Complete service repair manual with Electrical Wiring Diagrams for Komatsu Articulated Dump Truck HM300-2R, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Komatsu Articulated Dump Truck HM300-2R workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:
Total Pages: 2,023 pages
File Format: PDF
Language: English

SEN02269-06 - Articulated Dump Truck HM300-2R Shop Manual.pdf
GEN00091-00 - Articulated Dump Truck HM300-2R Field Assembly Instruction.pdf
PEN00193-09 - Articulated Dump Truck HM300-2R Operation & Maintenance Manual.pdf
PEN00470-11 - Articulated Dump Truck HM300-2R Operation & Maintenance Manual.pdf

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

Komatsu Articulated Dump Truck HM300-2R Repair Service Manuals