front transmission case and tighten bolt (67).
a For assembling the torque converter, refer
to the section of "Disassembly and assemly
of torque converter".
3) Carry out subassembly of PTO gears at 3

locations in the following steps.
i) Install to the PTO case in the order of
outer race (63), spacer (330) and outer
race (62).
12. Subassembly of PTO case assembly ii) Press-fit bearing (60) into PTO gear
1) Install dust seal (65) and oil seal (66) to (61), using tool D6.
retainer (64), using tools D4 and D5. a Check that a manufacturing No. and
2 Seal lip face and clearance between a counter mark on inner ring (58)
dust seal and oil seal and outer ring (60) match, i.e. match
: Silicone grease (G2-S (Three Bond 1855)) A and A, as well as B and B.
2 Periphery of press-fitted face on (This means that they are to be
retainer side used as a set part.)
: Gasket sealant (LG-5 (Three Bond 1110B))
a After press-fitting, wipe out oozed gas-
ket sealant completely.
34 HM300-2R
iii) Install spacer (59) to the shaft of PTO

gear (61), and assemble in the PTO
case.
iv) Press-fit bearing (58) and install spacer
(57) and snap ring (56).
14. Subassembly of front transmission case

assembly
1) Install cage (53).
13. PTO case assembly

1) Install guide bolt [27] to the front transmis-
sion case, and install PTO case assembly
(54) to the front transmission case.
2) Reverse the case and install bearing (50),

(50-1) and outer races (51) and (52).
2) Tighten nut (55) of the PTO gear, using tool

D1.
a Install the nut with its chamfered side
facing inward.
a Install the input coupling and use it as a
lock.
2 Nut: Liquid adhesive (LT-2)
3 Nut: 392 – 441 Nm {40 – 45 kgm}
3) Coat the bearing with 6cc of powertrain oil
(TO10 or TO30), rotate the bearing by 10
turns and check the nut tightening torque
again.
HM300-2R 35
15. Clutch assembly

1) Install seal rings (335) and (336) on the FL
clutch side.
a Check that the seal ring on the FL clutch
side has not enlarged at the abutment.
2 Seal ring: Grease (G2-LI)
9) Install spacer (333) and snap ring (332) to

FH and 1st clutch assembly (47).
2) Install FL and R clutch assembly (49).

a Tool [53] is shown just as an example.
16. Seal ring

Install seal rings (44), (45) and (46).
2 Seal ring: Grease (G2-LI)
3) Install FH and 1st clutch assembly (47).

a Install this assembly without idler gear
(138) and inner race (137).
4) Sling differential lock clutch assembly (401),
and set shroud (400) to its setting position.
a The shroud cannot be installed after the
differential lock clutch assembly is
installed.
5) Install differential lock clutch assembly (401)
after it is lowered.
6) Put shroud (400) to the differential clutch
assembly and tighten the mounting bolts in 17. Subassembly of rear transmission case
assembly
a position 1 mm away from the assembly.
1) Install collar (41).
7) Install 2nd and 3rd clutch assembly (48).
a Be careful of the installing direction.
8) Install idler gear (138) to FH and 1st clutch (Refer to the figure below.)
assembly (47), and shrink-fit inner race 2) Press-fit bearing (40), using tool D7.
(137).
36 HM300-2R
18. Rear transmission case assembly

1) Coat the case mating faces (both on the
front side and on the rear side) with gasket
sealant, referring to the drawing below.
a "a" mark stands for a tapped hole.
a "I" mark indicates the inside while "O"
mark indicates the outside.
a Coat so that area of the cross section of
the coated gasket sealant (B x H) is 2 to
5 mm2.
2 Case mating face
: Gasket sealant (LG-8 (Three Bond 1207B))
3) Expanshion-fit outer races (320) and (321)

to gear (38).
4) Install gear (38) and press-fit bearing (39).
a Before installing, make sure that a man-
ufacturing No. and counter mark on
inner ring (39) and outer ring (40) match
with each other. (This means that they
are to be used as a set parts.)
5) Install holder (37) and tighten the mounting
bolt.
2 Holder mounting bolt
3 Holder mounting bolt
2) Install guide bolt [28] to rear transmission
: 98 – 122.5 Nm {10 – 12.5 kgm} case assembly (29) and install the assem-
6) Install bearings (42) and (43). bly.
a When installing, be careful of interfer-
ence with the clutch assembly as well as
displacement of the seal ring.
3 Rear transmission case assembly
mounting bolt
: 98 – 122.5 Nm {10 – 12.5 kgm}
HM300-2R 37
19. Subassembly of retainer and cage (differen-

tial lock clutch rear output side)
1) Expanshion-fit outer race (36) to cage (33).
20. Expanshion-fit outer race (31) to cage (30) on

the 2nd clutch side.
2) Press-fit oil seal (35) and dust seal (34) to

retainer (32), using push tool [29].
a Oil seal press-fit dimension "a"
: 11.5 ± 0.2 mm
a Press-fit dust seal (34) in the direction
shown in the figure.
a Dust seal press-fit dimension "b"
: 2.5 ± 0.2 mm
a Wipe out oozed gasket sealant com-
pletely after press-fitting.
2 Seal lip face and clearance between
dust seal and oil seal
: Silicone grease (G2-S (Three Bond 1855)) 21. Shim adjustment of taper roller bearing (2nd
2 Press-fitted surface of periphery on clutch side and differential lock clutch side)
cover side 1) Install cages (30) and (33) without shims to
: Gasket sealant (LG-5 (Three Bond 1110B)) the rear transmission case.
3 Mounting bolts of cages (30) and (33)
: 8.8 – 10.8 Nm {0.9 – 1.1 kgm}
2) Blow air into oil passage A through oil hole
B for the differential lock clutch to operate
this clutch, using tool D9, and rotate output
shaft (200) by 20 turns.
38 HM300-2R
3) Check that there is no change in the tighten- 13) Measure rotation torque of output shaft
ing torque of cages (30) and (33) mounting (200), and check that increment from the
bolts. If any, repeat the steps 1) and 2). value of rotation torque obtained in the step
4) Loosen cages (30) and (33) mounting bolts. 9) remains within the following range of val-
5) Measure rotation torque of output shaft ues. (See a note below.)
(200). a Rotation torque increment
a Rotation torque : 1.9 – 9.8 Nm {0.2 – 1.0 kgm}
: 11.8 – 17.6 Nm {1.2 – 1.8 kgm} Note: Only with the 2nd clutch, this measure-
6) Measure clearance "a" between cage (30) ment is to be taken at the time of shim
and the rear transmission case at three adjustment.
points of periphery (120° apart) and calcu-
late the average value.
a If fluctuation of the values measured at
three points does not fall within 0.15
mm, check whether the bearing is cor-
rectly installed, or there is any other
cause. Take a corrective action as the
case may be, and measure again.
7) Assemble shims (201) having thickness of
average value of "a" obtained in the step 6
above minus the following dimensions.
a Thickness decrement: 0.15 – 0.20 mm
a Shim thickness tolerance (for refer-
ence): 0.55 – 2.20 mm
8) Tighten cage (30) mounting bolts.
3 Mounting bolt
: 98 – 122 Nm {10 – 12.5 kgm}
9) Activate the differential lock clutch to mea-
sure rotation torque of output shaft (200),
and check that increment from the value of
rotation torque obtained in the step 5
remains within the following range of values.
a Rotation torque increment
: 4.9 – 12.8 Nm {0.5 – 1.3 kgm}
10) Measure clearance "b" between cage (33)
and the rear transmission case at three
points of periphery (120° apart) and calcu- 22. Install retainer (32).
late the average value.
a If fluctuation of the values measured at
three points does not fall within 0.15
mm, check whether the bearing is cor-
rectly installed, or there is any other
cause. Take a corrective action as the
case may be, and measure again.
11) Assemble shims (202) having thickness of
average value of "b" obtained in the step 10
above minus the following dimensions.
a Thickness decrement: 0.20 – 0.25 mm
a Shim thickness tolerance (for refer-
ence): 0.55 – 3.40 mm
12) Tighten cage (33) mounting bolts.
3 Mounting bolt
: 98 – 122 Nm {10 – 12.5 kgm}
HM300-2R 39
23. Install cover (305). 3 Main relief valve assembly mounting

3 Mounting bolt bolt
: 59 – 74 Nm {6 – 7.5 kgm} : 44.1 – 53.9 Nm {4.5 – 5.5 kgm}
2 Torque converter intermediate pres-
sure oil pressure sensor thread
3 Torque converter intermediate pres-
sure oil pressure sensor
: 9.8 – 19.6 Nm {0.15 – 0.20 kgm}
2 Torque converter output oil tempera-
ture sensor thread
3 Torque converter output oil tempera-
ture sensor
: 29.4 – 49 Nm {3 – 5 kgm}
24. Sling the transmission assembly and put it on

blocks as horizontally as if mounted on a truck.
25. Install output coupling (28) and input coupling
(27) together with the holder.
3 Output coupling mounting bolt
3 Output coupling mounting bolt
: 662 – 730 Nm {67.5 – 74.5 kgm}
2 Input coupling mounting bolt
3 Input coupling mounting bolt
: 245 – 309 Nm {25 – 31.5 kgm}
27. Transmission control valve assembly
1) Install filter assembly (303) to valve seat
(302).
a When case (310) and plug (311) have
been removed from the filter assembly,
tighten each of them to the following
torque.
3 Case
: 34.3 – 44.1 Nm {3.5 – 4.5 kgm}
3 Plug
: 15.7 – 19.2 Nm {1.6 – 2.0 kgm}
2) Install orifice (337) and (338).
a Take care not to install them to opposite
position because orifice (337) and (338)
26. Main relief valve assembly, valve flow are different parts.
assembly and each sensor a Take care for orifice (337) not to turn
Install main relief valve assembly (22), input upside down.
shaft rotation sensor (24), torque converter
intermediate pressure oil pressure sensor (25)
and torque converter outlet oil temperature sen-
sor (26).
a Degrease the grounding wire mounting part
on the main relief valve assembly thor-
oughly.
a When installing the input shaft rotation sen-
sor, refer to the section of "Adjusting trans-
mission speed sensor" in Testing and
adjusting
40 HM300-2R
28. Strainer (left and right)

Install block (17) and then strainer (16) and
cover (15).
3) Install each transmission control valve (21)

on the valve seat (302).
3 Mounting bolt
: 8 – 10 Nm {0.8 – 1.0 kgm} 29. Relief valve assembly
4) Install transmission control valve assembly 1) Install in the order of piping (14) and relief
(21) together with the valve seat (302) after valve assembly (13).
installing O-rings to the rear transmission
case.
5) Install tubes (18), (19) and (20).
HM300-2R 41
2) Install block (12).

a Tighten the mounting bolt temporarily.
(Refer to the step 30 when tightening for
the last time.)
3) Install lubrication oil temperature sensor
(LUB) (11).
2 Sensor thread
3 Lubrication oil temperature sensor
(LUB): 29.4 – 49 Nm {3 – 5 kgm}
30. Wiring harness, each sensor and piping

1) Install tubes (8), (9) and (10).
2) Tighten the mounting bolts of block (12)
which were temporarily tightened in the step
29 2).
3) Install output shaft rotation sensor (differen-
tial input) (7), output shaft R rotation sensor
(7-1).
7) Install connector B09 (4-1), (4-2) and (4-3).

8) Install cover (4).
4) Install inter-mediate shaft rotation sensor

(6).
a When installing them, refer to the sec-
tion of "Adjusting transmission speed
sensor" in Testing and adjusting.
5) Install wiring harness assembly (5).
6) Install connector (4-4).
42 HM300-2R
31. Trunnion
1) Install bushing (301) to trunnion (1) in the
following steps.
i) Remove smudges and oil inside the
trunnion with detergent.
ii) Ingrain primer for hardening promotion
of Loctite 712 in cloth and clean the mat-
ing surface on the bushing side.
2 Adhesive surface on bushing side
: Primer for hardening promotion
(Loctite 712 or equivalent)
iii) Coat the trunnion mating surfaces with
instant adhesive of Loctite Prism 411 (or
equivalent). Approx. 3g a bushing is a
benchmark for the adhesive to coat.
2 Adhesive surface on trunnion side
: Instant adhesive
(Loctite Prism 411 or equivalent)
iv) Press-fit the bushing into the trunnion.
a Press-fit within 5 minutes after coat-
ing the hard-to-stick application
adhesive compound of Loctite
Prism.
a Do not mix the primer with the adhe-
sive.
2) Install trunnions (1) and (3).

3) Install plate (2).
HM300-2R 43

© 2007 KOMATSU
All Rights Reserved
44 HM300-2R
SEN04033-00
HM300-2R


Power train, Part 3
Removal and installation of center differential assembly ................................................................................ 2
Disassembly and assembly of center differential assembly............................................................................ 6
Removal and installation of rear differential assembly.................................................................................. 23
Disassembly and assembly of rear differential assembly ............................................................................. 25
HM300-2R 1
Removal and installation of center 2) Sling carrier assembly (1) to remove.

differential assembly 1 [*2]
4 Carrier assembly: 40 kg (one side)
Special tools
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
790-101-5441 • Plate 1
4
H 790-101-5421 • Grip 1
01010-51240 • Bolt 1
5 790-201-2770 Spacer t 1
Removal 3) Sling sun gear and drive shaft assembly (3)

k Turn the parking brake switch on and put to remove. [*3]
wooden blocks behind the wheels. 4 Sun gear and drive shaft assembly
k Raise the body assembly fully and insert a : 25 kg (one side)
lock pin.
1. Drain oil from the center differential case and

center final drive case.
6 Center differential case: 25 l
6 Center final drive case: 4 l (one side)
2. Remove the left and right drive shafts in the fol-
lowing steps.
1) Remove the mounting bolts of carrier
assembly (1), and pull out of the final drive
assembly, using forcing screws [1] and 3. Remove drive shaft guard (4).
guide bolts [2]. [*1]
4. Sling drive shaft (5) between the hitch frame
and center differential temporarily, and discon-
nect it at the center differential side. [*4]
2 HM300-2R
5. Sling drive shaft (6) between the center differen- 9. Remove coupling (13).
tial and rear differential and disconnect it at the
center differential side. [*5]
6. Remove the mounting bolts of coupling (7) on
the transfer output side and remove the cou-
pling. [*6]
10. Disconnect 2 brake cooling hoses (10).

11. Disconnect 2 brake cooling tubes (11).
a Remove the U clamp and tube mounting
bolts from the left and right brakes.
7. Remove bracket (16) for remote breather.

8. Remove the mounting bolts of bearing cage
assembly (9) and remove the bearing cage
assembly (9) together with transfer output shaft
(8), using forcing screw [3]. [*7]
a Do not remove a under side mounting bolt
(b), but remove only 6 mounting bolts (a)
and a upper side mounting bolt (b).
12. Sling center differential assembly (12) and

remove the mounting bolts; separate the center
differential assembly from the axle case, using
forcing screws [2], and remove. [*8]
4 Center differential assembly: 300 kg
HM300-2R 3
Installation [*4] [*5]

a When installing the drive shaft between
hitch frame and center differential, let it face
removal.
in the same direction as that of the yoke of
drive shaft between the transmission and
[*1] [*2] [*3]
hitch frame.
a Install the carrier assembly in the following
a When installing, the yoke of drive shaft
steps.
1) Insert the carrier assembly into the cen- between the hitch frame and center differen-
ter axle assembly up to the intermediate tial and the yoke of drive shaft between cen-
point of sun gear and drive shaft assem- ter differential and rear differential must be
bly (3). shifted from each other by 45° ± 6°.
2) Assemble the sun gear portion of sun a When installing the drive shafts, check that
gear and drive shaft assembly (3) in the convex section on spider cap completely
lifted carrier assembly (2). engages with groove of counter yoke, and
3) In that condition, match the carrier then tighten the mounting bolts.
assembly with guide bolt [3], then match 2 Mounting bolt
the ring gear of the final drive assembly : Liquid adhesive (LT-2)
3 Mounting
with the planetary gear of the carrier
bolts for drive shaft
assembly, and push them in.
between transmission and hitch
3 Carrier assembly mounting bolt
frame and drive shaft between center
: 157 – 196 Nm {16 – 20 kgm}
differential and rear differential
[Target value: 177 Nm {18 kgm}] : 98 – 123 Nm {10 – 12.5 kgm}
[*6]
a Install as shifted from the coupling on the
input side of center differential by 45° ± 6°.
2 Mating faces between coupling and bear-
ing
: Lubricant containing molybdenum
disulfide (LM-P)
2 Coupling mounting bolt
: 490 – 608 Nm {50 – 62 kgm}
4 HM300-2R
[*7]
2 Transfer output shaft spline portion
: Extreme-pressure grease containing
molybdenum disulfide
3 Bearing cage assembly mounting bolt
a: 98 – 123 Nm {10 – 12.5 kgm}
b: 54 – 64 Nm {5.5 – 6.5 kgm}
[*8]
3 Center differential mounting bolt
: 157 – 196 Nm {16 – 20 kgm}
[Target value: 177 Nm {18 kgm}]
• Refilling with oil (center differential case and

center final drive case)
a When disassembling the bearing cage Refill with oil through the oil filler ports of the
assembly, press-fit oil seal (13) and side center differential case and left and right final
seal (14) into cage (15) in the following drive cases up to the specified level.
manner. 5 Center differential case
i) Press-fit oil seal (13) into cage (15), : 25l Axle oil (AXO80)
using tool H4. 5 Center final drive case
a Keep press-fitting until the oil seal : 4l (one side) Axle oil (AXO80)
periphery surface is flush with the cage
end surface.
2 Oil seal periphery
2 Oil seal lip face: Grease (G2-LI)
ii) Press-fit side seal (14) into cage (15),

using tool H5.
a Keep press-fitting until the side seal
periphery surface is flush with the cage
end face.
2 Side seal periphery: Seal end 242
2 Side seal lip face: Grease (G2-LI)
HM300-2R 5
Disassembly and assembly of 3. Cover

center differential assembly 1 Remove cover (3).
Special tools
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
792T-423-1130 Push tool t 1 Q
2 790-101-5421 Grip t 1
01010-51240 Bolt t 1
Unit repair stand
790-501-5000 t 1
(AC100V)
Unit repair stand 4. Input shaft cage
6 790-501-5200 (AC110V, t 1 1) Remove input shaft cage assembly (4),
AC220V) using forcing screws [1].
H 790-901-2110 Bracket t 1 a Shims are provided, so check their
792T-222-1210 Plate t 1 Q
7 792-103-0901 Wrench t 1
8 792T-223-1120 Push tool t 1 Q
792T-423-1140 Push tool t 1 Q
9 790-101-5421 Grip t 1
01010-51240 Bolt t 1
10 792T-223-1110 Push tool t 1 Q
Disassembly
1. Setting center differential assembly to tool
Set the center differential assembly to tool H6.
2) Remove side seal (6) and oil seal (7) from

cage (5).
3) Remove outer race (64).
2. Transfer input coupling and holder

Remove holder (1) and then remove coupling
(2).
6 HM300-2R
5. Transfer input shaft and gear assembly 7. Transfer case

1) Remove transfer input shaft and gear 1) Sling transfer case assembly (17) to
assembly (8). remove, using forcing screws [2].
2) Remove bearings (10) and (11), 2 spacers 2) Remove bearing (19) and outer races (20)
(12) and gear (13) from transfer input shaft and (21) from transfer case (18).
(9).
6. Input shaft holder

a Before removing the holder, put wooden
blocks or the like under the bevel pinion so
as not to let it fall.
1) Remove holder (14).
2) Remove holder (15) and key (16).
HM300-2R 7
8. Spacer and input gear 10. Bevel pinion and bearing assembly
1) Remove spacer (22). 1) Remove bevel pinion and bearing assembly
2) Remover spacer cover (23) and then (28).
remove input gear (24).
2) Remove bearing (30) from bevel pinion (29).

9. Cage assembly
1) Remove cage assembly (25), using forcing
screws [3].
2) Remove outer race (27) from cage (26).
8 HM300-2R
11. Removal of differential gear assembly 2) Remove bearing (41) from case (40).
1) Reverse tool H6.
2) Remove locks (32) and (33) together with
cover (31).
3) Loosen adjusting nuts (34) and (35) using
tool H7 until they can be loosened manually.
4) Sling the differential gear assembly and
remove bearing caps (36) and (37) as well
as adjusting nuts (34) and (35).
5) Sling differential gear assembly (38) to
remove.
a Be careful then not to let fall the bearing
outer race.
12. Further disassembly of differential gear

assembly 4) Remove 3 plates (43) and 2 discs (44).
1) Remove case and bearing assembly (39).
HM300-2R 9
5) Remove pressure ring (45). 8) Remove pinion gears (49) and bushings
a Lift the ring with a finger inserted into the (50) 4 for each from shaft (48).
case side hole.


7) Remove pinion gear assembly (47) in one
piece.
10 HM300-2R
11) Remove 3 plates (54) and 2 discs (53). Assembly

a Clean each of the parts and check that it is free
of dust or damage, then coat the sliding surface
with axle oil (AXO80) and assemble.

: For 30 minutes at 120°C
a After shrink fitting, drip axle oil (AXO80)
on the bearing.
a Install the gear, matching the counter
marks which were put when removing.
2 Mounting bolt
13) Reverse the bevel gear assembly. : Liquid adhesive (LT-2)
14) Remove bevel gear (56) from case (57). 3 Mounting bolt
a Before removing, put a counter mark : 157 – 196 Nm {16 – 20 kgm}
both on the bevel gear and on the case.
3) Reverse the case and bevel gear assembly.

4) Put washer (55) in the case (54).
periphery.
Record the values measured at the 4 places
in the check sheet and obtain an average.
Average of level difference C2 = Total of val-
ues measured at 4 places / 4
HM300-2R 11
6) Assemble 3 plates (54) and 2 discs (53) for 9) Install bushings (50) and pinion gears (49) 4
each. for each to shaft (48).
lowing oil before installing.
discs.
10) Install pinion gear assembly (47) in one

piece.
7) Install pressure ring (52) to the case.
12 HM300-2R
iv) Using the depth gauge, measure level

a Immerse the discs and plates in the fol- the periphery.
lowing oil before installing. Record the values measured at the 4
average.

equally spaced on the periphery.
average.
Average of level difference A1 = Total of
ii) Set washer (42) on case (40).
a Direct the lined face toward the
gear.
iii) Using the depth gauge, measure level
difference C1 between case (40) and
washer (42) at 4 places equally spaced
on the periphery.
average.
Average of level difference C1 = Total of
HM300-2R 13
v) While pressing the disc and plate with a xi) If either or both of clearances B1 and B2
force of 686 N {70 kg}, perform steps vi) are out of the above range, replace
and vii). washers (42) and (55) and measure
vi) Using the depth gauge, measure level dimensions C1 and C2 again until
difference A2 between case (57) and proper clearances are obtained.
plate (43) at 4 places equally spaced on • Thicknesses of washers:
the periphery. Record the values mea- 4.0 mm, 4.1 mm
sured at the 4 places in the check sheet 15) Install washer (42).
and obtain an average. a Direct the lined face toward the gear.
vii) Using the depth gauge, measure level
the periphery. Record the values mea-
sured at the 4 places in the check sheet
and obtain an average.

• Bearing shrink-fit temperature
after installing.
viii) Calculation method for clearance A

between disc and plate.
Clearance A = Clearance A2 – Clear-
ance A1
a Check that clearance A is 0.2 – 0.75
mm.
ix) If clearance A is out of the above range,
replace plate (43) and measure dimen-
sion A2 again until a proper clearance is
obtained.
the same.
3.1 mm, 3.2 mm
a Use the clearance obtained in viii)
as clearance A.
a Check that both clearances B1 and
B2 are 0.15 – 0.35 mm.
14 HM300-2R
17) Install case and bearing assembly (39). 3. Adjustment of bearing pre-load
3 Mounting bolt 1) Tighten adjusting nuts (34) and (35), using
: 98 – 123 Nm {10.0 – 12.5 kgm} tool H7.
thoroughly.
a Rap the bevel gear with a copper ham-
mer, while rotating the bearing, so that
the bearing sits well with other parts in
contact.
2. Installation of differential gear assembly

1) Sling differential gear assembly (38) and
keep it above the installing position of differ-
ential case (60).
a Keep the differential gear assembly in
loose contact with the differential case.
2) Install an outer race to the bearing, and 2) Measure start torque in the tangential direc-
tighten adjusting nuts (34) and (35) to the tion at the peripheral addendums of bevel
differential case temporarily. gear (56), using push-pull scale [4].
: 7.1 – 19.6 N (0.73 – 2.0 kg)
a If the start torque is lower than the stan-
dard value, tighten the adjusting nuts,
and if it is higher, loosen the nuts.
a When the adjusting nut is loosened on
one side, tighten the nut on the opposite
side as much.
3) Install bearing caps (37) and (36) and

tighten the mounting bolts.
2 Mounting bolt
3 Mounting bolt
: 824 – 1,030 Nm {84 – 105 kgm}
HM300-2R 15
4. Subassembly of transfer input shaft 3) Press-fit side seal (6), using tool H2.
1) Install gear (13) and 2 spacers (12) to trans- a Keep press-fitting until the side seal
fer input shaft (9). periphery surface is flush with cage (12)
2 Spline portion of inserted gear end surface.
: Extreme-pressure grease containing 2 Side seal periphery surface
molybdenum disulfide : Seal end 242 or equivalent
2) Press-fit bearing (11), using tool H8. 2 Side seal lip face and inside of side
a Press-fit bearing (10) in the same man- seal (100% full): Grease (G2-LI)
ner, too.
6. Transfer case
5. Subassembly of transfer input shaft cage Install outer races (20) and (21) to transfer case
1) Install outer race (64) to cage (5). (18).
2) Press-fit oil seal (7), using tool H9.
a Keep press-fitting until distance " f "
between the oil seal periphery surface
and end surface of cage (12) is 10 ± 0.5
mm.
2 Oil seal lip face and inside of oil seal
16 HM300-2R
7. Adjustment of pre-load on transfer input 8. Bevel pinion and bearing assembly

shaft 1) Install bearing (30) to bevel pinion (29).
1) Support transfer case assembly (17) with a Shrink-fit bearing (30), or press-fit, using
wooden blocks, then assemble transfer push tool H10.
input shaft and gear assembly (8), and
install input shaft cage assembly (4).
a Assemble the standard shims (having
thickness checked at the time of disas-
sembling) and install the input shaft
cage assembly.
a Keep tightening the mounting bolts,
while rotating the bearing, until the bear-
ing is steadied.
3 Mounting bolt
: 157 – 196 Nm {16 – 20 kgm}
2) Measure the endplay with dial gauge [5]
while lifting and lowering input shaft and
gear assembly (8) with a crane.
3) Adjust thickness of shims (61) so that the
endplay may reach the standard value.
• Standard value for endplay
: 0 – 0.05 mm
• Shim adjustment allowance
: 0.8 – 1.7 mm
• Kind of shim thickness
: 0.15 mm, 0.18 mm, 0.2 mm,
0.3 mm and 0.8 mm
4) After adjusting the shim thickness, once
remove transfer input shaft and gear
assembly (8) and input shaft cage assembly
2) Install bevel pinion and bearing assembly
(4).
(28).
HM300-2R 17
9. Cage assembly 10. Spacer and input gear

1) Install outer race (27) to cage (26). 1) Assemble in input gear (24).
2) Install cover (23).
3 Mounting bolt
: 98 –123 Nm {10 – 12.5 kgm}
3) Assemble spacer (22) in.
a When changing thickness of the shims
as a result of carrying out "Tooth contact
and backlash adjustment" in the subse-
quent section of 12, change the spac-
ers, too, in reference to Table 1 above.
2) Install cage assembly (25).

a Assemble shims (62), whose thickness,
number in use and installed location
were confirmed at the time of disassem-
bling, in cage assembly (25), and install
the cage assembly.
a Determine thickness and number in use
of shims after carrying out "Tooth con-
tact and backlash adjustment" in the
subsequent section of 12. 4) Sling transfer case assembly (17) to install.
3 Mounting bolt 2 Case mating face
: 157 – 196 mm {16 – 20 kgm} : Gasket sealant (LT-515 or equivalent)
3 Mounting bolt
Table 1
MD shim Letter Dimension of : 98 – 123 Nm {10 – 12.5 kgm}
thickness Spacer part No. notched spacer width
range (mm) on spacer (mm)
1.07 – 1.16 56D-23-16900 A 24.765 ± 0.025
1.17 – 1.26 56D-23-16910 B 24.665 ± 0.025
1.27 – 1.36 56D-23-16920 C 24.565 ± 0.025
1.37 – 1.46 56D-23-16930 D 24.465 ± 0.025
1.47 – 1.56 56D-23-16940 E 24.365 ± 0.025
1.57 – 1.66 56D-23-16950 F 24.265 ± 0.025
1.67 – 1.76 56D-23-16960 G 24.165 ± 0.025
1.77 – 1.86 56D-23-16970 H 24.065 ± 0.025
1.87 – 1.96 56D-23-16980 I 23.965 ± 0.025
1.97 – 2.06 56D-23-16990 J 23.865 ± 0.025
18 HM300-2R
11. Bearing 12. Tooth contact and backlash adjustment

1) Assemble bearing (19) in. • Adjust backlash and at the same time,
2) Press-fit bearing (19) using push tool [5]. adjust tooth contact.
1) Adjustment of backlash
i) To shift the bevel gear, use adjusting
nuts (36) and (37). In that case, if loos-
ening the adjusting nut on one side,
tighten the adjusting nut on the opposite
side as much, in order not to change the
pre-load given to the bearing.
3) Install holder (14) after being fitted with

holder (15) and key (16).
a Assemble the shims whose thickness,
number in use and installed location
were confirmed at the time of disassem-
bling.
ii) Apply the probe of dial gauge [7] per-
: 0.15 mm, 0.18 mm, 0.2 mm and 0.5 mm
pendicularly to the addendums of bevel
• Shim adjustment allowance gear.
: 0.36 – 1.74 mm iii) Fix the bevel pinion and shift the bevel
2 Mounting bolt gear back and forth (in the direction of
: Liquid adhesive (LT-2) rotation), then read out the dial.
3 Mounting bolt • Standard value for backlash:
: 824 – 1,030 Nm {84 – 105 kgm} In the circumferential direction of the
4) Measure start torque of the input shaft at the gear: 0.36 – 0.55 mm
holder mounting bolt, using torque wrench In the perpendicular direction to the
[6]. gear: 0.25 – 0.38 mm
• Start torque a Make this adjustment at 3 points. Keep
: 4.1 – 9.0 N {0.42 – 0.92 kg} fluctuation of the backlash below 0.1
a If the measured start torque falls out of mm.
the standard value, either increase or
decrease the shim thickness and mea-
sure again.
HM300-2R 19
iv) If the measured value of backlash falls Inspection

out of the standard value as a result of i) Coat the tooth surface of bevel gear with
the measurement, make adjustment in minimum or red lead thinly, and check a
the following manner. tooth contact pattern on the bevel gear
• When there is small backlash: after moving the bevel gear back and
Loosen the adjusting nut on the left side forth.
of chassis and tighten the adjusting nut ii) The center of tooth contact must come
on the right side as much (shift the bevel in the middle of tooth height. Moreover,
gear in direction A). it must be approx. 33% away from the
and big end D.
load is applied.
• When there is big backlash:

Loosen the adjusting nut on the right
side of chassis and tighten the adjusting
nut on the left side as much (shift the
bevel gear in direction B).
2) Adjustment of tooth contact

• To shift the bevel pinion, increase or
decrease the number of shims (62) between
differential case (60) and cage (26).
20 HM300-2R
Adjustment
obtained as a result of inspection, make
a To shift the bevel gear, use the left and
right adjusting nuts. In that case, if loos-
ening the adjusting nut on one side,
tighten the adjusting nut on the other as
much, in order not to change the pre-
load given to the bearing.
small end tooth face of the bevel gear 3) After adjusting the tooth contact, tighten the
tooth face curved outward with the big bevel pinion cage mounting bolts.
3 Mounting bolt
face curved inward.
: 157 – 196 Nm {16 – 20kgm}
ner. 13. Lock and cover
Shift the bevel pinion in direction A by Install locks (32) and (33) for the left and right
adjusting the shims on the bevel pinion adjusting nuts and cover (31).
3 Mounting bolt
side.
In addition, shift the bevel gear in direc- : 157 – 196 Nm {16 – 20 kgm}
tion B and check the tooth contact pat-

inward.
ner.
side.
HM300-2R 21
14. Transfer input shaft 17. Bevel gear fall-proof bolt

1) Assemble transfer input shaft and gear Install bevel gear fall-proof bolt (63).
assembly (8). a Tighten the bolt until it touches the backside
2 Input shaft spline (both sides) of bevel gear, then loosen by a 3/4 turn and
: Extreme-pressure grease containing fix with a lock nut.
molybdenum disulfide 2 Mounting bolt: Gasket sealant (LG-5)
2) Assemble shims (61) selected in the forego- 3 Lock nut: 196 – 245 Nm {20 – 25 kgm}
ing step 7, then install an O-ring and install
input shaft cage assembly (4).
3 Mounting bolt
: 157 – 196 Nm {16 – 20 kgm}
15. Cover
Install cover (3).
2 Cover mating part
: Gasket sealant (LT-515)
3 Mounting bolt
: 98 – 123 Nm {10 – 12.5 kgm}
16. Transfer input coupling and holder
Install an O-ring and coupling (2), then install
holder (1).
2 Mating part g of bearing and coupling
disulfide (LM-P)
3 Mounting bolt
: 490 – 608 Nm {50 – 62 kgm}
22 HM300-2R
Removal and installation of rear 2) Sling carrier assembly (1) to remove.

differential assembly 1 [*2]
Removal 4 Carrier assembly: 40 kg (one side)
k Turn the parking brake switch on and put

wooden blocks behind the wheels.
1. Remove the body assembly, referring to the

section of "Removal and installation of body
assembly".
2. Drain oil from the rear differential case and rear
final drive case.
6 Rear differential case: 25l
6 Rear final drive case: 5l (one side)
3. Remove the left and right drive shafts in the fol-
lowing manner. 3) Sling sun gear and drive shaft assembly (3)
1) Remove the mounting bolts of carrier to remove. [*3]
assembly (1), and pull it out of the final drive 4 Sun gear and drive shaft assembly
assembly, using forcing screws [1] and : 25 kg (one side)
guide bolts [2]. [*1]
4. Sling drive shaft (6) between the center differen-

tial and rear differential temporarily and discon-
nect at the rear differential side. [*4]
HM300-2R 23
5. Remove the rear differential assembly. Installation

1) Remove the mounting bolts of rear differen-
tial assembly (7) and separate it from the
removal.
axle case, using forcing screw bolts [3].
[*5]
[*1] [*2] [*3]
a Install the carrier assembly in the following
steps.
1) Insert the carrier assembly into the cen-
ter axle assembly up to the middle point
of sun gear and drive shaft assembly
(3).
2) Assemble the sun gear portion of sun
gear and drive shaft assembly (3) in
lifted carrier assembly (2).
3) Push the carrier assembly in along
guide bolts [3], matching the ring gear of
the final drive assembly with the plane-
tary gear of the carrier assembly.
3 Carrier assembly mounting bolt
2) Sling rear differential assembly (7) to
: 157 – 196 Nm {16 – 20 kgm}
remove, using eyebolts [5] and guide bolts
[4].
4 Rear differential assembly: 200 kg
[*4]
a Install after confirming that the yoke of drive
shaft between the hitch frame and center
differential is shifted from the yoke of drive
shaft between center differential and rear
differential by 45° ± 6°.
a When installing the drive shafts, tighten the
mounting bolts only after confirming that
convex section on the spider cap completely
engages with groove of the counter yoke.
2 Mounting bolt
: Liquid adhesive compound (LT-2)
3 Mounting bolt for drive shaft between
center differential and rear differential
: 98 – 123 Nm {10 – 12.5 kgm}
24 HM300-2R
[*5] Disassembly and assembly of rear

3 Rear differential mounting bolt differential assembly 1
: 157 – 196 Nm {16 – 20 kgm}
[Target value: 177 Nm {18 kgm}] Special tools
New/Remodel
• Refilling with oil (rear differential case and
Sym-
Necessity
rear final drive case) Part No. Part name
bol
Sketch
Refill with oil through the oil filler port of rear dif-
Q'ty
ferential case and through oil filler ports of the
left and right rear final drives up to the specified Unit repair stand
790-501-5000 t 1
level. (AC100V)
5 Center differential case Unit repair stand
: 25l Axle oil (AXO80) 6 790-501-5200 (AC110V and t 1
5
AC220V)
Center final drive case H
: 5l (one side) Axle oil (AXO80) 790-901-2110 Bracket t 1
792T-222-1210 Plate t 1 Q
7 792-103-0901 Wrench t 1
10 792T-223-1110 Push tool t 1 Q
Disassembly
1. Setting rear differential assembly to tool H6
Set the rear differential assembly to tool H6.
2. Input coupling and holder
Remove holder (1) and then remove coupling
(2).
HM300-2R 25
3. Pinion and cage assembly 4) Further disassembly of pinion assembly

1) Remove pinion and cage assembly (3), Remove spacer (10) and bearing (11) from
using forcing screws [1]. pinion (9).
location beforehand.
5) Further disassembly of cage assembly

Remove bearing (13) and bearing outer
races (14) and (15) from cage (12).
2) Remove side seal (5) and oil seal (6) from
a Bearing (13) has already been removed
the pinion and cage assembly.
in the step 3).
3) Remove pinion assembly (7) from cage

assembly (8), using push tool [2].
26 HM300-2R
4. Removal of differential gear assembly 5. Further disassembly of differential gear

1) Reverse tool H6. assembly
2) Remove locks (16) and (17) together with 1) Remove case and bearing assembly (23).
the cover.
3) Loosen adjusting nuts (18) and (19), using
tool H7, until they can be turned manually.
4) Sling the differential gear assembly and
remove bearing caps (20) and (21) as well
as adjusting nuts (18) and (19).
2) Remove bearing (25) from case (24).
5) Sling differential gear assembly (22) to

remove.
a Be careful not to let fall the bearing outer
race.
HM300-2R 27
4) Remove 3 plates (27) and 2 discs (28). 7) Remove pinion gear assembly (31) in one
piece.

a Put your fingers in the side hole and 8) Remove pinion gears (33) and bushings
raise the ring. (34) 4 for each from shaft (32).
6) Remove differential side gear (30). 9) Remove differential side gear (35).
28 HM300-2R
10) Remove pressure ring (36). Assembly

a Clean each of the parts and check that it is free
of any dust and damage. Coat the sliding sur-
faces with axle oil (AXO80) before assembling.
• Bearing shrink-fit temperature
a After installing, drip axle oil (AXO80) on
the bearing.
a Install matching the counter marks
which were put at the time of disassem-
11) Remove 3 plates (38) and 2 discs (37). bling.
2 Mounting bolt
3 Mounting bolt
: 157 – 196 Nm {16 – 20 kgm}
13) Reverse the case and bevel gear assembly.

14) Remove bevel gear (40) from case (41).
a Before removing, put a counter mark
both on the bevel gear and on the case.
HM300-2R 29
3) Reverse the case and bevel gear case 7) Install pressure ring (36) to the case.
assembly.
4) Put washer (39) in the case (41).
periphery.
Record the values measured at the 4 places
in the check sheet and obtain an average.
Average of level difference C2 = Total of val-
ues measured at 4 places / 4

lowing oil before installing. 9) Install bushings (34) and pinion gears (33) 4
2 Disc and plate: Axle oil (AXO80) for each to shaft (32).
discs.
30 HM300-2R
10) Install pinion gear assembly (31) in one 13) Assemble 3 plates (27) and 2 discs (28).
piece. a Immerse the discs and plates in the fol-
lowing oil before installing.
11) Install differential gear (30).

equally spaced on the periphery.
average.
ii) Set washer (26) on case (24).
a Direct the lined face toward the
gear.
iii) Using the depth gauge, measure level
difference C1 between case (24) and
washer (26) at 4 places equally spaced
on the periphery.
average.
Average of level difference C1 = Total of
HM300-2R 31
iv) Using the depth gauge, measure level viii) Calculation method for clearance A
difference D2 between gear (30) and between disc and plate.
plate (27) at 4 places equally spaced on Clearance A = Clearance A2 – Clear-
the periphery. ance A1
Record the values measured at the 4 a Check that clearance A is 0.2 – 0.75
places in the check sheet and obtain an mm.
average. ix) If clearance A is out of the above range,
Average of level difference D2 = Total of replace plate (27) and measure dimen-
values measured at 4 places / 4 sion A2 again until a proper clearance is
obtained.
the same.
3.1 mm, 3.2 mm
a Use the clearance obtained in viii)
v) While pressing the disc and plate with a as clearance A.
force of 686 N {70 kg}, perform steps vi) a Check that both clearances B1 and
and vii). B2 are 0.15 – 0.35 mm.
vi) Using the depth gauge, measure level xi) If either or both of clearances B1 and B2
difference A2 between case (41) and are out of the above range, replace
plate (27) at 4 places equally spaced on washers (26) and (39) and measure
the periphery. Record the values mea- dimensions C1 and C2 again until
sured at the 4 places in the check sheet proper clearances are obtained.
and obtain an average. • Thicknesses of washers:
Average of level difference A2 = Total of 4.0 mm, 4.1 mm
values measured at 4 places / 4 15) Install washer (26).
vii) Using the depth gauge, measure level a Direct the lined face toward the gear.
the periphery. Record the values mea-
sured at the 4 places in the check sheet
and obtain an average.
32 HM300-2R
16) Shrink-fit bearing (25) to case (24). 2) Install an outer race to the bearing and
• Bearing shrink-fit temperature tighten adjusting nut (19) to the differential
: For 30 minutes at 120°C case temporarily.
a Drip axle oil (AXO80) on the bearing a Install an outer race and tighten the
after installing. adjusting nut in the same manner on the
other side, too.
17) Install case and bearing assembly (23).

3 Mounting bolt 3) Install bearing caps (21) and (20), and
: 98 – 123 Nm {10.0 – 12.5 kgm} tighten the mounting bolts.
a Install the caps in the same manner on
the other side, too.
2 Mounting bolt
3 Mounting bolt
: 824 – 1,030 Nm {84 – 105 kgm}
2. Installation of differential gear assembly

1) Sling differential gear assembly (22) on the
installing position of differential case (43).
a Do not fix it to the differential case yet.
HM300-2R 33
3. Adjustment of bearing pre-load 4. Subassembly of bevel pinion and cage

1) Tighten adjusting nuts (19) and (18), using assembly
tool H7. 1) Subassembly of cage assembly
a Drip an ample amount of axle oil (AXO80) Install outer races (15) and (14) to cage
on the bearing. (12).
a Rap the bevel gear with a copper ham-
mer, while rotating the bearing, so that
the bearing can have a good contact
with other parts.
2) Subassembly of bevel pinion assembly

Install bearing (11) to bevel pinion (9).
a When installing the bearing, either
shrink-fit or press-fit it using push tool
2) Measure start torque in the tangential direc- H10.
tion at the peripheral addendums of bevel
gear (40), using push-pull scale [3].
: 7.2 – 19.6 N {0.73 – 2.0 kg}
a If the measured start torque is lower
than the standard value, tighten the
adjusting nut. If it is higher than the stan-
dard value, loosen the adjusting nut.
a When tightening the adjusting nut on
one side, loosen the adjusting nut on the
opposite side as much.
34 HM300-2R
3) Install spacer (10) to bevel pinion (9). 7) Press-fit oil seal (6), using tool [5].
a Keep press-fitting until distance "f"
between the peripheral surface of oil
seal and the end surface of cage (12) is
10 ± 0.5 mm.
2 Oil seal peripheral surface
4) Mount cage assembly (8) on bevel pinion

assembly (7).
5) Assemble bearing (13) in.
6) Press-fit bearing (13), while turning case
assembly (8), using coupling (2), holder (1)
and push tool [4].
a Drip axle oil (AXO80) on bearing (13).
a Remove holder (1) and coupling (2)
after press-fitting. 8) Press-fit side seal (5), using tool [6].
a Press-fit so that the peripheral surface
of the side seal is flush with the end sur-
face of cage (12).
2 Side seal peripheral surface
2 Side seal lip face and inside of side
seal (100% full): Grease (G2-LI)
HM300-2R 35
5. Installation of bevel pinion and cage 7. Adjustment of tooth contact and backlash
assembly • Adjust the backlash and also the tooth con-
Assemble shims (4) whose thickness, number tact at the same time.
in use and installed location were confirmed at 1) Adjustment of backlash
the time of disassembling, then sling bevel pin- i) When shifting the bevel gear, do so with
ion and cage assembly (3) to install. adjusting nuts (18) and (19). In that case,
• Kind of shim thickness if tightening the adjusting-nut on one
: 0.15 mm, 0.2 mm, 0.3 mm and 0.8 mm side, loosen the adjusting-nut on the
3 Mounting bolt opposite side as much in order not to
: 157 – 196 Nm {16 – 20 kgm} change the preload given on the bearing.
a Determine the thickness and number of
shims to be used after carrying out the fol-
lowing "Adjustment of tooth contact and
backlash".
ii) Apply the probe of dial gauge [7] per-

pendicularly to the addendums of bevel
gear.
iii) Read out the dial when moving the
bevel gear back and forth (in the direc-
6. Input coupling and holder
tion of rotation), while fixing the bevel
Remove coupling (2) and holder (1) with the O-
pinion.
ring.
• Standard value for backlash:
3 Mounting bolt
In the circumferential direction of the
: 490 – 608 Nm {50 – 62 kgm} gear: 0.36 – 0.55 mm
In the perpendicular direction of the
gear: 0.25 – 0.38 mm
a Make this adjustment at 3 points and
keep fluctuation of the measured back-
lash values less than 0.1 mm.
36 HM300-2R
iv) If the measured backlash is found to fall 2) Adjustment of tooth contact

out of the standard value as a result of • Adjust the tooth contact of bevel pinion by
the measurement, make adjustment in either increasing or decreasing the number
the following manner. of shims (4) between differential case (41)
• When there is small backlash: and cage (12).
Loosen the adjusting nut on the right
side of chassis and tighten the adjusting
nut on the left side as much shift (i.e.
shifting the bevel gear in direction A).
• When there are big backlash:

Loosen the adjusting nut on the left side
of chassis and tighten the adjusting nut
on the right side as much (i.e. shifting
the bevel gear in direction B).
HM300-2R 37
Inspection • Make adjustment in the following man-

i) Coat the tooth surface of bevel gear with ner.
minimum or red lead thinly, and check a Shift the bevel pinion in direction A by
tooth contact pattern on the bevel gear adjusting the shims on the bevel pinion
after moving the bevel gear back and side.
forth. In addition, shift the bevel gear in direc-
ii) The center of tooth contact must come
in the middle of tooth height. Moreover,
it must be approx. 33% away from the
and big end D.
load is applied.

inward.
ner.
side.
Adjustment
obtained as a result of the inspection, make
small end tooth face of the bevel gear
tooth face curved outward with the big
face curved inward.
38 HM300-2R
3) After adjusting the tooth contact, tighten the

bevel pinion cage mounting bolts.
3 Bevel pinion cage mounting bolts
: 157 – 196 Nm {16 – 20kgm}
8. Lock and cover
Install adjusting nut locks (17) and (16) as well
as cover (44).
3 Mounting bolt
: 157 – 196 Nm {16 – 20 kgm}
9. Bevel gear fall-proof bolt

Install bevel gear fall-proof bolt (45).
a Tighten the bolt until it touches the backside
of bevel gear, then loosen by a 3/4 turn and
fasten with the lock nut.
2 Mounting bolt: Gasket sealant (LG-5)
3 Lock nut: 196 – 245 Nm {20 – 25 kgm}
HM300-2R 39

© 2007 KOMATSU
All Rights Reserved
40 HM300-2R
SEN04034-00
HM300-2R


Power train, Part 4
Removal and installation of front final drive and brake assembly ................................................................... 2
Disassembly and assembly of front final drive and brake assembly............................................................... 5
Removal and installation of center final drive and brake assembly .............................................................. 15
Disassembly and assembly of center final drive and brake assembly .......................................................... 17
HM300-2R 1
Removal and installation of front 4) Sling front wheel (2) and remove the mount-
final drive and brake assembly 1 ing bolts. [*1]
4 Front wheel: 550 kg (one side)
Removal
1. Drain oil from the front final drive case.

6 Front final drive case: 4.5l (one side)
2. Remove the front wheels.
1) Push up the underside of front axle on the
side of wheel to be removed, using hydrau-
lic jacks [1].
2) Support the front axle underside with a ped- 3. Remove cover (20).
estal (frame) [2].
4. Disconnect drive shaft (3) at the front differential

3) Sling left fender (1) to remove. side. [*2]
4 Left fender: 80 kg
2 HM300-2R
5. Remove brake cooling tube (4).

6. Disconnect breather hose (5).
7. Disconnect brake actuating hose (6) and drain
hose (6-1).
8. Disconnect catch tank drain hose (7).
9. Disconnect wiring connectors (If equipped) (8).

• Right final drive: B28
• Left final drive: B01
10. Remove brake wear sensor (If equipped) (9).
11. Sling final drive and brake assembly (10) tem-

porarily, and remove the 14 mounting bolts (11)
and 8 mounting nuts (12). [*3]
4 Front final drive and brake assembly
(including drive shaft)
: 420 kg (one side)
HM300-2R 3
Installation
removal.
[*1]
3 Front wheel mounting bolt
: 824 – 1,030 Nm {84 – 105 kgm}
[*2]
a When installing the drive shaft, check that
the convex section on spider cap completely
engages with groove of the counter yoke,
and then tighten the mounting bolts.
2 Drive shaft mounting bolt
: 98 – 123 Nm {10 – 12.5 kgm}
[*3]
mounting bolt: Liquid adhesive (LT-2)
mounting bolt
: 490 – 608 Nm {50 – 62 kgm}
mounting nut
: 422 – 520 Nm {43 – 53 kgm}
• Refilling with oil (front final drive case)

Refill with oil through the oil filler port of front
final drive up to the specified level.
5 Front final drive case
: 4.5l (one side) Axle oil (AXO80)
• Air bleeding (brake)

After installing, bleed air from the brake circuit,
referring to the section of "Bleeding air from
brake circuit". in Testing and adjusting.
4 HM300-2R
Disassembly and assembly of 2. Remove cover (51).

front final drive and brake
assembly 1
Special tools
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
792T-227-1120 Fixture t 3 Q
792T-223-1140 Plate t 3 Q
01010-61240 Bolt t 3
1 01643-31232 Washer t 3 3. Removal of carrier assembly
01580-01210 Nut t 3 1) Separate carrier assembly (2), using forcing
01010-61245 Bolt t 3 screws [1].
01010-62440 Bolt t 3
2 792T-222-1220 Push tool t 1 Q
J 792T-227-1130 Push tool t 1 Q
3 790-101-5221 Grip t 1
01010-81225 Bolt t 1
4 791-580-1520 Installer t 1
5 791-580-1510 Installer t 1
793T-622-1110 Push tool t 1 Q
6 790-101-5421 Grip t 1
01010-81240 Bolt t 1
7 797T-622-1240 Push tool t 1 Q
2) Sling carrier assembly (2) to remove.
Disassembly
1. Drive shaft
Remove drive shaft (1).
a Take care so that the drive shaft cap (yoke)
will not slip off.
HM300-2R 5
4. Further disassembly of carrier assembly 3) Remove shaft (10).

1) Drive spring pin (3) into shaft (4), using a Drain oil remaining in the case.
round bar [2].
2) Drive out shaft (4) and remove bearing (5)
and gear (6).
3) Pull spring pin (3) out of shaft (4).
6. Plate
1) Remove plate (11), using forcing screws [3].
7. Retainer and shim

1) Fix tools J1 at three points between the
5. Sun gear and shaft
outer gear and wheel hub (inner gear).
a Be sure to fix tools J1 before removing
2) Remove sun gear (8) and collar (9).
retainer (12) in order not to give damage
a When removing the snap ring, be careful not
to the floating seal.
to expand it too widely. Moreover, if the snap a Fix tools J1 at an equal interval.
ring inner diameter is found to exceed 46.5 2) Remove retainer (12) and shims (13).
mm, or if there is a height difference of more a Check their thickness, number in use
than 0.3 mm when it is put on a flat surface, and installed location beforehand.
do not use it but replace with new one.
8. Removal of ring gear
Remove ring gear (14).
6 HM300-2R
9. Further disassembly of ring gear 12. Separation of outer gear assembly and inner
1) Remove 6 plates (15). gear assembly
2) Remove inner hub (17) from ring gear (16). 1) Remove cylinder and piston assembly (23).
3) Remove bearing (18) from inner hub (17).
2) Remove piston (25) from cylinder (24).

10. Floating seal retainer and floating seal
1) Remove the assembly of floating seal
retainer (19) and floating seal (20), using
forcing screws [4].
3) Remove seal rings (26) and (27) from cylin-

der (24) and piston (25).
11. Removal of brake assembly

1) Remove brake assembly (22) from shaft
(tube) (21).
a Before removing, put a counter mark on
the assembly and shaft.
2) Remove tools J1 from the brake assembly.
HM300-2R 7
4) Remove the mounting bolts (28-1) and sling 14. Further disassembly of inner gear assembly
outer gear and disc plate assembly (28) to 1) Remove sleeve (47) and plate (34) from hub
remove. (inner gear) (37).
2) Remove floating seals (38) and (39).
3) Remove outer races (40) and (41).
13. Further disassembly of outer gear assembly

1) Remove dampers (30a) and (30b), 6 plates
(31), 7 discs (32) and plate (33) from outer 15. Further disassembly of shaft assembly
gear (29). 1) Remove bearing (43) and retainer (44) from
shaft (tube) (42).
2) Remove oil seal (35) from outer gear (29).

3) Remove floating seal (36). 2) Remove oil seal (45) and bushing (46).
8 HM300-2R
Assembly 3) Install bushing (46) to shaft (42).

• Install so that dimension "b" between
a Before installing, clean each of the parts thor-
the shaft end surface and bushing end
oughly; also check that it is free of dust and
damage and coat the sliding surface with axle surface is 5 ± 0.2 mm.
oil (AXO80). 4) Install oil seal (45), using tool J3.
a Install so that dimension "d" between the
a Precautions when installing floating seal
shaft end surface and bushing end surface
• When installing a brand-new oil seal, com-
is 33 ± 0.2 mm.
pletely wipe out white dust on the O-ring
surface with alcohol.
• Degrease the mating face of O-ring before
installing.
• Install the O-ring with a push-in type special
tool.
• Coat sealing face A with engine oil. Also
check that the face is free of dust.
• Measure dimension "a" (at 4 points on the
circumference) that is the seal height
against the gear and hub as well as retainer
and confirm that the difference of the mea-
sured dimension "a" is less than 1 (mm).
2. Subassembly of inner gear assembly

1) Install outer races (41) and (40) to hub
(inner gear) (37).
2) Put plate (34).
3) Press-fit sleeve (47) for the oil seal, using
tool [5].
2 Insertion face: Axle oil or LM-P
a Keep press-fitting until the top end of the
sleeve (47) is flush with the hub end
1. Subassembly of shaft assembly face.
1) Install retainer (44) to shaft (tube) (42).
2) Press-fit bearing (43), using tool J2.
HM300-2R 9
4) Install floating seal (39) to hub (inner gear) 2) Install floating seal (35) to outer gear (29),
(37), using tool J4. using tool [6].
a Refer to the section of "Precautions 2 Oil seal peripheral surface
when installing floating seal". : Gasket sealant LG-8
(Three Bond 1207B)
a The end face of outer gear is flush with
that oil seal.
2 Oil seal lip face and inside G of oil
seal (60% full): Grease (G2-LI)
5) Install floating seal (38) to hub (inner gear)

(37), using tool J5.
a Refer to the section of "Precautions
when installing floating seal".
• Summary of oil seal
3. Subassembly of outer gear assembly

1) Install floating seal (36) to outer gear (29),
using tool J5.
10 HM300-2R
4. Brake assembly
1) Install outer gear (29) to hub (inner gear)
(37).
a When installing, take care so that the
floating seal will not be damaged or
turned up.
2) Install plate (34) with mounting bolts (28-1).
3 Mounting bolt
: 59 – 74 Nm {6 – 7.5 kgm}
5) Install piston (25) to cylinder (24).
3) Install plate (33), 7 discs (32), 6 plates (31)

and dampers (30a) and (30b) to outer gear
(29).
a When installing, take care so that the
surfaces of discs and plates are not
damaged. 6) Install cylinder and piston assembly (23).
7) Fix tool J1.
4) Install seal rings (26) and (27) to cylinder

(24) and piston (25) respectively.
HM300-2R 11
8) Install brake assembly (22) to shaft (21). 6. Subassembly of ring gear assembly
a When installing, match both counter 1) Install ring gear (16) to inner hub (17).
marks which were put at the time of dis- 2) Install 6 plates (15).
assembling. 2 Mounting bolt
3 Mounting bolt
: 27.5 – 34.5 Nm {2.8 – 3.5 kgm}
3) Press-fit bearing (18) into inner hub (17),
using tool J7.

1) Install floating seal assembly (20) to floating
seal retainer (19), using tool J4.
2) Install the assembly of floating seal retainer

(19) and floating seal assembly (20), hold- 7. Installation of ring gear assembly
ing forcing screw [4]. Install ring gear assembly (14).
8. Adjustment of bearing pre-load
1) Install retainer (12) temporarily without
shims being assembled in.
2) Remove tools J1 (at 3 points).
12 HM300-2R
3) Fasten the ring gear assembly to the forks 6) Assemble retainer (12) and shims (13)
of lift truck [5], and tighten hub bolt in every whose thickness was determined in the
2 (4 bolts in total) to the specified torque of foregoing step, and install the retainer.
49 ± 4.9 Nm {5 ± 0.5 kgm}., while rotating a Tighten the mounting bolts evenly, rotat-
the hub (inner gear) (37) by 20 to 30 turns. ing hub (inner gear) (37), until an even
a If the bolts are tightened without hub tightening torque is obtained for all the
(inner gear) (37) being rotated, the bear- bolts.
ing will not fit in well, thus giving no 2 Mounting bolt
appropriate pre-load. : Liquid adhesive (LT-2)
(The photo below differs a bit from the 3 Mounting bolt
actual ring gear in its outer gear configu- : 98 – 123 Nm {10 – 12.5 kgm}
ration.) [Target value: 113 Nm {11.5 kgm}]
a After finishing tightening, check that
there is nothing wrong with its rotation,
while actually rotating hub (inner gear)
(37).
4) Measure dimension "f" between the end

surface of shaft and the end surface of
retainer (12), using depth micrometer [6].
a Take measurement at 2 points and
9. Plate
obtain the average value.
Install plate (11).
5) Remove retainer (12) and measure retainer
thickness "g", then calculate difference
"h" (=f – g) and add 0.27 mm to it. That
value is the thickness of shim.
: 0.05 mm, 0.2 mm, 0.3 mm and 1.0 mm
HM300-2R 13
10. Shaft 13. Installation of carrier assembly

Install shaft (10). Sling carrier assembly (2) to install.
3 Mounting bolt
: 157 – 196 Nm {16 – 20 kgm}
11. Collar and sun gear

1) Install collar (9) and sun gear (8).
2) Install snap ring (7).
14. Drive shaft
Install drive shaft (1).
3 Mounting bolt
: 98 – 123 Nm {10 – 12.5 kgm}
12. Subassembly of carrier assembly

1) Set bearings (5) to gear (6) and install them
to the carrier.
2) Install shaft (4).
a When installing, pay attention to the
spring pinholes.
3) Install spring pin (3).
15. Install cover (51).
2 Mating face
: Gasket sealant
(Loctite LT-515 or equivalent)
3 Mounting bolt
: 59 – 74 Nm {6 – 7.5 kgm}
14 HM300-2R
Removal and installation of center 3. Remove cover (2).

final drive and brake assembly 1
Removal
k Raise the body assembly to the maximum
and insert a lock pin.
terminal of battery beforehand.
1. Drain oil from the center differential case and 4. Disconnect brake wearing switch connector (3)
the center final drive case.
(If equipped).
6 Center differential case: 25l
5. Disconnect wiring connectors (4) (If equipped).
6 Center final drive case: 4l (one side) • Final drive, right: B26
2. Disconnect the center wheel. • Final drive, left: B02
1) Raise the underside of center axle on the 6. Disconnect left and right brake actuating tubes
side of wheel to be removed, using hydrau-
(5).
lic jack [1].
7. Disconnect brake cooling tubes (6) and (7).
2) Sling the center wheel (1) and remove the

mounting bolts. [*1] 8. Remove cover (20).
4 Center wheel: 550 kg (one side)
HM300-2R 15
9. Disconnect drain hose (21), catch tank drain Installation

hose (22) and breather hose (23).
removal.
[*1]
3 Center wheel mounting bolt
: 824 – 1,030 Nm {84 – 105 kgm}
[*2]
a Install the sun gear and drive shaft assem-
bly and the carrier assembly, referring to the
section of "Removal and installation of cen-
ter differential assembly".
10. Remove carrier assembly (8) and the sun gear
[*3]
2
and drive shaft assembly from the final drive
Center final drive and brake assembly
assembly, referring to the section of "Removal
mounting bolt: Liquid adhesive (LT-2)
3
and installation of center differential assembly".
Center final drive and brake assembly
[*2]
mounting bolt
11. Sling final drive and brake assembly (9) tempo- : 490 – 608 Nm {50 – 62 kgm}
rarily and remove the 22 mounting bolts. [*3] [Target value: 549 Nm {56 kgm}]
4 Center final drive and brake assembly
: 350 kg (one side) • Refilling with oil (center differential case and
center final drive case)
Refill with oil through the oil filler ports of center
differential case and left and right center final
drive up to the specified level.
5 Center differential case
: 25l Axle oil (AXO80)
5 Center final drive case
: 4l (one side) Axle oil (AXO80)
• Air bleeding
Bleed air from the brake circuit after finishing
installation, referring to the section of "Bleeding
air from brake circuit" in Testing and adjusting.
16 HM300-2R
Disassembly and assembly of

center final drive and brake
assembly 1
Special tools
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
2 792T-222-1220 Push tool t 1 Q
4 791-580-1520 Installer t 1
5 791-580-1510 Installer t 1
3. Further disassembly of ring gear assembly
793T-622-1110 Push tool t 1 Q 1) Remove 6 plates (4).
6 790-101-5421 Grip t 1 2) Remove inner hub (6) from ring gear (5).
01010-81240 Bolt t 1 3) Remove bearing (7) from inner hub (6).
7 797T-622-1240 Push tool t 1 Q
J
792T-223-1130 Fixture t 3 Q
792T-223-1140 Plate t 3 Q
01010-61240 Bolt t 3
8 01643-31232 Washer t 3
01580-01210 Nut t 3
01010-61245 Bolt t 3
01010-62440 Bolt t 3
a For further disassembly and assembly of carrier

assembly, refer to the section of "Disassembly
and assembly of rear final drive assembly". 4. Floating seal retainer and floating seal
1) Remove the assembly of floating seal
Disassembly retainer (8) and floating seal assembly (9)
by fitting forcing screws [1].
1. Retainer and shim
1) Fix tools J8 at 3 points between the outer
gear and wheel hub (inner gear).
a Be sure to fix tools J8 before removing
retainer (1) in order to protect the float-
ing seal from damage.
a Fix tools J8 at an equal interval.
2) Remove retainer (1) and shim (2).
a Check the thickness, number in use and
installed location of the shims before-
hand.
2. Removal of ring gear assembly
1) Remove ring gear assembly (3).
HM300-2R 17
5. Removal of brake assembly 3) Remover seal rings (15) and (16) from cylin-
1) Remove brake assembly (11) from shaft der (13) and piston (14) respectively.
(tube) (10).
a Before removing, put a counter mark on
both of them.
2) Remove tools J8 from the brake assembly.
6. Separation of outer gear assembly and inner

gear assembly
1) Remove cylinder and piston assembly (12).
4) Remove mounting bolts (17-1), and sling

outer gear and disc plate assembly (17) to
remove.
2) Remove piston (14) from cylinder (13).
18 HM300-2R
7. Further disassembly of outer gear assembly 9. Further disassembly of shaft assembly

1) Remove dampers (19a) and (19b), 8 plates Remove bearing (32) and retainer (33) from
(20), 9 discs (21) and plate (22) from outer shaft (31).
gear (18).
2) Remove oil seal (24) from outer gear (18).

3) Remove floating seal (25).
8. Further disassembly of inner gear assembly

1) Remove floating seals (27) and (28) from
hub (inner gear) (26).
2) Remove sleeve (36).
3) Remove plate (23).
4) Remove outer races (29) and (30).
HM300-2R 19
Assembly 2. Subassembly of inner gear assembly

1) Install outer races (30), (29) to hub (inner
a Before assembling, clean each of the parts thor- gear) (26).
oughly; check that it is free of dust and damage, 2) Put plate (23).
and coat the sliding surface with axle oil
3) Press-fit sleeve (36) for the oil seal, using
(AXO80).
tool [2].
a Precautions when installing floating seal
2 Insertion face: Axle oil or LM-P
• When installing a brand-new O-ring, com-
pletely wipe out white dust on the O-ring a Keep press-fitting until the top end of the
sleeve (36) is flush with the hub end
surface with alcohol.
face.
• Degrease the mating surface of O-ring
before installing.
• Install an O-ring with a push-in type special
tool.
• Coat seal face A with engine oil, and check
that the seal is free of dust and damage.
• Measure dimension "a" (at 4 points on the
circumference) that is the seal height as
against the carrier and hub as well as
retainer and confirm that the difference of
the measured dimension "a" is less than 1
(mm).

1. Subassembly of shaft assembly

1) Install retainer (33) to shaft (31).

20 HM300-2R
3. Subassembly of outer gear assembly 4. Brake assembly

1) Install floating seal (25) to outer gear (18), 1) Install outer gear (18) to hub (inner gear)
using tool J5. (26).
a Refer to the section of "Precautions a When installing, take care so that the
when installing floating seal". floating seal will not be damaged or
turned up.
2) Install plate (23) with mounting bolt (17-1).
3 Mounting bolt
: 59 – 74 Nm {6 – 7.5 kgm}
2) Install oil seal (24) to outer gear (18), using

tool [6].
: Gasket sealant LG-8
(Three Bond 1207B) 3) Install plate (22), 9 discs (21), 8 plates (20)
a The end face of outer gear is flush with and dampers (19a) and (19b) to outer gear
that oil seal. (18).
2 Oil seal lip face and inside G of oil a When installing, take care so that the
seal (60% full): Grease (G2-LI) surfaces of discs and plates are not
damaged.
• Summary of oil seal
HM300-2R 21
4) Install seal rings (15) and (16) to cylinder 6) Install cylinder and piston assembly (12).
(13) and piston (14) respectively. 7) Fix tool J8.
8) Install brake assembly (11) to shaft (tube)

(10).
a When installing, pay attention to the
counter marks which were put at the
time of disassembly.
5) Install piston (14) to cylinder (13).

1) Install floating seal (9) to floating seal
retainer (8), using tool J4.
22 HM300-2R
2) Install the assembly of floating seal cage (8) 7. Installation of ring gear assembly
and floating seal assembly (9), holding forc- Install ring gear assembly (3).
ing screw [1]. 8. Adjustment of bearing pre-load
1) Install retainer (1) temporarily without shim
(2) being assembled in.
2) Remove tools J8 (at 3 points).
6. Subassembly of ring gear assembly

1) Install ring gear (5) to inner hub (6).
2) Install 6 plates (4).
2 Mounting bolt 3) Fasten the ring gear assembly to the forks
: Liquid adhesive (LT-2) of lift truck [3], and tighten hub bolt in every
3 Mounting bolt 2 (4 bolts in total) to the specified torque of
: 27.5 – 34.5 Nm {2.8 – 3.5 kgm} 49 ± 4.9 Nm {5 ± 0.5 kgm}, while rotating
[Target value: 31 Nm {3.2 kgm}] hub (inner gear) (26) by 20 to 30 turns.
3) Press-fit bearing (7) to inner hub (6), using a If the bolts are tightened without hub
tool J7. (inner gear) (26) being rotated, the bear-
ing will not fit in well, thus giving no
appropriate pre-load.
(The photo below differs a bit from the
actual ring gear in its outer gear configu-
ration.)
HM300-2R 23
4) Measure dimension "f" between the end

surface of shaft and the end surface of
retainer (1), using depth micrometer [4].
a Take measurement at 2 points and
obtain the average value.
5) Remove retainer (1) and measure retainer
thickness "g", then calculate difference
"h" (= f – g) and add 0.27 mm to it. That
value is the thickness of shim.
: 0.05 mm, 0.2 mm, 0.3 mm and 1.0 mm
6) Assemble in retainer (1) and shims (2)

which were selected in the foregoing step.
a Tighten the mounting bolts evenly, while
rotating hub (inner gear) (26), until all
the mounting bolts are tightened to even
torque.
2 Mounting bolt
3 Mounting bolt
: 98 – 123 Nm {10 – 12.5 kgm}
a After finishing installing, check that there
is nothing wrong with rotation, while
turning hub (inner gear) (26).
24 HM300-2R
HM300-2R 25

© 2007 KOMATSU
All Rights Reserved
26 HM300-2R
SEN04035-00
HM300-2R


Power train, Part 5
Disassembly and assembly of rear final drive assembly ................................................................................ 2
Removal and installation of center axle assembly .......................................................................................... 9
Removal and installation of rear axle assembly............................................................................................ 12
HM300-2R 1
Disassembly and assembly of rear 2) Sling rear wheel (1), then remove the
final drive assembly 1 mounting bolts and remove the rear wheel.
4 Rear wheel: 550 kg
Special tools
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
2 792T-222-1220 Push tool t 1 Q
J
7 797T-622-1240 Push tool t 1 Q
Disassembly
4. Removal of carrier assembly
1. Body assembly
1) Remove the mounting bolts, and pull carrier
Remove the body assembly, referring to the
assembly (2) out of the final drive assembly,
using forcing screws [2] and guide bolts [3].
assembly".
[*1]
2. Draining oil (Remove the carrier assembly without a
Drain oil from the rear differential case and the wheel unlike the photo below)
rear final drive case.
6 Rear differential case: 25l
6 Rear final drive case: 5l (one side)
3. Rear wheel
1) Raise the underside of rear axle with
hydraulic jack [1].
2) Sling carrier assembly (2) to remove. [*2]

4 Carrier assembly: 40 kg (one side)
(Remove the carrier assembly without
wheel unlike the photo below)
2 HM300-2R
5. Further disassembly of carrier assembly 2) Remove snap ring (9).

1) Drive spring pin (3) into shaft (4), using 3) Remove sun gear (11) and spacer (12) from
round bar [4]. drive shaft (10).
2) Pull out shaft (4) and then take out bearing
(5) and gear (6).
3) Pull spring pin (3) out of shaft (4) before-
hand.
7. Removal of ring gear assembly

1) Sling flywheel hub assembly (13).
2) Remove retainer (14).
6. Sun gear and drive shaft

1) Remove sun gear and drive shaft assembly
(8).
3) Remove ring gear (16).
4 Sun gear and drive shaft assembly
: 25 kg
HM300-2R 3
8. Further disassembly of ring gear assembly 10. Retainer assembly

1) Remove 6 plates (17). 1) Remove bearing (24).
2) Remove inner hub (19) from ring gear (18). 2) Remove oil seal (23).
3) Remove bearing (20) from inner hub (19). 3) Remove retainer (27).
4) Remove protector (28) from retainer (27).
5) Remove sleeve (29).
9. Wheel hub assembly

1) Sling flywheel hub assembly (21) to remove.
4 Flywheel hub assembly: 60 kg
2) Remove outer races (25) and (26) from

wheel hub (22).
4 HM300-2R
Assembly 2. Wheel hub assembly

1) Install outer races (25) and (26) to wheel
a Before assembling, clean each of the parts thor- hub (22).
oughly, then check that it is free of dust and 2) Assemble bearing (24) in.
damage and coat the sliding surface with axle
a Drip axle oil (AXO80) on the bearing.
oil (AXO80).
1. Retainer assembly
1) Install protector (28) to retainer (27), using
push tool [5].
a Keep press-fitting until the protector is
flush with the retainer.
3) Press-fit oil seal (23), using push tool [6].

a Keep press-fitting until the oil seal
comes into close contact with the wheel
hub. (Clearance is less than 0.2 mm)
2) Press-fit sleeve (29) to retainer (27), using
tool [6].
2 Insertion face (S) of sleeve (29)
: Axle oil (AXO80) or LM-P
a Keep press-fitting until the top end of the
sleeve is flush with the retainer.
3) Install retainer (27) with an O-ring to the axle
housing.
HM300-2R 5
4) Sling wheel hub assembly (21) and install it

to the axle housing.
4 Wheel hub assembly: 60 kg
3) Install ring gear assembly (16).
4. Adjustment of pre-load on bearing

1) Install retainer (14) temporarily without
shims being assembled in.
3. Subassembly of ring gear assembly 2) Tighten mounting bolt in every 2 (4 bolts in
1) Press-fit bearing (20) into inner hub (19), total) evenly to the specified torque of 49 ±
using push tool J7. 4.9 Nm {5 ± 0.5 kgm}, while wheel hub
a Drip axle oil (AXO80) on the bearing assembly (21) by 20 to 30 turns.
after assembly. a If the mounting bolts are tightened with-
out rotating the wheel hub assembly
(21), the bearing will not sit in well and
no right preload is given to the bearing.
2) Assemble inner hub (19) in ring gear (18)

and install plate (17).
2 Mounting bolt
3 Mounting bolt
: 27.5 – 34.5 Nm {2.8 – 3.5 kgm}
6 HM300-2R
3) Measure dimension "f" between the end 5. Sun gear and drive shaft
surface of the shaft and the end surface of 1) Assemble spacer (12) and sun gear (11) in
retainer (14), using depth micrometer [7]. drive shaft (10) and install snap ring (9).
a Take measurement at 2 points and cal-
culate the average value.
4) Remove retainer (14) and measure thickness
"g" of the retainer. Add 0.27mm to difference
"h" of the measured values h (= f – g), and
the shim thickness is obtained.
: 0.05 mm, 0.2 mm, 0.3 mm and 1.0 mm
2) Install sun gear and drive shaft assembly

(8).
4 Sun gear and drive shaft assembly
: 25 kg
5) Assemble shims (15) having thickness

selected in the step 4) above in retainer (14)
and install the retainer.
a Tighten the mounting bolts evenly, while
rotating ring gear assembly (16), until
the tightening torque is equal for all the
bolts.
2 Mounting bolt
3 Mounting bolt 6. Subassembly of carrier assembly
: 98 – 123 Nm {10 – 12.5 kgm} 1) Set bearings (5) to gear (6) and assemble
[Target value: 11.3 Nm {11.5 kgm}] the gear in the carrier.
a After finishing tightening, check that 2) Install shaft (4).
there is nothing wrong with rotation a When installing the shaft, pay attention
when turning ring gear assembly (16). to its pinhole for spring pin.
3) Install spring pin (3).
HM300-2R 7
7. Installation of carrier assembly

1) Sling carrier assembly (2) after installing an
O-ring and install along guide bolt [3].
3 Mounting bolt
: 157 – 196 Nm {16 – 20 kgm}
8. Rear wheel assembly

Sling rear wheel (1) to install.
4 Rear wheel assembly (one side)
: 550 kg
3 Mounting bolt
: 824 – 1,030 Nm {84 – 105 kgm}
• Refilling with oil (rear differential case and

rear final drive case)
Refill with oil through oil filler ports of rear differ-
ential case and left and right rear final drives up
to the specified level.
5 Rear differential case
: 25l Axle oil (AXO80)
5 Rear final drive case
: 5l (one side) Axle oil (AXO80)
8 HM300-2R
Removal and installation of center 3. Separate drive shaft (2) between the hitch frame
axle assembly 1 and center differential and drive shaft (3)
between the center differential and rear differen-
Removal tial at the center differential side. [*2]
a After slinging, separate by removing the
drive shaft mounting bolts.
terminal of battery.
k Release nitrogen gas from the rear sus-
pension cylinder, referring to the section
of "Testing and adjusting suspension cyl-
inder" in the chapter of Testing and adjust-
ing.
1. Raise the underside of center axle and rear axle

at the left and right sides, using hydraulic jacks
[1].
4. Remove cover (4). (If equipped)

5. Disconnect left and right wiring connectors (5).
(If equipped)
2. Sling center wheel (1) to remove the mounting
• Final drive, right: B26
bolts, and remove the left and right center
• Final drive, left: B02
wheels. [*1]
HM300-2R 9
6. Disconnect wiring connector (T14) (6). 12. Sling center axle and arm assembly (12).
7. Disconnect brake actuator hose (7).
8. Disconnect pump suction hoses (8).
9. Disconnect 2 brake cooling hoses (9).
13. Remove left and right caps (13) at a pin of the

arm mounting base, and take down center axle
and arm assembly (12) to remove. [*4]
4 Center axle and arm assembly
10. Remove the mounting bolts for center lateral rod : 1,600 kg
(10) and sling the rod to remove. [*3]
4 Center lateral rod: 40 kg
11. Remove the mounting bolts for equalizer bar

spring (11) and separate the spring.
10 HM300-2R
Installation • Refilling with oil (transmission case and

brake oil tank)
Refill with oil through the oil filler port up to the
removal.
specified level, then start the engine and run at
[*1]
low idle, and check the oil level again.
: 824 – 1,030 Nm {84 – 105 kgm} • Air Bleeding (brake)
[Target value: 927 Nm {94.5 kgm}] After finishing the installation, bleed air from the
brake circuit , referring to the section of "Bleed-
[*2] ing air from brake circuit" in Inspection and
a Install the center axle assembly after con- adjustment.
firming that the yoke of drive shaft between
the hitch frame and center differential and
the yoke of drive shaft between center dif-
ferential and rear differential are shifted from
each other at 45° ± 6°.
a When installing the drive shafts, check that
convex section on the spider cap engages
completely with groove of the counter yoke,
: 98 – 123 Nm {10 – 12.5 kgm}
[*3]
a When installing bearing (B) to center lateral rod
(A), align tapped hole "c" with centerline "d" of
bearing (B).
[*4]
3 Cap mounting bolt
: 455 – 565 Nm {46.5 – 58 kgm}
a Adjust the suspension cylinder stroke, referring

to the section of "Testing and adjusting suspen-
sion cylinder" in the chapter of Inspection and
adjustment.
HM300-2R 11
Removal and installation of rear 4. Separate drive shaft (2) between the center dif-
axle assembly 1 ferential and rear differential at the rear differen-
tial side. [*2]
Removal a After slinging temporarily, remove the drive
k
shaft mounting bolts and separate the shaft.
Turn the parking brake switch on and put
wooden blocks behind wheels. 4 Drive shaft: 30 kg
ing.
1. Remove the body assembly, referring to the

assembly".
2. Raise the underside of center axle and rear axle
at the left and right sides, with hydraulic jacks
[1].
5. Remove the mounting bolts of rear lateral rod
(3) and sling the rod to remove. [*3]
4 Rear lateral rod: 50 kg
3. Sling rear wheel (1) to remove the mounting

bolts and then remove the left and right rear
wheels. [*1]
4 Rear wheel: 550 kg (one side)
6. Sling rear axle and arm assembly (4).
4 Rear axle and arm assembly: 1,100 kg
12 HM300-2R
7. Remove left bracket (5). [*4] Installation

8. Remove rear suspension pins (6) of both left • Installation is carried out in the reverse order to
and right sides at their head side. removal.
[*1]
3 Rear wheel mounting bolt
: 824 – 1,030 Nm {84 – 105 kgm}
[*2]
convex section on the spider cap engages
completely with groove of the counter yoke,
9. Remove left and right caps (7) at a pin of the 3 Drive shaft mounting bolt
arm mounting base, and take down rear axle : 98 – 123 Nm {10 – 12.5 kgm}
arm (4) to remove. [*5] [Target value: 113 Nm {11.5 kgm}]
4 Rear axle and arm assembly: 1,100 kg
[*3]
a When installing bearing (B) to rear lateral
rod (A), align tapped hole "c" with centerline
"d" of bearing (B).
[*4]
3 Bracket mounting bolt
: 455 – 565 Nm {46.5 – 58 kgm}
[*5]
3Cap mounting bolt
: 455 – 565 Nm {46.5 – 58 kgm}
a Adjust the suspender cylinder stroke, referring
to the section of "Testing and adjusting suspe-
nion cylinder" in the chapter of Testing and
adjusting.
HM300-2R 13

© 2007 KOMATSU
All Rights Reserved
14 HM300-2R
SEN04036-01
HM300-2R


Undercarriage and frame
Removal and installation of front suspension cylinder assembly .................................................................... 2
Removal and installation of rear suspension cylinder assembly..................................................................... 4
Removal and installation of equalizer bar ....................................................................................................... 5
Removal and installation of hitch frame assembly .......................................................................................... 7
Disassembly and assembly of hitch frame assembly ................................................................................... 17
HM300-2R 1
Removal and installation of front

suspension cylinder assembly 1
Special tools
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
Suspension tool
Q 792-610-1000 t 1
assembly
Removal
4) Sling front wheel (2) temporarily, and re-
k Turn the parking brake switch on and put move the mounting bolts to remove the
wooden blocks behind the wheels. wheel. [*1]
k
4
Release nitrogen gas from the front sus-
Front wheel: 550 kg (one side)
ing.
a Show left side.

1. Remove the front wheel.
1) Sling left fender (1) to remove.
4 Left fender: 80 kg
2. Remove 3 covers (3).

2) Raise the underside of front axle on the side

of wheel to be removed with hydraulic jack
[1].
3) Support the front frame underside with ped-
estal (frame) [2].
2 HM300-2R
4. Remove bracket (5). [*3] Installation

5. Disconnect grease hose (6) from the head pin. • Installation is carried out in the reverse order to
removal.
[*1]
: 824 – 1,030 Nm {84 – 105 kgm}
[*2]
3 Cover clamp
: 6.28 – 7.25 Nm {0.64 – 0.74 kgm}
[Target value: 6.8 Nm {69 kgm}]
[*3]
6. Disconnect grease tube (7). 3 Bracket mounting bolt
7. Sling the front suspension cylinder assembly : 69 – 74 Nm {6 – 7.5 kgm}
(10) temporarily. [Target value: 66.5 Nm {6.75 kgm}]
8. Remove head pin (8) and bottom pin (9), and [*4]
sling front suspension cylinder (10) off. [*4] 3 Pin mounting bolt
4 Front cylinder suspension assembly : 98 – 123 Nm {10 – 12.5 kgm}
: 75 kg [Target value: 110.5 Nm {11.3 kgm}]
• Refilling with nitrogen gas and adjusting cyl-

inder stroke
Refill with nitrogen gas and adjust the cylinder
stroke, referring to the section of "Testing and
adjusting suspension cylinder" in the chapter of
Testing and adjusting.
HM300-2R 3
Removal and installation of rear 5. Remove pin (4) on the head side and pin (5) on
suspension cylinder assembly 1 the bottom side, and sling rear suspension cyl-
inder assembly (4) to remove.
Special tools a You hold a pole tool [3] at the opposite side
with rear suspension cylinder assembly.
New/Remodel
Keeping the balance, move the crane slowly
Sym-
Necessity
Part No. Part name and take rear suspension cylinder assembly
bol
Sketch
(3) down.
Q'ty
4 Rear suspension cylinder assembly:
Suspension tool
Q 792-610-1000 t 1 55 kg
assembly
Removal
ing.
1. Raise the underside of rear axle and equalizer

bar (underside of rear frame) with hydraulic
jacks [1] and [2].
Installation
2. Support rear lateral rod (1) with a hydraulic jack
and remove. [*1] • Installation is carried out in the reverse order to
removal.
4 Rear lateral rod: 50 kg
3. Remove left bracket (2). [*2] [*1]
a Install bearing (B) to rear lateral rod (A) and
align tapped hole "c" with centerline "d" of bear-
ing (B).
4. Sling rear suspension cylinder assembly (3)

with balance bar [3] temporarily.
a Hold a pole tool [3] with a crane. [*2]
: 455 – 565 Nm {46.5 – 58 kgm}

inder stroke
4 HM300-2R
Removal and installation of 3. Remove bottom pin (3) of rear suspension cylin-
equalizer bar 1 der assembly (2).
a Tilt back the rear suspension cylinder
Special tools toward the rear and secure it.
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
Suspension tool
Q 792-610-1000 t 1
assembly
Removal
and insert a lock pin. 4. Separate equalizer spring (4) after removing its
k Release nitrogen gas in the rear suspen- mounting bolts.
sion cylinder, referring to the section of
"Testing and adjusting suspension cylin-
der" in the chapter of Testing and adjust-
ing.
1. Raise the center axle, rear axle and rear frame

on the side of equalizer bar to be removed,
using 3 hydraulic jacks [1].
5. Sling the equalizer bar.

6. Remove plate (5) in the center of equalizer bar.
[*2]
2. Sling center wheel (1), and remove its mounting

bolts to remove. [*1]
HM300-2R 5
7. Remove bushing (6), using 3 forcing screws [2] Installation

and tool [3].
removal.
[*1]
: 824 – 1,030 Nm {84 – 105 kgm}
[*2]
a Tighten 3 cover bolts (M24) after confirming
the following installing dimensions.
• Check that when dimension "x" between
upper and lower pins of rear suspension
cylinder is 518 mm (x = 518 mm),
8. Sling equalizer bar (7) to remove.
dimension "a" between the bottom pin
4 Equalizer bar: 200 kg
center of rear suspension cylinder and
the rear frame upper face is 17 mm and
dimension "b" between the equalizer
upper face and the rear frame upper
face is 162 mm.
3 Cover mounting bolt (M14)
: 157 – 196 Nm {16 – 20 kgm}
3 Cover mounting bolt (M24)
: 824 – 1,030 Nm {84 – 105 kgm}

inder stroke
6 HM300-2R
Removal and installation of hitch

frame assembly 1
Special tools
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
1 792T-246-1130 Plate t 1 Q
2 792T-246-1140 Plate t 1 Q
792T-446-1120 Push tool t 1 Q
790-101-2310 Block t 2
4. Remove drive shaft (3) between the transmis-
790-101-2390 Leg t 2 sion and hitch frame. [*2]
4
K 790-101-2420 Adapter (16 mm) t 2 Drive shaft between transmission and
6 790-101-2360 Plate t 2 hitch frame: 30 kg
02215-11622 Nut t 2
Puller 300 kN
790-101-2102 t 1
{30 ton}
790-101-1102 Pump t 1
Removal
k Key switch ON and set the dump lever
"down" to release residual pressure from
hoist hydraulic circuit. 5. Sling exhaust box (4) to remove.
Do not start the engine during this proce- 4 Exhaust box: 35 kg
dure.
6. Remove guard (5).
terminal of the battery beforehand. 7. Remove hose covers (6) and (7).
1. Unscrew the cap on the hydraulic tank.

2. Remove drive shaft guard (1).
3. Sling drive shaft (2) between the hitch frame
and center differential to remove. [*1]
4 Drive shaft between hitch frame and cen-
ter differential: 45 kg
HM300-2R 7
8. Gradually loosen hoist cylinder hoses (8) and 11. Disconnect the following wiring connectors and
(9) between the front frame and rear frame as terminal from the rear frame front side.
well as brake cooling hoses (10) and (11) and • (15): J15
evacuate oil. • (16): J13
6 Hydraulic oil [hoses (8) and (9)] • (17): Grounding terminal (ER)
: Approx. 50l
6 Transmission and brake cooling oil [hos-
es (10) and (11)]: Approx. 15l
9. Disconnect the following hoses between the
front frame and rear frame.
a Either put an identification tag or put a
counter mark on the piping in order to make
no mistake about the installing position later.
a Disconnect the parking brake hose at the
rear frame side.
• Hoist cylinder hoses (8) and (9)
• Brake cooling hoses (10) and (11)
• Parking brake hose (12) 12. Disconnect the following wiring connectors and
• Brake hose (13) terminal from the front frame rear side.
• (18): J14
• (19): J12
• (20): Grounding terminal (ER)
10. Disconnect connector (14) (If equipped) for a

rearview camera at the machine rear.
8 HM300-2R
13. Sling exhaust duct assembly (21) to remove. 2) Support the body underside at the machine
4 Exhaust duct assembly: 40 kg rear with block [2].
14. Remove brackets (22) and (23).
3) Support the front frame underside at the

rear and the rear frame underside at the
15. Remove left and right steering cylinder head front with block [3] and pedestal [4] to
pins (29). [*3]
ensure safety in the work.
4) Align the hinge pinhole centers by raising
and lowering the front frame and rear frame
with hydraulic jacks [5] and [6].
16. Support the chassis front and rear in the follow-

ing manner.
1) Lift the chassis front part with sling [1], using
a crane.
17. Remove the upper hinge pin and bushing in the
following manner. [*4]
1) Remove retainer (30).
HM300-2R 9
2) If it is difficult to remove upper hinge pin

(31), set puller [7], plate [8] and 4 bolts [9]
between retainer (30) and upper hinge pin
(31) and push down upper hinge pin (31) to
remove.
19. Check that there is clearance between the front

frame and hitch frame.
20. Push up lower bushing (35) on the upper pin
side toward the hitch frame (36) side by approx.
1 mm in order to avoid a step of the front frame
3) Hook puller [10] to a step inside the bush- (37). (Lower bushing (35) is not pressed.)
ing, and take out bushing (32) upward by
pushing up the claw of puller [10], using
push tool [11] and puller [12].
21. While keeping the front portion of frame assem-

bly lifted with a crane, move the assembly a bit
forward, using a lift truck, and separate front
18. Remove the lower hinge pin in the following
frame assembly (38) from hitch frame assembly
manner. [*5] (39).
1) Remove the mounting bolts for the lower
k Before separating, carefully check level-
hinge pin.
ness of the front frame and hitch frame
2) Remove the mounting bolts and nuts, and
and also check that there is clearance
then remove 2 O-rings (33).
between the two frames.
3) Put hydraulic jack [13] to lower hinge pin
(34) and take the pin out by pushing
upward.
a If the truck body is lifted with the lower
hinge pin and the pin cannot be pulled
out, hit the frame around the pin from
above in that lifted condition and strike
the pin out downward.
10 HM300-2R
22. Remove cover (40). 26. Sling parking brake disc (43) to remove.
23. Turn parking brake releasing bolt (41) counter- [*8]
clockwise to release the parking brake. [*6] 4 Parking brake disc: 30 kg
24. Sling parking brake caliper assembly (42) and 27. Sling bracket (44) to remove, using eyebolts
remove brackets (43) for expanding the pads [14]. [*9]
and bracket (44). [*7] 4 Bracket: 30 kg
25. Sling parking brake caliper assembly (42) to
remove.
4 Parking brake caliper assembly: 45 kg
28. Remove coupling (45). [*10]
HM300-2R 11
29. Remove retainer (46), using forcing screws [15].

[*11]
32. Remove retainer (50) and dust seal (51) from

the rear frame. [*14]
30. Remove retainer (47), using forcing screws [16].

[*12]
a Shims are provided, so check their thick-
ness, number in use and installed locations
beforehand.
31. Sling hitch frame assembly (48) to remove.

[*13]
4 Hitch frame assembly: 600 kg
a Bearing (49) may fall off from the rear frame,
so secure it to prevent fall-off.
12 HM300-2R
Installation 8) Assemble retainer (30) by tightening the

mounting bolt (52).
removal.
: 245 – 309 Nm {25.0 – 31.5 kgm}
a After confirming thorough running-in of
[*1]
each contact surface, tighten mounting
a Before installing, check that the yoke of drive
bolt (52) again to the specified torque.
shaft between the hitch frame and center dif-
9) Measure dimension "gg" with clearance
ferential and the yoke of drive shaft between
between top of retainer (30) and the front
center differential and rear differential are frame at 3 points.
shifted from each other by 45° ± 6°.
10) Select appropriate shims and assemble
them in so that the total shim thickness is
[*1] [*2]
"g", i.e. the difference between "gg" and "f"
dimensions (g = gg – f) minus 0.08 to 0.18
convex section on the spider cap completely
mm.
engages with groove of the counter yoke,
0.08 < g = gg – f < 0.18 (mm)
: 0.1 mm and 0.5 mm
• Standard shim thickness: 2 mm
11) Install a combination of the selected shims
: 98 – 123 Nm {10 – 12.5 kgm}
to retainer (30) and tighten retainer mount-
ing bolts (52) and (53).
[*3]
k
When aligning the pinholes, never put a
finger into the hole.
: 245 – 309 Nm {25.0 – 31.5 kgm}
[*4] [*5]
a Install the hinge pin in the following steps.
1) Set bushing (58) to the front frame.
2) Set bushing (35) to the hitch frame and
match the articulation center (position of
center pin) by moving the front frame
assembly to the rear.
2 Dust seal lip face: Grease (G2-LI)
3) Insert lower hinge pin (34) from above.
2 Dust seal lip face: Grease (G2-LI)
2 Bearing inside perimeter
disulfide (LM-P)
4) Install 2 O-rings (33).
2 O-ring: Grease (G2-LI)
5) Measure thickness "f" of retainer (30).
6) Insert upper hinge pin (31) from below.
2 Dust seal lip: Grease (G2-LI)
2 Upper hinge pin outside perimeter
disulfide (LM-P)
7) Assemble bushing (32) from above.
HM300-2R 13
[*6] [*7]
a Check the parking brake pad wear amount
and adjust the pad clearance, referring to
the section of "Testing wear of parking brake
pad" in Testing and adjusting.
3 Pad expanding bracket mounting bolt
(43): 98 – 123 Nm {10 – 12.5 kgm}
2 Bracket mounting bolt (44)
3 Bracket mounting bolt (44)
: 824 – 1,030 Nm {84 – 105 kgm}
[*8]
2 Parking brake disc mounting bolt
3 Parking brake disc mounting bolt
: 490 – 608 Nm {50.0 – 62.0 kgm}
[*9]
: 157 – 196 Nm {16.0 – 20.0 kgm}
[*10]
2 Coupling spline portion
: Grease containing molybdenum
disulfide (LM-G)
: 455 – 565 Nm {46.5 – 58.0 kgm}
[*11]
a When removing dust seal (54) from retainer
(46), press-fit dust seal (54), using tool K1.
14 HM300-2R
[*12] [*13] a Method for adjusting bearing at oscillating

a Before installing the hitch frame assembly portion
and retainer (47), fill the space H – Q listed 1) Measure thickness "s" of retainer (47) at 2
below completely with hub grease. points. (Calculate the average value of the 2
2 H space: 350 g (inside of dust seal and points.)
dust seal lip) 2) Tighten retainer (47) without shims with 3
2 J space: 620 g mounting bolts (54).
2 K space: 1,030 g (inside of bearing) 3 Mounting bolt: 49 Nm {5 kgm}
2 L space: 2,400 g 3) In that condition, measure dimension "t"

2 M space: 2,085 g with a micrometer.
2 N space: 680 g (inside of bearing) 4) Rotate the hitch by 5 to 6 turns and repeat
2 P space: 530 g the steps 2) and 3) above.
2 Q space: 295 g (inside of dust seal and a Repeat the steps 2) to 4) until
dust seal lip) dimension "t" is constant.
a Select hub grease to be filled from among 5) Select appropriate shims so that the total
those listed below. shim thickness is "u", i.e. the difference
No. Manufacturer Hub Grease Brand between dimensions "t" and "s" (u = t – s)
minus 0 to 0.15 mm.
1 Nihon Ryuyu Hilex HD-2
• Standard thickness of shim: 3.0 mm
2 SHELL OIL Super Duty Grease2
3 ESSO OIL RONEX MP : 0.2 mm, 0.3 mm and 1.0 mm
4 BP Energrease LS-EP2 6) Install a combination of selected shims (55)
to retainer (47) and install the retainer with
12 mounting bolts (54).
2 Mounting bolt
3 Mounting bolt
: 245 – 309 Nm {25.0 – 31.5 kgm}
HM300-2R 15
• Using push tool K6, press fit inner race of

bearing (49) after installing hitch frame
assembly.
[*14]
a Press-fit dust seal (55), using tool K2.
16 HM300-2R
Disassembly and assembly of 2) Remove ring (3), and dust seal (4), from
hitch frame assembly 1 rear retainer (5).
Special tools
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
3 792T-246-1110 Push tool t 1 Q
790-101-5341 • Plate 1
4 790-101-5331 • Plate 1
790-101-5221 • Grip 1
K 3. Center shaft
01010-51225 • Bolt 1
1) Remove center shaft and bearing assembly
(6) from hitch frame assembly (7).
790-201-1640 • Plate 1
5
790-101-5021 • Grip 1
01010-50816 • Bolt 1
Disassembly
1. Coupling
Remove the mounting bolts and remove cou-
pling (1).
2) Remove bearing (8) and bearing inner race

(9) from center shaft (10).
2. Rear retainer
1) Remove rear retainer assembly (2), using
forcing screws [1].
HM300-2R 17
4. Further disassembly of hitch frame Assembly

1) Remove front cage assembly (11) from hitch
frame (12). a Clean each of the parts thoroughly and check
2) Remove ring (13), bearing (14) and rings that it is free of dust and damage.
a When installing the seals, use a push tool of the
(15) and (16).
size which corresponds with the seal diameter.
3) Remove dust seal (17) from front cage (18).
a Select hub grease to be filled from among
those listed below.
No. Manufacturer Hub Grease Brand
1 Nihon Ryuyu Hilex HD-2
2 SHELL OIL Super Duty Grease2
3 ESSO OIL RONEX MP
4 BP Energrease LS-EP2
1. Subassembly of upper and lower hinge pin

portions of hitch frame
a Adjust shims in the following manner.
1) Install dust seals (30) and (29) to hitch
frame (12), using tool K4 for dust seal (29)
4) Remove bearing (19) and spacer (20) from and K5 for dust seal (30).
hitch frame (12). 2) Install dust seals (28) and (27) to retainers
(22) and (21), using tool K4 for dust seal
(27) and K5 for dust seal (28).
2 Dust seal lip: Grease (G2-LI)
3) Install bearings (25) and (26) to the hitch

frame.
a Bearings (25) and (26) are a set part, so do
not change the combination of bearing and
spacer.
5) Remove retainers (21) and (22) and shims

(23) and (24) from the hinge portion, and
then remove bearings (25) and (26).
6) Remove dust seals (27), (28), (29) and (30)
from retainers (21) and (22) and hitch frame
(12) respectively.
18 HM300-2R
4) Install retainers (21) and (22) after adjusting

the shims.
i) Measure respective thickness "a" and
"b" of retainers (21) and (22) of the hitch
frame.
ii) Install retainer (21) to the hitch frame
upper side with 5 mounting bolts.
: 58.8 Nm {6 kgm} ± 10%
iii) Install retainer (22) to the hitch frame
underside with 4 mounting bolts.
: 39.2 Nm {4 kgm} ± 10%
iv) Measure respective dimensions "d" and
"e" of clearance between retainer (21)
and the hinge plate, and retainer (22)
and the hinge plate.
v) Select and make a combination of the
shims so that the total shim thickness is
"f", i.e. the difference between "d" and
"a" dimensions (f = d – a) minus 0.02 to
0.12mm, and likewise "g", i.e. the differ-
ence between "e" and "b" dimensions (g
= e – d) minus 0.02 to 0.12 mm.
a Kind of shim thickness
: 0.1 mm and 0.5 mm
a Retainer (21) portion
2. Subassembly of hitch frame
: Standard shim thickness: 2 mm
1) Install spacer (20) to hitch frame (12).
a Retainer (22) portion
2) Press-fit bearing (19), using tool K3.
: Standard shim thickness: 1 mm
a Fill space A inside the bearing with hub
vi) Install a combination of the shims to
grease completely.
retainers (21) and (22), and tighten all
2 Space A: Hub grease 1,030 g
the mounting bolts.
: 98 – 123 Nm {10.0 – 12.5 kgm}
HM300-2R 19
3. Center shaft
1) Press-fit roller bearing inner race (9) and
ball bearing inner race (8-1) to center shaft
(10), using a push tool.
2 Bearing roller surface (RF1) and
(RF2):
Grease (G2-LI) (Coat it thinly after
press-fitting of inner race)
3) Install rings (16) and (15) to hitch frame

(12).
a Fill spaces B and C with grease to
100%.
2 Space B: Grease (G2-LI) 48 g
2 Space C: Grease (G2-LI) 33 g
4) Install bearing (14).
a Fill space D inside the bearing with
grease to 100%. 2) There are product number (PN) and mark
2 Space D: Grease (G2-LI) 35 g on inner race (8-1) and (8-2) and outer race
a Be careful not to make a mistake about (8-3) of ball bearing (8). Align the mark sur-
the grease amount. Such a mistake will face (MARK A) with inner race and outer
likely cause the bearing to overheat. race.
a Fill space E inside the bearing (8) with
grease to 100%.
2 Space E: Grease (G2-LI) 65 g
a Be careful not to make a mistake about
the grease amount. Such a mistake will
likely cause the bearing to overheat.
20 HM300-2R
3) Insert center shaft and bearing assembly (6) 5. Coupling

into hitch frame assembly (7). Install coupling (1).
a Press-fit the portion of bearing outer 2 Coupling spline portion
race of the center shaft and bearing : Grease with molybdenum disul-
assembly. fide (LM-G)
3 Mounting bolt
: 455 – 565 Nm {46.5 – 58 kgm}
4. Front cage assembly

1) Install ring (13) to the hitch frame front side.
2) Using tool K4, install dust seal (17) to the
front cage (11). 6. Rear retainer
a Coat the dust seal lip F with grease and 1) Using tool K4, press fit dust seal (4) to rear
also fill the inside space with grease to retainer (5).
100%. a Supply grease of 25 g to the dust seal
2 Space F: Grease (G2-LI) 25 g lip and the inner space H.
a Be careful not to make a mistake about 2 Dust seal lip and the inner space H:
the grease amount. Such a mistake will Grease (G2-LI) 25 g
likely cause the bearing to overheat. a If the quantity of the grease is improper,
3) Fill space G with grease to 100%. the bearing will overheat. Accordingly,
2 Space G: Grease (G2-LI) 100 g take care extremely.
a Be careful not to make a mistake about 2) Install ring (3) to rear retainer (5).
the grease amount. Such a mistake will a Fill space J of the ring with grease of
likely cause the bearing to overheat. 65 g to 100%.
4) Install front cage assembly (11) to hitch 2 Space J of ring: Grease (G2-LI) 65 g
frame (12). a If the quantity of the grease is improper,
the bearing will overheat. Accordingly,
take care extremely.
HM300-2R 21
3) Install rear retainer assembly (2).

2 Mounting bolt
: Liquid adhesive compound (LT-2)
3 Mounting bolt
: 59 – 74 Nm {6.0 – 7.5 kgm}
a Supply grease to the retainer through
the grease fitting to 100%.
2 Inside of retainer
: Grease (G2-LI) 62 g
22 HM300-2R
HM300-2R 23

© 2009 KOMATSU
All Rights Reserved
24 HM300-2R
SEN04037-00
HM300-2R


Hydraulic system
Removal and installation of flow amp valve .................................................................................................... 2
Removal and installation of hoist valve assembly........................................................................................... 4
Disassembly and assembly of steering cylinder assembly ............................................................................. 7
Disassembly and assembly of hoist cylinder assembly .................................................................................11
HM300-2R 1
Removal and installation of 1. Drain hydraulic oil.

flow amp valve 1 6 Hydraulic tank: 120l
2. Remove left fender • inner cover assembly (1).
Special tools
4 Left fender • inner cover assembly:
New/Remodel
85 kg
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
Removal
s t r ai gh t ah ea d p o si t i o n a n d s t o p t h e
k Lock the dump lever with the dump lever 3. Open up the engine hood.
lock knob. 4. Remove 4 each mounting bolts from the right
k Turn the parking brake switch ON and and left mounts at the front of the cab.
chock the wheels. a Check the thickness, quantity, and positions
k Set the lock bar to the frame and lock front of the inserted shims.
and rear frame.
5. Sling operator's cab (32) and tilt it up.
q Precautions in tilting cab a Use 2 shackles (S) so that hook (F) of the
k When tilting the cab, check that the lock sling will not hit glass (G) of the cab assem-
lever is fixed securely. bly.
tilted. 6. Pull lock lever (31) and set lock bar (30) with the
k When it is obliged to start the engine for care the direction of the lock bar (30).
testing etc., check that there is nobody k Check that the lock lever (31) closes and
under the cab. the operator cab assembly (32) is held
k Do not operate the gear shift lever or dump securely in position by the lock bar (30).
lever. For details about cab tilt, see "Method of tilting
k Do not give a large shock to the machine. cab up" in chapter Testing and adjusting.
k Do not tilt the cab while it is loaded. a Pump assembly X1 is necessary for tilting

2 HM300-2R
7. Disconnect clamp (2). 11. Remove the mounting bolts for flow amp valve
assembly (15) and then remove the assembly.
8. Disconnect the following hoses.
4 Flow amp valve assembly: 35 kg
• (3): Sending out hose from hoist pump
• (4): The flow amp valve HP port hose
• (5): Hose for centralized pressure check
9. Disconnect tube (6) between the flow amp valve Installation
(15) and hoist valve. • Installation is carried out in the reverse order to
10. Disconnect hoses and tubes, (7) to (14) from removal.
the flow amp valve assembly (15).
• (7): LS port hose • Refilling with oil (hydraulic tank)
• (8): P port hose Refill with oil through the oil filler port up to the
• (9): CL port hose specified level, then start the engine to let the oil
• (10): T port hose circulate in the piping and check the oil level
• (11): L port hose again.
• (12): HT port tube 5 Hydraulic tank: 120 l (TO10)
• (13): CL port tube
• (14): CR port tube
HM300-2R 3
Removal and installation of 1. Drain hydraulic oil.

hoist valve assembly 1 6 Hydraulic tank: 120l
2. Remove left fender • inner cover assembly (1).
Special tools
4 Left fender • inner cover assembly:
New/Remodel
85 kg
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
Removal
k Lock the dump lever with the dump lever 3. Open up the engine hood.
lock knob. 4. Remove 4 each mounting bolts from the right
k Turn the parking brake switch ON and and left mounts at the front of the cab.
chock the wheels. a Check the thickness, quantity, and positions
k Set the lock bar to the frame and lock front of the inserted shims.
and rear frame.
5. Sling operator's cab (32) and tilt it up.
q Precautions in tilting cab a Use 2 shackles (S) so that hook (F) of the
k When tilting the cab, check that the lock sling will not hit glass (G) of the cab assem-
lever is fixed securely. bly.
tilted. 6. Pull lock lever (31) and set lock bar (30) with the
k When it is obliged to start the engine for care the direction of the lock bar (30).
testing etc., check that there is nobody k Check that the lock lever (31) closes and
under the cab. the operator cab assembly (32) is held
k Do not operate the gear shift lever or dump securely in position by the lock bar (30).
lever. For details about cab tilt, see "Method of tilting
k Do not give a large shock to the machine. cab up" in chapter Testing and adjusting.
k Do not tilt the cab while it is loaded. a Pump assembly X1 is necessary for tilting

k Check that the body is lowered completely.
4 HM300-2R
• (17): A1 port hose

• (18): A1 port tube
• (19): T2 port tube
• (20): B1 port tube
• (21): P port tube
a Remove a U clamp and coupling from each
tube.
7. Remove the following to slide the bracket (12) of

EPC valve (2).
• Connector T01 (3), DT4 (4), P05 (5), T02
(6), BOS (7)
• Clamp (8)
• Oil hose (9), (10), (11)
8. Remove bracket (12). • (22): PB port hose
a Disconnect clamp of the hose (H) on the • (23): A1 port hose
back of the bracket. • (24): B1 port hose
9. Disconnect the following piping from the hoist a Start the work from the hitch frame side.
valve (13). a Disconnect U clamps from A1 port tube (18)
• (14): T port hose and B1 port tube (20).
• (15): T port tube
a Disconnect the tube coupling.
a Do not separate the tube assembly (15) be-
cause of the orifice in A portion.
• (16): PA port hose
HM300-2R 5
10. Disconnect following from flow amp valve (FAV). Installation

• (25): Clamp
• (26): Discharging hose from hoist pump
removal.
• (27): Hose for centralized pressure check
• (21): Tube between flow amp valve (FAV)
• Refilling with oil (hydraulic tank)
and hoist valve
Refill with oil through the oil filler port up to the
specified level, then start the engine to have the
oil circulate in the piping, and check the oil level
again.
5 Hydraulic tank: 120l (TO10)
11. Remove the mounting bolts for hoist valve

assembly (28) and then remove the assembly.
4 Hoist valve assembly: 35 kg
6 HM300-2R
Disassembly and assembly of 3) Pull out cylinder head and piston rod
steering cylinder assembly 1 assembly (3) from cylinder (4) and remove.
a When the piston rod assembly is pulled
Special tools out from the cylinder, oil will come out,
so catch it in a container.
New/Remodel
4 Cylinder head and piston rod assem-
Sym-
Necessity
bol
Part No. Part name bly: 35 kg
Sketch
4) Remove cylinder (4) from tool U1.
Q'ty
Cylinder repair
790-502-1003 t 1
1 stand
790-101-1102 Hydraulic pump t 1
Socket (width
3 790-102-1480 t 1
across flats: 80 mm)
790-720-1000 Expander t 1
4 796-720-1660 Ring t 1
U 07281-01159 Clamp t 1
790-101-5021 • Grip 1
5 2. Disassembly of piston rod assembly
01010-50816 • Bolt 1 1) Set piston rod assembly (3) in tool U1.
790-202-1811 • Push tool 1 2) Using tool U3, remove nut (5).
790-101-5021 • Grip 1
6
01010-50816 • Bolt 1
790-201-1620 • Plate 1
Disassembly
a Be careful not to give damage to the rod pack-
ing, dust seal, piston ring, wear ring, etc. during
the work.
1. Piston rod assembly
1) Set cylinder assembly (1) in tool U1.
3) Remove cap (20) from the rod (8).
4 Cylinder assembly: 60 kg
4) Remove 9 balls (21) and plunger (22).
2) Raise lock of cylinder head nut, and using
tool U2, remove cylinder head assembly (2).
HM300-2R 7
5) Remove piston assembly (6) and cylinder Assembly

head assembly (7) from the rod (8).
a Clean all parts, and check for dirt or damage.
Coat the sliding surfaces of all parts with engine
oil before installing.
1. Assembly of cylinder head assembly
1) Using tool U5, press fit bushing (15) to cylin-
der head (16).
a Take care not to deform bushing (15)
when press fitting it.
3. Disassembly of piston assembly

1) Remove wear ring (9) from piston (10).
2) Remove wear ring (11) from piston (10).
2) Install rod packing (14).

a Take care of installing direction.
3) Install backup ring (18) and O-ring (17) in
order.
a Do not insert the backup ring forcibly,
but heat it in water at about 50 – 60°C,
then insert it.
4. Disassembly of cylinder head assembly
1) Remove snap ring (12), then remove dust
seal (13).
2) Remove rod packing (14).
3) Remove bushing (15) from cylinder head
(16).
4) Remove O-ring (17) and backup ring (18).
8 HM300-2R
4) Using tool U6, install dust seal (13) to cylin- 3) Using tool U4, shrink the piston ring.
der head (16).
4) Install wear ring (9).

5) Install snap ring (12).
3. Assembly of piston rod assembly

2. Assembly of piston assembly 1) Assemble cylinder head assembly (7) and
1) Using tool U4, expand piston ring (11). piston assembly (6) to piston rod (8).
a Set piston ring (11) to the tool and rotate
the handle by 8 – 10 turns to expand the
ring.
2) Remove piston rod (11) from tool U4 and
install it to piston (10).
HM300-2R 9
2) Install plunger (22) with 9 balls (21). 3) Using tool U2, tighten cylinder head assem-
3) Install cap (20) in the rod (8). bly (2).
3 Cylinder head nut
: 931 ± 93.1Nm {95 ± 9.5kgm}
4) Set cylinder head and piston rod assembly

(3) to tool U1.
5) Using tool U3, tighten nuts (5).
2 Nut: Liquid adhesive (LT-2)
3 Nut
: 3.97 ± 0.4 kNm {405 ± 40.5 kgm}
4. Piston rod assembly

1) Set cylinder (4) in tool U1.
2) Assemble cylinder head and piston rod
assembly (3) into the cylinder (4).
4 Cylinder head and piston rod assem-
bly: 35 kg
10 HM300-2R
Disassembly and assembly of 3) Remove cylinder and rod assembly (3)

hoist cylinder assembly 1 from cylinder (2).
4 Cylinder and rod assembly:
Special tools 140 kg
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
790-502-1003 Cylinder repair stand t 1
1
790-101-1102 Hydraulic pump t 1
790-720-1000 Expander t 1
4 796-720-1660 Ring t 1
07281-01159 Clamp t 1
790-101-5021 • Grip 1
5 01010-50816 • Bolt 1 4) Remove snap ring (12) and screw (12a).
U
790-201-1831 • Push tool 1 5) Remove piston assembly (13), using tool
790-201-1871 • Push tool 1 U7, and then sling rod (5) to detach from
790-201-1500 Push tool kit t 1 cylinder (4).
790-101-5021 • Grip 1 6) Remove wear ring (7) from cylinder (4).
6 01010-50816 • Bolt 1
790-201-1640 • Plate 1
790-201-1680 • Plate 1
790-102-4300 Wrench assembly t 1
7
790-102-4310 Pin t 1
Disassembly
a Be careful not to damage the rod packing, dust
seal, piston ring, and wear ring.
1. Rod assembly
1) Set cylinder assembly to tool U1.
4 Cylinder assembly: 185 kg 2. Further disassembling cylinder assembly
2) Using tool U2, remove cylinder head 1) Remove snap ring (8), then remove dust
assembly (1) from cylinder (2). seal (9) and rod packing (10).
2) Remove bushing (11).
3) Remove the O-ring and backup ring (6a).
HM300-2R 11
3. Further disassembling piston assembly Assembly

Remove piston ring (14), wear ring (15), O-ring
and backup ring (15a) from piston assembly a Clean all parts, and check for dirt or damage.
(13). Coat the sliding surfaces of all parts with engine
oil before installing.
1. Cylinder
1) Using tool U5, press fit bushing (19) to cylin-
der (4).
4. Cylinder
Remove snap ring (16) from cylinder (4), then
remove dust seal (17), rod packing (18) and
bushing (19).
2) Install rod packing (18).
a Check the direction of assembly for the
rod packing when installing.
3) Using tool U6, fit dust seal (17) and install
snap ring (16).
12 HM300-2R
2. Assembly of piston assembly 3. Assembly of cylinder head assembly

1) Using tool U4, expand piston ring (14), and 1) Using tool U5, press fit bushing (11).
assemble to piston (13).
a Set the piston ring on tool, and turn the
handle 8 – 10 times to expand the ring.
2) Set tool U4 in position, and compress piston
ring (14).
3) Install wear ring (15).
4) Fit the O-ring and backup ring (15a).
2) Assemble rod packing (10) to cylinder head

(6).
a Check the direction of assembly for the
rod packing when installing.
3) Using tool U6, install dust seal (9).
HM300-2R 13
4) Fit snap ring (8), O-ring and backup ring (6). 6) Assemble the cylinder • rod assembly into
the cylinder (2).
4 Cylinder • rod assembly: 140 kg
4. Rod assembly
1) Fit wear ring (7) to cylinder (4).
2) Tighten piston assembly (13), using tool U7.
3 Piston assembly 7) Install cylinder head assembly (1) to cylin-
: 294 ± 29.4Nm {30 ± 3.0kgm} der (2), using tool U2.
3) Sling rod (5) and assemble it into the cylin- 3 Cylinder head assembly
der (4). : 1.23 ± 0.12kNm {125 ± 12.5kgm}

4) Tighten screw (12a).
a When using a new part for either or both
of piston assembly (13), or rod (5),
make a drill hole for screw.
Hole depth: 27 mm
Tap depth: 20 mm
Tap used: 10 x 1.5
a Degrease the threads of the screw suffi-
ciently.
2 Screw
: Liquid adhesive (Loctite #262)
3 Screw
: 27.5 – 34.3Nm {2.8 – 3.5kgm}
5) Fit snap ring (12).
14 HM300-2R
HM300-2R 15

© 2007 KOMATSU
All Rights Reserved
16 HM300-2R
SEN04038-00
HM300-2R


Body
Removal and installation of body assembly .................................................................................................... 2
HM300-2R 1
Removal and installation of 4. Separate body potentio linkage (2) at the body
body assembly 1 side. [*2]
5. Sling the body assembly at 4 points.
Removal
6. Remove 2 body hinge pins (3) on the left and
k Turn the parking brake switch on and put right sides. [*3]
a Shims are provided, so check their thick-
ness, number in use and installed locations
1. Sling the bottom side of hoist cylinder.
beforehand.
2. Remove bottom pins (1) of the left and right
hoist cylinders. [*1]
k When the bottom pin is removed, the
hoist cylinder will swing outward, so fas-
ten the hoist cylinder with lever lock [1]
inwardly.
7. Sling body assembly (4) to remove. [*4]

4 Body assembly: 3,500 kg
3. Loosen lever block [1] by lowering the crane

and put the hoist cylinder on the wheel.
a Put block [2] between the hoist cylinder and
wheel.
2 HM300-2R
Installation [*4]
a Adjust the shims in the body mount in the
following steps.
removal.
1) Insert spacer [1] of 58 mm in thickness in
the front end of body (4). (1 each for left and
[*1] right)
k When matching the pinholes, never put a 2) Measure clearance "x" between the center
finger into the hole. of bottom mount (5) and the upper surface
3 Cylinder bottom pin mounting bolt of rear frame (6).
: 157 – 196 Nm {16 – 20 kgm} a Measure clearance at 4 points of A and
B on the left and right sides.
[*2] 3) Calculate the shim thickness at A and B
a Adjust the body positioner sensor, referring points both on the left and right sides.
to the section of "Adjusting body positioner • Shim thickness = (x – 26) mm
sensor" in Testing and adjusting. 4) Assemble shim (7) having thickness calcu-
lated in the step 3) above in bottom mount
[*3] (5).
k When matching the pinholes, never put a • Standard shim thickness: 4 mm
finger into the pinhole. • Kind of shim thickness
3 Hinge pin mounting bolt : 1 mm and 3.2 mm
: 157 – 196 Nm {16 – 20 kgm} 5) Remove spacer [1] and check that the bot-
tom mount is in contact with the upper sur-
face of the rear frame at all 4 points of A and
B.
HM300-2R 3

© 2007 KOMATSU
All Rights Reserved
4 HM300-2R
SEN04039-00
HM300-2R


Cab and its attachments
Removal and installation of operator's cab ..................................................................................................... 2
Removal and installation of operator's cab glass (Stuck glass) ...................................................................... 7
Disassembly and assembly of operator's seat assembly (If equipped) ........................................................ 14
HM300-2R 1
Removal and installation of k In the case that you do not drain the cool-
operator's cab 1 ant, if you disconnect the heater hose when
the coolant temperature in the radiator is
Special tools high, you may be scalded. In this case, wait
until the coolant temperature lowers and
New/Remodel
then disconnect the heater hose.
Sym-
Necessity
Part No. Part name
bol 1. Open engine hood (1).
Sketch
Q'ty
Removal
lock knob.
k Turn the parking brake switch ON and 2. Remove 4 each mounting bolts from the right
chock the wheels. and left mounts at the front of the cab.
k Set the lock bar to the frame and lock front a Check the thickness, quantity, and positions
and rear frame. of the inserted shims.
k When tilting the cab, check that the lock 3. Sling operator's cab (3) and tilt it up.
lever is fixed securely. a Use 2 shackles (S) so that hook (F) of the
k Do not start the engine while the cab is sling will not hit glass (G) of the cab assem-
tilted. bly.
testing etc., check that there is nobody 4. Pull lock lever (2-1) and set lock bar (2) with the
under the cab. care the direction of the lock bar (2).
lever. the operator cab assembly (3) is held
k Do not give a large shock to the machine. securely in position by the lock bar (2).
k Do not tilt the cab while it is loaded. For details about cab tilt, see "Method of tilting
k Disconnect the cable from the negative (–) up by tilt cylinder.
k Collect the air conditioner refrigerant
(R134a) from air conditioner circuit in
advance.
a Ask professional traders for collecting and filling
operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the
atmosphere.
k If refrigerant gas (R134a) gets in your eyes,

you may lose your sight. Accordingly, put
on protective goggles while you are collect-
ing the refrigerant (R134a) or filling the air
conditioner circuit with the refrigerant
(R134a). Collecting and filling work must be
conducted by a qualified person.
2 HM300-2R
6. Disconnect air conditioner hoses (10). [*1]

a Stop the openings with tapes, etc. to prevent
air from entering them
7. Disconnect heater hoses (11).

a Prepare an oil container.
8. Disconnect hoses (12) from steering valve (SV).
a Underview of operator's cab.
9. Disconnect connectors (13) – (20).

• (13): J08, (14): J01
• (15): J09, (16): J02
• (17): J03, (18): J05
• (19): J04, (20): J06
5. Disconnect hoses (5) – (9) from brake valve

(BV).
• (5), (6): Port PA and PB
• (7): Port T
• (8): Port B
• (9): Port A
• (SV): Steering valve
a Check the destination of each hose.
a Put plugs to the hoses.
a When disconnecting the hose from brake
valve (BV), make a matchmark at the posi-
tion of the hose clamp and take care that
noise will not be increased by the sag of the
hose.
HM300-2R 3
10. Disconnect ground terminal (22). 2) Remove cover (31)

a Disconnect connector PWR from inside
11. Fix cylinder (24) temporarily to prevent it from of the cover.
falling down and remove pin (23). 3) Remove cover (32).
a Retract cylinder (24).
of the inserted shims.
4) Remove covers (33) and (34).
12. Return the operator's cab assembly (3) to the

horizontal position.
13. Disconnect rearview monitor cable (21) in the

following steps.
5) Remove storage box (35).

6) Remove cover (36).
7) Remove clamp (37) from rear view monitor
cable (21).
1) Remove seat (30).
4 HM300-2R
8) Remove the external air filter cover (38) 14. Sling the operator's cab assembly temporarily
from outside of the operator's cab and by using plate (P).
remove the external air filter.
9) Remove external air filter box (39).
15. Remove pin (25). [*3]

10) Remove the rear mounting bolts and of the inserted shims.
remove cover (40) from the dashboard.
16. Lift off operator's cab assembly (3).

11) Disconnect band (41).
4 Operator's cab assembly: 1,200 kg
12) Disconnect connector (42) from monitor (M).
13) Remove the molding material of grommet
(G). [*2]
14) Drop monitor cable (21) below the opera-
tor's cab.
HM300-2R 5
Installation [*3]
a Adjust the shims so that the clearance
• Carry out installation in the reverse order to between operator's cab (3) and mount (26)
removal. will be "a" on each side.
• Standard clearance "a": 0.2 mm (Each side)
[*1] • Kinds of shim thickness:
a When installing the air conditioner circuit 0.5 mm, 1.0 mm, 2.3 mm
hoses, take care that dirt and water will not
enter them.
a When installing each air conditioner hose,
check that the O-ring is fitted to the joint.
a Check each O-ring for a flaw and deteriora-
tion.
a When connecting the refrigerant piping, coat
the O-rings with compressor oil for new
refrigerant R134a (DENSO: ND-OIL 8,
ZEXEL: ZXL 100 PG (equivalent to PAG
46).
3 Tightening torque for air conditioner pip-
ing
Thread size Tightening torque
16 x 1.5 11.8 – 14.7 Nm {1.2 – 1.5 kgm} • Filling air conditioner circuit with refrigerant
22 x 1.5 19.6 – 24.5 Nm {2.0 – 2.5 kgm} (R134a)
Fill the air conditioner circuit with refrigerant
24 x 1.5 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
(R134a).
a Quantity of refrigerant: 1,200 ± 50 g
[*2]
Make seal the grommet (G) area of the monitor • Refilling with coolant
cable. Add coolant through the coolant filler to the
2 Oblique line area in the grommet (G)
(100% full): coolant through the system. Then, check the
CEMEDINE 366E or equivalent coolant level again.
6 HM300-2R
Removal and installation of Procedure

operator's cab glass (Stuck glass)1 Preparation (Cleaning)
O
a Among the panes of window glass on the 4 Applying primer
sides of the operator's cab, 5 panes (1) – (5)
• Cab side: SUNSTAR 435-95
shown in the figure are stuck.
• Glass side: SUNSTAR 435-40
a In this section, the procedure for replacing the
stuck glass is explained. O Dry for at least 5 minutes and stick within 24
(1) Front window glass hours.
(2) Left rear window glass Sticking both-sided adhesive tape (cab side)
(3) Rear window glass O
(4) Right rear window glass Positioning window glass
(5) Right door sash assembly (Sash is stuck) O
Applying adhesive (SUNSTAR Industrial sealant,
Petaseal 551) (cab side)
O Within 5 minutes
Sticking window glass
* Keep pressing the glass for at least 10 hours.
HM300-2R 7
Special tools a If the window glass is broken finely, it may

be removed with knife [4] and a screwdriver.
New/Remodel
a Widening the cut with a flat-head screw-
Sym- driver, cut the adhesive and both-sided
Necessity
Part No. Part name
bol
Sketch
adhesive tape with knife [4].
Q'ty
Lifter (The following figure shows the operator's cab
2 793-498-1210 t 2
X (Suction cup) of a wheel loader.)
3 20Y-54-13180 Stopper rubber t 2
Removal
a Remove the window glass to be replaced
according to the following procedure.
1. Using seal cutter [1], cut the adhesive between

broken window glass (7) and operator's cab
(metal sheet) (8).
2. Remove the window glass.
a If a seal cutter is not available, make holes

on the adhesive and both-sided adhesive
tape with a drill and pass a fine wire (piano
wire, etc.) [2] through the holes. Grip the
both ends of the wire with pliers [3], etc. (or
hold them by winding them onto something)
and move the wire to the right and left to cut
the adhesive and both-sided adhesive tape.
Since the wire may be broken by the fric-
tional heat, apply lubricant to it.
(The following figure shows the operator's cab

of a wheel loader.)
8 HM300-2R
Installation Applying primer

3. Apply primer (10).
Preparation a The using limit of the primer is 4 months
1. Using a knife and scraper [5], remove the after the date of manufacture. Do not use
remaining adhesive and both-sided adhesive the primer after this limit.
tape from the metal sheets (glass sticking sur- a Use the primer within 2 hours after unpack-
faces) of the operator's cab. ing it.
a Remove the adhesive and both-sided adhe- a Even if the primer is packed again just after
sive tape to a degree that they will not affect it is unpacked, use it within 24 hours after it
adhesion of the new adhesive. Take care is unpacked for the first time. (Discard the
not to scratch the painted surfaces. (If the primer 24 hours after it is unpacked.)
painted surfaces are scratched, adhesion 1) Stir both of the paint primers and glass
will be lowered.) primer sufficiently before using them.
a If the primer has been stored in a refrig-
(The following figure shows the operator's cab erator, leave it at the room temperature
of a wheel loader.) for at least half a day before stirring it.
(If the primer is unpacked just after
taken out of the refrigerator, water will
be condensed. Accordingly, leave the
primer at the room temperature for a
sufficient time.)
2) When reusing primer brush (11), wash it in
white gasoline.
a After washing the brush, check it again
for dirt and foreign matter.
a Prepare respective brushes for the paint
primer and glass primer.
2. Remove oil, dust, dirt, etc. from the sticking sur-

faces of cab (8) and window glass (9) with white
gasoline.
a If the sticking surfaces are not cleaned well,
the glass may not be stuck perfectly.
a Clean the all black part on the back side of
the window glass.
a After cleaning the sticking surfaces, leave
them in air for at least 5 minutes to dry.
(The following figure shows the operator's cab
of a wheel loader.)
HM300-2R 9
3) Evenly apply paint primer to the surfaces to 4) Evenly apply glass primer all around inside
stick both-sided adhesive tapes. of the black coated surface of window glass
a: Min. 30 mm (9).
2 Primer for cab (painted surface): a: Min. 30 mm
SUNSTAR 435-95 2 Glass primer: SUNSTAR 435-40
a Do not apply the primer more than 2 a The black coating is for prevention of
times. (If it is applied more than 2 times, deterioration by light.
its performance will be lowered.) a Do not apply the primer more than 2
a Never apply wrong primer. If you have times. (If it is applied more than 2 times,
applied the glass primer, etc. by mis- its performance will be lowered.)
take, wipe it off with white gasoline.
a After applying the primer, leave it for at
least 5 minutes in air to dry and stick the
both-sided adhesive tape within 24
hours.
(The figure shows the operator's cab of
a hydraulic excavator.)
a (8): Cab
a (9): Glass
a Never apply wrong primer. If you have

applied the paint primer, etc. by mistake,
wipe it off with white gasoline.
10 HM300-2R
Sticking both-sided adhesive tape a (8): Cab

4. Stick both-sided adhesive tape (6) along the a (a): Range to apply primer (Described
edge of cab (8). above)
a Do not remove the release tape of the both- a (15): Adhesive (Described below)
sided adhesive tape on the glass sticking
side before sticking the glass.
a When sticking the both-sided adhesive tape,
do not touch the cleaned surface as long as
possible.
a Take that the both-sided adhesive tape will
not float at each corner of the window
frame.
Positioning window glass

5. Position the new window glass.
1) Check the clearance between the window
glass and the operator's cab on the right,
left, upper, and lower sides, and then adjust
it evenly.
2) Stick tapes [6] between window glass (9)
a When sticking both-sided adhesive tape (6) and operator's cab (8) and draw positioning
around a frame, do not lap its finishing end line (n).
over the starting end but make clearance "e" a Stick tapes [6] to the right, left, and lower
of about 5 mm between them. parts of the glass for accurate position-
1) Stick both-sided adhesive tape (6) for right ing.
window glass (1) as shown in the figure. 3) Cut the tape between window glass (9) and
a (The figure shows the operator's cab of operator's cab (8) with a knife, and then
a hydraulic excavator.) remove the window glass.
a Do not remove the release tape of the
both-sided adhesive tape on the glass
sticking side before sticking the glass.
(The figure shows the operator's cab of a
hydraulic excavator.)
HM300-2R 11
Applying adhesive 7. Apply the adhesive.

6. Prepare for applying the adhesive. a Apply adhesive (15) to dimensions (s) and
• Adhesive: (t) of both-sided adhesive tape (6) of opera-
SUNSTAR Industrial sealant, Petaseal tor's cab (8).
551 • Dimension (s): 10 mm
a The using limit of the adhesive is 4 months • Dimension (t): 15 mm
after the date of manufacture. Do not use 2 Adhesive: SUNSTAR Industrial sealant,
the adhesive after this limit. Petaseal 551
a Keep the adhesive in a dark place where a Apply adhesive (15) higher than both-sided
the temperature is below 25°C. adhesive tape (6).
a Never heat the adhesive higher than 30°C. a Apply the adhesive evenly.
a When reusing the adhesive, remove the all a (a): Range to apply primer (Described
hardened part from the nozzle tip. above)
a Stick the glass within 5 minutes after apply-
1) Set adhesive cartridge (12) to caulking gun ing the adhesive.
[7].
a An electric caulking gun is more effi-
cient.
2) Cut the tip of the adhesive nozzle (14) so

that dimensions (q) and (r) will be as fol-
lows.
• Dimension (q): 10 mm
• Dimension (r): 15 mm
3) Remove the release tape of the both-sided

adhesive tape on the glass side.
12 HM300-2R
Installing window glass

8. Install the window glass.
1) Install window glass (9), matching it to the
lines of the positioning tapes drawn in step
5.
a Since the window glass cannot be
removed and stuck again, stick it very
carefully.
2) After sticking window glass (9), press all
around it until it is stuck to the both-sided
adhesive tape.
a Press the corners of the window glass
firmly.
2) Using styrene foam blocks [9] and rubber

a You can perform this work efficiently by
bands [10], fix the window glass and both-
pulling window glass (9) from inside of
sided adhesive tape for at least 10 hours to
the operator's cab with suction cup X2.
fit them completely.
a Wipe off the projected adhesive.
9. Fix the window glass.

10. After installing the window glass, remove the
1) After installing right window glass (1) to the
primer and adhesive from the operator's cab
operator's cab, insert stopper rubbers X3 in
and window glass.
2 places (v) at the bottom of the glass to fix
a Using white gasoline, wipe off the adhesive
the glass.
before it is dried up.
a When cleaning the glass, do not give an
impact to it.
HM300-2R 13
Disassembly and assembly of operator's seat assembly (If equipped) 1

a The procedure for disassembling and assembling the operator’s seat assembly {Air suspension (product
made from ISRING HAUSEN)} is shown below.
A: Headrest E : Left-hand armrest

B: Seatback F : Suspension cover
C: Seat cushion G : Sliderails
D: Right-hand armrest
Disassembly
1. Headrest
1) Referring to the figure, check the positions of
the 2 clips (2) of headrest stay (1) on both
sides.
14 HM300-2R
2) Apply force b to part a of each clip (2) in the 2. Seatback

direction of the arrow to turn the clip. Re- 1) Disconnect 3 air hoses (5) from the rear left
lease headrest stay (1) from part d of the clip of seatback (4).
and pull out up headrest (3). a Before disconnecting the air hoses,
check their types.
2) Remove seatback hinge mounting bolt (6)

(M8 bolt).
a Pushing in both clips (2) simultaneously,

remove headrest (3).
3) Bring seatback (4) down forward.
HM300-2R 15
4) Apply force E to the right side of seatback (4) 2) Push cushion stopper wire (9) down with
in the direction of the arrow. screwdriver [1], etc.
5) Applying the force to seatback (4), pull its 3) Pull out seat cushion (8) forward and remove
right side up. it.
6) Slide seatback (4) sideway and remove it.
4. Armrest
3. Seat cushion • The procedure for disassembling right-hand
1) Push cushion adjuster lever (7) inward and armrest (10) is shown below.
slide seat cushion (8) to the front end. (Disassemble left-hand armrest (11) similar-
ly.)
16 HM300-2R
1) Remove plastic cap (12) from the armrest 6) Remove right-hand armrest (10).
hinge. a There are 2 position adjustment wash-
a Use a flat-head screwdriver, etc. to ers (16) installed to each bolt between
remove the cap. the armrest and seatback. Take care not
2) Loosen armrest hinge mounting bolt (13). lose them.
3) Remove plastic cap (14), and then remove 5. Suspension cover

lower mounting bolt (15A) (M8 bolt) of right- 1) Remove right-hand hinge cover (17).
hand armrest (10). 2) Remove plastic plate (18) from the rear with
screwdriver [1], etc.
a Take care not to damage the plastic plate
by prying it off forcibly with a screwdriver,
etc.
4) Turn right-hand armrest (10) up by 180°.

a If the armrest is not turned, you cannot
apply the tool to upper mounting bolt
(15B).
5) Remove plastic cap (14) and upper mount-
ing bolt (15B).
HM300-2R 17
3) Remove 4 suspension cover fixing rings 6) Remove 6 plastic suspension cover clips
(19). (small) (25) and 2 plastic suspension cover
clips (large) (26).
a Clips (small) (25):
Front upper part; 2 places
Each side; 1 place
Rear lower part; 2 places
Clips (large) (26):
Front lower part; 2 places
7) Remove suspension cover (27).
a If you remove the suspension cover with-
out performing the work in steps 5) and
6), the suspension cover may be broken.
4) Remove 4 mounting bolts (20), cushion rear

fixing plate (21), 2 cushion rails (22), and 4
bushings (23).
6. Rails
1) Turn over the seat assembly to set rails (28)
on the upside.
5) Remove 3 metallic suspension cover clips

(24).
18 HM300-2R
2) Slide rails (28) to the rear end. Assembly

3) Remove 1 hexagon socket head bolt (29)
and 1 lock washer (30) from the front part of 1. Rails
each rail. [*6] 1) Put height adjustment washers (31) between
rails (28) and suspension, and then set rails
(28) in position.
4) Slide rails (28) to the front end.

5) Remove 1 hexagon socket head bolt (29)
and 1 lock washer (30) from the rear part of 2) Set rails (28) to the front end and install 1
each rail, and then remove rails (28). [*7] lock washer (30) and 1 hexagon socket head
bolt (29) to each rail.
3 Hexagon socket head bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
a Take care not to lose height adjustment

washers (31) between the rails and sus-
pension.
HM300-2R 19
3) Set rails (28) to the rear end and install 1 lock 2) Install 3 metallic suspension cover clips (24).
washer (30) and 1 hexagon socket head bolt
(29) to each rail.
3 Hexagon socket head bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
3) Set 4 bushings (23) and 2 cushion rails (22),

and then install cushion rear fixing plate (21),
and 4 mounting bolts (20).
3 Cushion rail mounting bolt:
2. Suspension cover 21.4 – 27.6 Nm {2.18 – 2.82 kgm}
1) Set suspension cover (27) in position and in-
stall 6 plastic suspension cover clips (small)
(25) and 2 plastic suspension cover clips
(large) (26).
a Clips (small) (25):
Front upper part; 2 places
Each side; 1 place
Rear lower part; 2 places
Clips (large) (26):
Front lower part; 2 places
4) Install 4 suspension cover fixing rings (19).
20 HM300-2R
5) Install plastic plate (18) to the rear. 2) Tighten lower mounting bolt (15A) lightly and
6) Install right-hand hinge cover (17). turn armrest (10) by 180 degrees.
3) Tighten upper mounting bolt (15B) lightly.
4) Tighten lower mounting bolt (15A) and upper
mounting bolt (15A) permanently.
3 Upper and lower armrest mounting
bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
5) Install 2 plastic caps (14).
3. Armrest
• The procedure for assembling right-hand
armrest (10) is shown below.
(Assemble left-hand armrest (11) similarly.)
6) Tighten armrest hinge mounting bolt (13).

a Tighten the bolt so that the arm will move
smoothly.
• Operating effort at armrest end:
49 – 78.4 N {5 – 8 kg}
7) Install plastic cap (12).
1) Install 2 position adjustment washers (16) for

each bolt and set right-hand armrest (10) in
position.
HM300-2R 21
4. Seat cushion 5. Seatback

1) Slide in the seat cushion from the front of the 1) Insert the left side of seatback (4), and then
fitting position. lower and set the right side.
a If seat cushion (8) is slid to the rear, it is
locked by cushion stopper wire (9).
2) Install seatback hinge mounting bolt (6) (M8

bolt).
3 Seatback hinge mounting bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
22 HM300-2R
3) Connect 3 air hoses (5) to the rear left of the

seatback (4).
6. Headrest
1) Insert headrest (3) in seatback (4).
a Check that 2 clips (2) on both sides are
locked securely.
HM300-2R 23

© 2007 KOMATSU
All Rights Reserved
24 HM300-2R
SEN04040-00
HM300-2R


Electrical system
Removal and installation of air conditioner unit assembly .............................................................................. 2
Removal and installation of engine controller ................................................................................................. 7
Removal and installation of retarder controller................................................................................................ 9
Removal and installation of transmission controller assembly.......................................................................11
HM300-2R 1
Removal and installation of air k In the case that you do not drain the cool-
conditioner unit assembly 1 ant, if you disconnect the heater hose when
the coolant temperature in the radiator is
Special tools high, you may be scalded. In this case, wait
until the coolant temperature lowers and
New/Remodel
then disconnect the heater hose.
Sym-
Necessity
Part No. Part name
bol 1. Open engine hood (1).
Sketch
Q'ty
Removal
lock knob.
k Turn the parking brake switch ON and 2. Remove 4 each mounting bolts from the right
chock the wheels. and left mounts at the front of the cab.
k Set the lock bar to the frame and lock front a Check the thickness, quantity, and positions
and rear frame. of the inserted shims.
k When tilting the cab, check that the lock 3. Sling operator's cab (3) and tilt it up.
lever is fixed securely. a Use 2 shackles (S) so that hook (F) of the
k Do not start the engine while the cab is sling will not hit glass (G) of the cab assem-
tilted. bly.
testing etc., check that there is nobody 4. Pull lock lever (2-1) and set lock bar (2) with the
under the cab. care the direction of the lock bar (2).
lever. the operator cab assembly (3) is held
k Do not give a large shock to the machine. securely in position by the lock bar (2).
k Do not tilt the cab while it is loaded. For details about cab tilt, see "Method of tilting
k Disconnect the cable from the negative (–) up by tilt cylinder.
k Collect the air conditioner refrigerant
(R134a) from air conditioner circuit in
advance.
a Ask professional traders for collecting and filling
operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the
atmosphere.
k If refrigerant gas (R134a) gets in your eyes,

you may lose your sight. Accordingly, put
on protective goggles while you are collect-
ing the refrigerant (R134a) or filling the air
conditioner circuit with the refrigerant
(R134a). Collecting and filling work must be
conducted by a qualified person.
2 HM300-2R
8. Return the operator's cab assembly (3) to the

horizontal position.
9. Remove seat (9).
5. Disconnect heater hoses (4).

a Check the destination of each hose.
6. Remove covers (5) and (6). 10. Remove cover (10).

a Disconnect connector PWR from inside of
the cover.
11. Remove covers (11) and (12).
7. Disconnect drain hose clamps (7) and (8).
HM300-2R 3
13. Disconnect connector EM (14). 18. Disconnect hose (19).
14. Disconnect relay plate assembly (15). 19. Remove mounting bolt (20) and disconnect
hose assembly (21).
15. Remove internal air filter box (16).
a Move relay plate assembly (15) in advance. 20. Remove mounting bolt (22) and disconnect air
conditioner hose assembly (23). [*1]
a Stop the openings with tapes, etc. to prevent
air from entering them
a Take care not drop the inside O-ring.
16. Remove duct (17).
21. Remove external air filter cover (24) from out-

side of the operator's cab.
a Remove the 4 rear mounting bolts of the air
conditioner unit assembly from this place.
22. Remove external air filter box (25).
17. Remove duct (18).
4 HM300-2R
23. Remove rear mounting bolts (26) and (27) of air

conditioner unit assembly (28).
24. Remove the front mounting bolts (29) and lift

and pull out air conditioner unit assembly (28).
25. While pulling out air conditioner unit assembly

(28), disconnect the following.
• Connector AC1 (30).
a Disconnect the wiring harness clamp, too.
• Drain hose (31) from bottom.
HM300-2R 5
Installation
removal.
[*1]
a When installing the air conditioner circuit
hoses, take care that dirt and water will not
enter them.
a When installing each air conditioner hose,
check that the O-ring (70) is fitted to the
joint.
a Check each O-ring for a flaw and deteriora-
tion.
a When connecting the refrigerant piping, coat
the O-rings with compressor oil for new
refrigerant R134a (DENSO: ND-OIL 8,
ZEXEL: ZXL 100 PG (equivalent to PAG
46)).
3 Air conditioner hose assembly mounting

bolt: 8 – 12 Nm {0.8 – 1.2 kgm}
• Filling air conditioner circuit with refrigerant

(R134a)
Fill the air conditioner circuit with refrigerant
(R134a).
a Quantity of refrigerant: 1,200 ± 50 g

6 HM300-2R
Removal and installation of 3. Disconnect connectors J3P (5) and J2P (6) and
engine controller 1 (7) from engine controller (4). [*1]
a Disconnect the clamp, too.
Removal
4. Remove engine controller (4).
the engine.
k Chock the wheels.
HM300-2R 7
Installation
removal.
[*1]
• Check that there is no sand, dust, water,
etc. in the controller connector (especially
on the lower side). If there is any, remove
completely by blowing air. (Sand, dust,
water, etc. can cause defective contact and
entry of water.)
a Reference
• Method of replacing O-ring seal of power con-

nector J3P (5)
O-ring seal:
1010-074-0406 (NIHON-DEUTSCH LIMITED)
1) Using tweezers [1], pinch the claw and

remove cover (8).
2) Using tweezers [1], remove O-ring (9).
8 HM300-2R
Removal and installation of 4. Remove cover (5).

retarder controller 1
Removal
the engine.
k Chock the wheels.
1. Remove seat (1).

a PWR: Connector removed in step 2

a Disconnect connector PWR from inside of
the cover.
6. Disconnect connector EM (7).
7. Disconnect relay plate assembly (8).
HM300-2R 9
8. Remove retarder controller (9). Installation

a T/M: Transmission controller
removal.
[*1]
3 Mounting screw: 2.82 Nm {0.288 kgm}
9. Disconnect connectors BRC1 (10), BRC2 (11),

and BRC3 (12) from retarder controller (9). [*1]
a Loosen lock (L) with 4-mm hexagonal
wrench in advance.
10 HM300-2R
Removal and installation of Installation

transmission controller assembly1 • Carry out installation in the reverse order to
removal.
Removal
[*1]
k
3
Stop the machine on level ground.
Mounting screw: 2.82 Nm {0.28 kgm}
the engine.
k Chock the wheels.
1. Disconnect relay plate assembly (1). For details,

see "Removal and installation of retarder con-
troller assembly".
a R: Retarder controller
2. Remove transmission controller (2).
3. Disconnect connectors ATC1 (3), ATC2 (4), and

ATC3 (5) from transmission controller (2). [*1]
a Loosen the lock of each connector with 4-
mm hexagonal wrench in advance.
a See Removal and installation of retarder
controller assembly.
HM300-2R 11

© 2007 KOMATSU
All Rights Reserved
12 HM300-2R
SEN02281-00
HM300-2R

90 Diagrams and drawings 1

Hydraulic diagrams and drawings
Power train hydraulic circuit diagram .............................................................................................................. 3
Steering and hoist hydraulic circuit diagram ................................................................................................... 5
Brake hydraulic circuit diagram....................................................................................................................... 7
Brake cooling hydraulic circuit diagram .......................................................................................................... 9
HM300-2R 1
SEN02281-00 90 Diagrams and drawings
2 HM300-2R
Power train hydraulic circuit diagram Power train hydraulic circuit diagram
HM300-2R
HM300-2R 3
Steering and hoist hydraulic circuit diagram 1
HM300-2R 5
6 HM300-2R
Brake hydraulic circuit diagram Brake hydraulic circuit diagram

HM300-2R
HM300-2R 7
Brake cooling hydraulic circuit diagram 1
HM300-2R 9

© 2007 KOMATSU
All Rights Reserved
10 HM300-2R
SEN02282-03
HM300-2R

90 Diagrams and drawings 1

Electrical diagrams and drawings
Electrical circuit diagram for inside cab (1/4) .................................................................................................. 3
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
Electrical circuit diagram for payload meter .................................................................................................. 17
Connectors table and arrangement drawing ................................................................................................. 19
HM300-2R 1
2 HM300-2R
Electrical circuit diagram for inside cab (1/4) Electrical circuit diagram for inside cab (1/4) 1
HM300-2R
SEN02282-03
HM300-2R 3
HM300-2R
SEN02282-03
HM300-2R 5
HM300-2R
SEN02282-03
HM300-2R 7
HM300-2R
SEN02282-03
HM300-2R 9
Electrical circuit diagram for outside cab (1/3) Electrical circuit diagram for outside cab (1/3) 1
HM300-2R
SEN02282-03
HM300-2R 11
HM300-2R
SEN02282-03
HM300-2R 13
HM300-2R
SEN02282-03
HM300-2R 15
Electrical circuit diagram for payload meter Electrical circuit diagram for payload meter 1
HM300-2R
SEN02282-03
HM300-2R 17
Connectors table and arrangement drawing
Connectors table and arrangement drawing HM300-2R HM300-2R
Type of Number Type of Number Type of Number Type of Number

Connector No. connector of pins Location Address Connector No. connector of pins Location Address Connector No. Location Address Connector No. Location Address
connector of pins connector of pins
41 Terminal 1 Backup alarm buzzer M-8 CN3 DT 2 Injector #3 AL-9 HAZ M 6 Hazard switch R-7 RWM KES1 2 Washer motor (rear) A-4
47 M 2 Backup lamp M-8 CN3 DT-T 2 Input shaft speed sensor AD-7 HEAT M 6 Rear heater switch (if equipped) O-2 SBS DT-T 2 Seat belt switch Y-2
49 Terminal 1 Backup alarm buzzer L-8 CN4 DT 2 Injector #4 AN-7 HEAT1 KES1 1 Rear glass heater (if equipped) (right) E-8 SCT — — Socket W-1
50 Terminal 1 Battery relay (-) terminal C-7 CN4 DT-T 2 Intermediate shaft speed sensor AH-5 HEAT2 KES1 1 Rear glass heater (if equipped) (left) I-9 SDE M 6 Side lamp switch (i fequipped) P-2
53 Terminal 1 Battery relay (+) terminal A-7 CN5 DT 2 Injector #5 AN-6 HN KES1 1 Horn switch R-2 SF1 DT-T 12 Gear shift lever X-1
58 Terminal 1 Emergency steering relay (-) terminal A-9 CN5 DT-T 2 Output shaft speed sensor AH-6 HSL DT-T 4 Hoist lever potentiometer Y-2 SF2 DT-T 2 Gea rshift lever X-1
59 Terminal 1 Emergency steering relay (+) terminal C-9 CN6 DT 2 Injector #6 AN-6 INJ DT 12 Intermediate connector AL-5 SPARE X 4 Spare connector X-9
60 Terminal 1 Emergency steering relay (-) terminal C-9 CN6 DT-T 2 Low clutch ECMV AG-8 J01 HD-24 9 Intermediate connector K-1 SPL KES1 2 Speaker(left) H-9
61 Terminal 1 Emergency steering relay (+) terminal A-8 CN7 DT-T 2 Low fill switch AH-7 J02 HD-24 31 Intermediate connector L-1 SPR KES1 2 Speaker (right) F-8
62 Terminal 1 Circuit breaker (80A) E-9 CN8 DT-T 2 R clutch ECMV AG-8 J03 HD-24 31 Intermediate connector L-2 ST1 Terminal 1 Emergency steering switch O-9
63 Terminal 1 Circuit breaker (80A) E-9 CN9 DT-T 2 R fill switch AG-8 J04 HD-24 31 Intermediate connector L-2 ST2 Terminal 1 Emergency steering switch O-8
64 Terminal 1 Circuit breaker (80A) E-8 CN10 DT-T 2 High solenoid AH-7 J05 HD-18 14 Intermediate connector L-2 ST3 Terminal 1 Emergency steering switch O-8
65 Terminal 1 Circuit breaker (80A) E-9 CN11 DT-T 2 High fill switch AH-6 J06 DTP04 4 Intermediate connector (engine) L-2 ST4 Terminal 1 Emergency steering switch P-9
66 Terminal 1 Battery relay (B) terminal A-7 CN12 DT-T 2 1st clutch ECMV AH-7 J08 HD-18 14 Intermediate connector (transmission) K-1, AD-8 T01 DT-T 3 Hoist selector valve J-3
69 Terminal 1 Battery relay (M) terminal A-8 CN13 DT-T 2 1st fill switch AH-7 J09 HD-24 31 Intermediate connector (transmission) K-2, AD-8 T02 DT-T 2 Hoist EPC valve J-3
74 Terminal 1 Emergency steering relay (B) terminal B-9 CN14 DT-T 2 2nd clutch ECMV AF-8 J12 DT-T 8 Intermediate connector I-2 T03 DT-T 2 Transmission oil filter switch A-3
75 Terminal 1 Emergency steering relay (M) terminal B-9 CN15 DT-T 2 2nd fill switch AF-8 J13 DT-T 8 Intermediate connector K-4 T04 DT-T 2 Steering oil temperature sensor K-3
76 Terminal 1 Emergency steering relay (B) terminal B-9 CN16 DT-T 2 3rd clutch ECMV AF-8 J14 DT-T 8 Intermediate connector I-2 T06 DT-T 2 Hydraulic oil level switch (if equipped) I-2
77 Terminal 1 Emergency steering relay (M) terminal C-9 CN17 DT-T 2 3rd fill switch AG-8 J15 DT-T 8 Intermediate connector L-4 T10 DT-T 3 Pitch angle sensor L-9
78 DT 2 Starting motor terminals R and S AJ-1 CN18 DT-T 2 Torque converter lockup solenoid AE-8 J18 DT-T 12 Intermediate connector D-1 T10A L-9
80 Terminal 1 Alternator terminal R AK-1 CN20 DT-T 2 DIFF solenoid AH-6 J19 HD-24 9 Intermediate connector E-1 T14 DT-T 3 Body position sensor K-9
81 Terminal 1 Circuit breaker (30A) D-8 CN22 DT-T 2 Torque converter oil pressure sensor AD-6 J1939 DT 3 CAN AM-9 TC20D DRC 40 KOMTRAX Terminal R-8
82 Terminal 1 Circuit breaker (30A) D-9 CN23 DT-T 2 Torque converter oil temperature sensor AD-7 J2P DRC 50 Engine controller AK-5 TCHET X 4 Heater & touch unit P-5
83 Terminal 1 Circuit breaker (30A) D-8 CN24 DT-T 2 Transmission oil temperature sensor AG-2 J3P DT06 4 Engine controller AK-6 TEL DT-T 12 Tele-management P-8
84 Terminal 1 Circuit breaker (30A) D-9 CNS1 DT-T 12 Console wiring harness Y-2 JCA SWP 16 Joint connector X-9 TFUEL PACKARD 2 Fuel temperature sensor AN-5
86 Terminal 1 Side lamp (left) (if equipped) I-2 CNS2 DT-T 12 Console wiring harness (gear shift lever) X-2 JCC SWP 16 Joint connector T-1 TIM PACKARD 2 Boost temperature sensor AN-5
94 Terminal 1 Ground M-7 CNS3 DT-T 12 Console wiring harness X-2 JCD SWP 16 Joint connector T-1 TSL DT-T 2 turn signal (left) K-3
AC1 AMP 18 Intermediate connector (air conditioner wiring harness) W-9 COMP X 2 Compressor B-2 JCE SWP 16 Joint connector T-1 TWTR PACKARD 2 Engine coolant temperature sensor AK-1
AC2 AMP 8 Air conditioner panel P-5 CON DC/DC converter W-1 JM01 Terminalarray AL-5 WFM M 6 Wiper motor (fo rfront) U-1
ACC M 6 Accelerator-linked switch Q-3 D01 YAZAKI 2 Diode P-4 JM02 Terminalarray AL-5 WFR KES0 6 Wiper relay (for front) U-1
ACC Terminal 1 Starting switch O-7 D02 YAZAKI 2 Diode AB-1 JM03 Terminalarray AL-5 WM M 4 Intermediate connector(washer motor) F-1,P-4
ACRD SUMITOMOD 2 Pressure switch E-1 D03 YAZAKI 2 Diode AB-1 JM04 Terminalarray AM-8 WPS DT-T 12 Wiper switch S-1
ENSO
D04 YAZAKI 2 Diode AA-2 KA1 Plugconnector 1 Rotary lamp (if equipped) D-7 WRF M 6 Working lamp switch (if equipped) P-1
A1-F M 1 Emergency escape switch (female connector) Y-8
D05 YAZAKI 2 Diode AA-2 KA2 Plugconnector 1 Rotary lamp (if equipped) D-7 WRM KES 4 Wiper motor (for rear) J-9
A1-M M 1 Emergency escape switch (male connector) Y-8
D06 YAZAKI 2 Diode AA-2 LKO DT-T 2 Lever kick-out solenoid Z-3
AISS M 6 AISS switch Q-6
D07 YAZAKI 2 Diode P-5 LS M 3 Rheostat V-1
AS1 DT-T 6 Acceleration sensor R-2
D08 YAZAKI 2 Diode P-4 M01 X 2 Radiator coolant level switch A-4
AS2 DT 2 Acceleration sensor R-2
D09 YAZAKI 2 Diode P-5 M04 DT-T 2 Brake oil temperature sensor (M) M-5
ASS DT-T 2 Air suspension seat Z-5
D10 DT-T 2 Diode E-1 M06 DT-T 2 Fuel gauge sensor A-4
ATC1 DT-T 24 Transmission controller AB-7
D10 YAZAKI 2 Diode AA-2 M07 DT-T 2 Front brake oil temperature sensor AI-1
ATC2 DRC 40 Transmission controller AB-7
D11 YAZAKI 2 Diode AB-2 M11 DT-T 2 Air cleaner clogging sensor A-4
ATC3 DRC 40 Transmission controller AA-8
D12 YAZAKI 2 Diode AB-2 M-2 Terminal 1 Emergency steering motor (+) terminal F-1
ATC6 X 4 Intermediate connector (brake controller) Y-9
D13 YAZAKI 2 Diode AB-2 MON M 4 Rear view monitor (if equipped) P-6
B Terminal 1 Starting switch P-7
D14 YAZAKI 2 Diode AB-2 NE FRAMATOME 3 NE sensor AM-5
B Terminal 1 Starting motor terminal B AI-2
D15 YAZAKI 2 Diode C-8 OL DT 2 Oil level AJ-1
B Terminal 1 Alternator terminal B AK-1
DEF M 6 Differential lock switch P-3 OP DT-T 4 Optional connector E-7
B06 DT-T 2 BCV solenoid (front) A-5, AI-2
DEL M 6 Right and left differential lock switch (if equipped) Q-2 OP7-F M 1 Option setting connector (female) U-1
B07 DT-T 2 BCV solenoid (rear) A-5, AI-2
DFS DT-T 3 Differential lock foot switch R-2 OP7-M M 1 Option setting connector (male) U-1
B09 DT-T 2 Transmission differential speed sensor H-1, AH-4, AH-6
DL DT-T 12 Intermediate connector Y-8 P01 M 3 Head lamp (left) C-1
B14 DT-T 2 Parking brake solenoid M-3
DPC1 070 20 Electronic display panel T-8 P01 M 3 Head lamp (right) A-3
B15 DT-T 2 Service brake switch K-3
DPC2A 070 18 Electronic display panel S-8 P02 DT-T 3 Combination lamp (left) D-1
B16 DT-T 2 Retarder brake switch (F) L-3
DPC2B 070 12 Electronic display panel S-7 P02 DT-T 3 Combination lamp (right) A-3
B17 DT-T 2 Parking brake operation switch M-4
DPC3A 070 18 Electronic display panel S-7 P05 DT-T 2 Intermediate connector (turn signal, left) H-2
B18 DT-T 2 Solenoid proportional pressure regulator valve (rear) K-3
DPC3B 070 12 Electronic display panel S-7 P06 DT-T 2 Turn signal (right) E-8
B19 DT-T 2 Solenoid proportional pressure regulator valve (front) J-2
DPC4 070 12 Electronic display panel T-8 P07 X 2 Fog lamp (left) (if equipped) C-1
B21 DT-T 2 ACC oil pressure switch (F) M-4
DPC6 040 8 Electronic display panel R-7 P07 X 2 Fog lamp (right) (if equipped) A-3
B22 DT-T 2 ACC oil pressure switch (R) M-3
DPC7 X 4 Electronic display panel R-7 P13 YAZAKI 1 Horn valve (left) C-1
B23 DT-T 2 Retarder brake switch (R) J-3
DSL M 1 Door switch (left) (room lamp) G-9 P13 YAZAKI 1 Horn valve (right) A-3
B24 DT-T 3 ACC oil pressure sensor (R) M-5
DSR M 1 Door switch (right) (room lamp) D-7 P20 M 6 Winker tail stop lamp (left) M-8
B25 DT-T 3 ACC oil pressure sensor (F) M-3
DT DT-T 8 Intermediate connector F-1 P21 M 6 Winker tail stop lamp (right) L-9
BLS M 6 Rotary lamp switch (if equipped) P-1
DT1 DT-T 12 Intermediate connector B-5 P22 DT-T 2 Side lamp (right) (if equipped) M-3
BR Terminal 1 Starting switch terminal BR O-6
DT2 DT-T 8 Intermediate connector B-6 PAMB AMP 3 Ambient pressure sensor AL-9
BRC1 DRC 24 Brake controller AA-8
DT4 DT-T 3 Intermediate connector H-2 PCV1 SUMITOMO 2 Supply pump control valve AJ-6
BRC2 DRC 40 Brake controller AA-8
DT5 DT-T 4 Intermediate connector N-3 PCV2 SUMITOMO 2 Supply pump control valve AJ-6
BRC3 DRC 40 Brake controller Z-8
DT6 DT-T 6 Intermediate connector N-4 PFUEL AMP 3 Common rail pressure sensor AM-4
BRC6 X 4 Intermediate connector Y-9
DT7 DT-T 12 Intermediate connector (hoist lever) Z-4 PHO Terminal 1 Heater relay C-7
BT1 — 10 Fuse box AA-4
DT8 DT-T 12 Intermediate connector (front lighting) (left) Z-4 PIM SUMITOMO 3 Boost pressure sensor AN-6
DT8 DT-T 4 Intermediate connector (air suspension seat) B-1 POIL FRAMATOME 3 Engine oil pressure sensor AJ-7
DT9 DT-T 12 Intermediate connector (front lighting) (right) A-2 PWL M 1 Power window motor (left) J-3
E1 Terminal 1 Ground (alternator side) AK-1 PWM M 6 Power mode switch P-3
BZR M 2 Buzzer V-1
E02 DT-T 3 Emergency steering oil pressure switch B-5 PWR Plugconnector 1 Power window motor (right) (if equipped) F-8
C Terminal 1 Starting switch O-7
E3 Terminal 1 Ground (Engine side) AJ-1 R01 SHINAGAWA 5 Engine start relay Z-2
C Terminal 1 Starting motor terminal C AJ-2
E11 Terminal 1 Air heater relay (+) terminal C-8 R02 SHINAGAWA 5 Parking brake relay Z-2
CAB1 SWP 12 Cab wiring harness C-6, T-8
E12 Terminal 1 Air heater relay (-) terminal C-8 R03 SHINAGAWA 5 Dust indicator Z-2
CAB2 SWP 8 Cab wiring harness C-6, U-8
EM KES1 6 Emergency steering timer Z-8 R04 SHINAGAWA 6 Brake lamp relay Z-1
CAN1 DT-T 3 Terminal resistor (120z) AM-5
ENG DRC 60 Engine controller AK-6 R05 SHINAGAWA 6 Backup lamp/buzzer relay Z-1
CAN2 DT-T 3 Resistor S-1
EP DT 2 Electric air bleeding pump AK-6 R06 SHINAGAWA 6 Fog lamp relay (if equipped) Z-2
CG — 2 Cigarette lighter P-3
EPF KES1 2 Fuse A-7 R07 SHINAGAWA 5 Auto preheater relay Z-2
CH1 S 8 Electronic panel display selector switch 1 O-2
EPTS DT 6 Electric air bleeding pump switch A-4 R08 SHINAGAWA 5 Rotary lamp relay (if equipped) Z-2
CH2 S 8 Electronic panel display selector switch 2 O-2
ER Terminal 1 Ground A-9 R09 SHINAGAWA 6 Working lamp (front) relay Z-1
CHK1 X 1 Setting connector (male connector) R-7
ER Terminal 1 Ground B-2 R10 SHINAGAWA 5 Horn relay Z-1
CHK2 X 1 Setting connector (female connector) Q-7
ER Terminal 1 Ground E-7 R11 SHINAGAWA 6 Side lamp relay Z-2
CJA DT-T 6 Joint connector L-4
ER Terminal 1 Ground H-2 R12 SHINAGAWA 6 Hazard relay 1 Z-2
CJB DT-T 8 Joint connector G-1
ER Terminal 1 Ground I-2 R13 SHINAGAWA 5 Hazard relay 2 Z-1
CJE DT-T 8 Join connector D-7
ER Terminal 1 Ground L-4 R14 SHINAGAWA 5 Headlamp relay Z-1
CJE 4 DT-T 8 Joint connector AL-5
ER1 Terminal 1 Ground C-1 R15 SHINAGAWA 5 Headlamp selector relay Z-1
CJF DT-T 8 Joint connector G-1
ER2 Terminal 1 Ground Z-7 R16 SHINAGAWA 6 Headlamp high relay AA-2
CJG DT-T 8 Joint connector G-1
ER3 Terminal 1 Ground Q-2 R17 SHINAGAWA 5 Parking brake safety relay AA-2
CJK DT-T 6 Joint connector M-7
ER4 Terminal 1 Ground Z-7 R21 SHINAGAWA 5 Rear heater relay (if equipped) Z-1
CJL DT-T 6 Joint connector C-8
FLS KES1 4 Flasher V-1 R25 YAZAKI 11 Power window relay Z-8
CJP DT-T 6 Joint connector B-2
FOG M 6 Fog lamp switch (if equipped) P-1 R33 M 6 Parking brake manual switch W-1
CJR DT-T 8 Joint connector B-6
FS2 X 4 Intermediate connector X-9 R34 M 7 Power window switch (right) (if equipped) V-9
CJS DT-T 8 Joint connector C-6
FWL Plugconnector 1 Working lamp (left front) F-8 R35 M 7 Power window switch (left) V-9
CJT DT-T 8 Joint connector C-6
FWL2 Plugconnector 1 Working lamp (left front) F-8 R38 SHINAGAWA 5 Engine cut relay Z-1
CJU DT-T 6 Joint connector G-1
FWM KES1 2 Washer motor (front) A-4 RAD YAZAKI 9 Cassette stereo AM/FM radio Q-3
CJY DT-T 8 Joint connector B-2
FWR Plugconnector 1 Working lamp (right front) D-6 RE1 KES1 2 Resistor S-1
CM DT-T 8 Lighting switch, passing switch, turn switch S-1
FWR2 Plugconnector 1 Working lamp (right front) C-6 RES DT 2 Resistor AM-9
CM DT-T 2 Intermediate connector (air conditioner pressure switch) D-1
G SUMITOMO 3 G sensor AJ-6 RL KES1 2 Room lamp E-7
CN1 DT 2 Injector #1 AJ-8
G1 Terminal 1 Ground A-2 RL2 KES1 4 Room lamp 2 G-9
CN2 DT 2 Injector #2 AL-9
GS Terminal 1 Engine ground AK-5 RTL DT-T 6 Retarder lever potentiometer S-2
SEN02282-03
HM300-2R 19
HM300-2R 21
3

© 2010 KOMATSU
All Rights Reserved
22
4 HM300-2R

HM300-2 Shop Manual

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SEN02269-04

ARTICULATED HM300 -2R

ARTICULATED DUMP TRUCK 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN02269-04

00 Index and foreword SEN02270-04

10 Structure, function and maintenance standard SEN02275-01

20 Standard value table SEN02276-01

30 Testing and adjusting SEN02277-01

Troubleshooting by failure code (Display of code), Part 3 SEN03426-00

50 Disassembly and assembly SEN02279-01

90 Diagrams and drawings SEN02280-03

Foreword and general information SEN02272-02

10 Structure, function and maintenance standard

Proportional reducing valve......................................................................................................... 19

20 Standard value table

30 Testing and adjusting

Handling of fuel system devices.................................................................................................. 20

Failure code [15H0MW] (Hi clutch: Slipping) .............................................................................. 11

Failure code [CA263] (Fuel temperature sensor too high) .......................................................... 48

Troubleshooting by failure code (Display of code), Part 5 SEN03428-01

H-1 Machine does not start ......................................................................................................... 4

50 Disassembly and assembly

90 Diagrams and drawings

Electrical circuit diagram for outside cab (2/3) ............................................................................ 13

HM300-2R Articulated dump truck

ARTICULATED DUMP TRUCK 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

1. General precautions 7) If welding repairs are needed, always

2. Preparations for work 6) When removing a cover which is under

4. Precautions for sling work and making

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value or allow-

Handling of electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector