Komatsu HM300-2R Articulated Dump Truck Workshop Repair Service Manual PDF - MKMTSHM300R.zip
A full service and repair guide, complete with electrical wiring diagrams, for the Komatsu HM300-2R Articulated Dump Truck — containing every technical detail needed to service, troubleshoot, fix, and rebuild the machine the way a professional technician would.
The Komatsu HM300-2R Articulated Dump Truck workshop service and repair manual covers:
* 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 (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEN02269-06 - Articulated Dump Truck HM300-2R Shop Manual.pdf
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PEN00470-11 - Articulated Dump Truck HM300-2R Operation & Maintenance Manual.pdf
MAIN SECTIONS
COVER...1
00 Index and foreword...0
Index...3
Composition of shop manual...4
Table of contents...6
Foreword and general information...17
Safety notice...18
How to read the shop manual...23
Explanation of terms for maintenance standard...25
Handling of electric equipment and hydraulic component...27
Handling of connectors newly used for engines...36
How to read electric wire code...39
Precautions when carrying out operation...42
Method of disassembling and connecting push-pull type coupler...45
Standard tightening torque table...48
Conversion table...52
01 Specification...0
Specification and technical data...59
Specification drawings...60
Specifications...61
Weight table...64
Fuel, coolant and lubricants...65
10 Structure, function and maintenance standard...0
Engine and cooling system...69
Radiator, oil cooler, aftercooler...70
Output shaft...71
Power train, Part 1...75
Power train skeleton...76
Torque converter and transmission hydraulic piping...78
Brake cooling oil control valve (BCV)...80
Power train pump...81
Torque converter...84
Transmission...90
Transmission control valve...118
ECMV...119
Main relief, torque converter relief valve...126
Power train, Part 2...129
Drive shaft...130
Axle...131
Differential...134
Limited slip differential...140
Final drive...144
Steering system...151
Steering column...152
Brake system...155
Brake piping...156
Brake valve...158
Accumulator charge valve...161
Accumulator...165
Slack adjuster...166
Brake...168
Proportional reducing valve...173
Brake system tank...174
Parking brake...176
Parking brake solenoid...180
Undercarriage and frame...183
Suspension...184
Suspension cylinder...190
Oscillation hitch...192
Hydraulic system...197
Steering, hoist oil pressure piping diagram...198
Dump body control...199
Hydraulic tank and filter...200
Flow amp valve...201
Steering valve...204
Steering cylinder...208
Hoist valve...210
EPC valve...216
Hoist cylinder...217
Hydraulic pump...218
Cab and its attachments...221
ROPS cab...222
Cab tilt...223
Air conditioner...224
Rear view monitor...232
Controller related...235
Electrical system, Part 1...237
Machine monitor system...238
Electrical system, Part 2...259
Automatic shift control system...260
Retarder control system...292
Auto emergency steering system...304
Dump control lever...305
Electrical system, Part 3...311
Payload meter (Card type)...312
Electrical system, Part 4...345
Sensors, switches...346
KOMTRAX terminal system (If equipped)...354
20 Standard value table...0
Standard service value table...357
Standard value table for engine...358
Standard value table for chassis...359
30 Testing and adjusting...0
Testing and adjusting, Part 1...367
Tools for testing, adjusting, and troubleshooting...369
Sketches of special tools...374
Measuring engine speed...375
Measuring intake air pressure (boost pressure)...376
Measuring exhaust temperature...377
Measuring exhaust gas color...379
Adjusting valve clearance...380
Measuring compression pressure...382
Measuring blow-by pressure...384
Measuring engine oil pressure...385
Handling of fuel system devices...386
Releasing residual pressure from fuel system...386
Testing fuel pressure...387
Testing fuel return and leak amount...388
Bleeding air from fuel circuit...391
Testing fuel circuit for leakage...393
Testing and adjusting alternator belt tension...394
Testing and adjusting air conditioner compressor belt tension...394
Adjusting the body mount...395
Testing and adjusting, Part 2...397
Measuring torque converter stall speed...399
Measuring power train oil pressure...400
Adjusting transmission speed sensor...408
Testing and adjusting brake oil pressure...410
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas...414
Testing brake performance...417
Bleeding air from brake circuit...418
Measuring wear of wheel brake disc...419
Measuring wear of parking brake pad...420
Method for emergency release of parking brake...422
Testing and adjusting steering circuit oil pressure...423
Testing and adjusting suspension cylinder...425
Method of tilting cab up...429
Testing and adjusting dump circuit oil pressure...431
Adjusting body positioner sensor...434
Procedure for adjusting length of spring in body heating spherical joint...435
Handling engine controller high voltage circuit...435
Adjusting transmission controller...436
Method for emergency escape at electrical system failure...437
Testing and adjusting, Part 3...443
Setting and adjusting various equipments...444
Special function of machine monitor (EMMS)...455
How to start operation of KOMTRAX terminal...489
Lamp display of KOMTRAX terminal...492
Pm Clinic check sheet...495
40 Troubleshooting...0
Failure code table and fuse locations...499
Failure code table...500
Before troubleshooting by failure codes...507
General information on troubleshooting...511
Points to remember when troubleshooting...512
Sequence of events in troubleshooting...513
Checks before troubleshooting...514
Classification and procedures for troubleshooting...515
Information in troubleshooting table...516
Connection table for connector pin numbers...518
T-branch box and T- branch adapter table...554
Troubleshooting by failure code (Display of code), Part 1...559
Failure code [1500L0] (Dual engagement)...561
Failure code [15B0NX] (Transmission oil filter: Clogged)...562
Failure code [15F0KM] (R ? F shifting abuse 1: Operational error or incorrect setting)...564
Failure code [15F0MB] (R ? F shifting abuse 2: Functional deterioration)...564
Failure code [15F7KM] (forward clutch disc abuse)...565
Failure code [15G0MW] (R clutch: Slipping)...566
Failure code [15G7KM] (reverse clutch disc abuse)...568
Failure code [15H0MW] (Hi clutch: Slipping)...569
Failure code [15J0MW] (Lo clutch: Slipping)...572
Failure code [15K0MW] (1st clutch: Slipping)...574
Failure code [15L0MW] (2nd clutch: Slipping)...576
Failure code [15M0MW] (3rd clutch: Slipping)...578
Failure code [15SBL1] (R clutch solenoid: Fill signal is ON when command current is OFF.)...580
Failure code [15SBMA] (R clutch solenoid: Malfunction)...584
Failure code [15SCL1] (Hi clutch solenoid: Fill signal is ON when command current is OFF.)...586
Failure code [15SCMA] (Hi clutch solenoid: Malfunction)...590
Failure code [15SDL1] (Lo clutch solenoid: Fill signal is ON when command current is OFF.)...592
Failure code [15SDMA] (Lo clutch solenoid: Malfunction)...594
Failure code [15SEL1] (1st clutch solenoid: Fill signal is ON when command current is OFF)...598
Failure code [15SEMA] (1st clutch solenoid: Malfunction)...602
Failure code [15SFL1] (2nd clutch solenoid: Fill signal is ON when command current is OFF.)...604
Failure code [15SFMA] (2nd clutch solenoid: Malfunction)...608
Failure code [15SGL1] (3rd clutch solenoid: Fill signal is ON when command current is OFF.)...610
Failure code [15SGMA] (3rd clutch solenoid: Malfunction)...614
Failure code [15SJMA] (Lockup clutch solenoid: Malfunction)...616
Failure code [15SKMA] (Inter-axle differential lockup pressure control valve: Malfunction)...618
Failure code [2F00KM] (Parking brake: Error in operation or setting)...620
Failure code [2G42ZG] (Front accumulator: Oil pressure too low)...622
Failure code [2G43ZG] (Rear accumulator: Oil pressure too low)...622
Troubleshooting by failure code (Display of code), Part 2...625
Failure code [989A00] (Engine over run prevention command signal: Operating)...627
Failure code [989D00] (Rear section tipping over alarm: Alarm is activated.)...627
Failure code [AA10NX] (Air cleaner element: Clogged)...628
Failure code [AB00MA] (Alternator: Malfunction)...630
Failure code [B@BAZK] (Engine oil : Level too low)...631
Failure code [B@BCNS] (Eng overheat)...632
Failure code [B@BCZK] (Radiator coolant: Level too low)...633
Failure code [B@BFZK] (Fuel level: Level too low)...634
Failure code [B@C6NS] (Front brake oil: Overheat)...635
Failure code [B@C8NS] (Center brake oil: Overheat)...635
Failure code [B@CENS] (Torque converter: Overheat)...636
Failure code [B@HAZK] (Hydraulic tank oil: Level too low)...637
Failure code [B@JANS] (Steering oil: Overheat)...638
Failure code [CA111] (Abnormality in engine controller)...639
Failure code [CA115] (Abnormal engine Ne and Bkup sensors)...640
Failure code [CA122] (Charge pressure sensor too high)...642
Failure code [CA123] (Charge pressure sensor too low)...644
Failure code [CA131] (Throttle sensor tool high)...646
Failure code [CA132] (Throttle sensor tool low)...648
Failure code [CA135] (Oil pressure sensor too high)...650
Failure code [CA141] (Oil pressure sensor too low)...652
Failure code [CA144] (Coolant temperature sensor too high)...654
Failure code [CA145] (Coolant temperature sensor too low)...656
Failure code [CA153] (Charge temperature sensor too high)...658
Failure code [CA154] (Charge temperature sensor too low)...660
Failure code [CA187] (Sensor power source 2 too low)...660
Failure code [CA221] (Atmospheric sensor too high)...662
Failure code [CA222] (Atmospheric sensor too low)...664
Failure code [CA227] (Sensor power source 2 too high)...666
Failure code [CA234] (Engine over speed)...668
Failure code [CA238] (Abnormal power source for Ne speed sensor)...670
Failure code [CA263] (Fuel temperature sensor too high)...672
Failure code [CA265] (Fuel temperature sensor too low)...674
Failure code [CA271] (PCV1 short circuit)...675
Failure code [CA272] (PCV1 disconnection)...676
Failure code [CA273] (PCV2 short circuit)...677
Failure code [CA274] (PCV2 disconnection)...678
Failure code [CA322] (Injector No. 1 system disconnection or short circuit)...680
Failure code [CA323] (Injector No. 5 system disconnection or short circuit)...682
Failure code [CA324] (Injector No. 3 system disconnection or short circuit)...684
Failure code [CA325] (Injector No. 6 system disconnection or short circuit)...686
Failure code [CA331] (Injector No. 2 system disconnection or short circuit)...688
Failure code [CA332] (Injector No. 4 system disconnection or short circuit)...690
Troubleshooting by failure code (Display of code), Part 3...693
Failure code [CA342] (Abnormal engine controller data consistency)...695
Failure code [CA351] (Abnormal injector drive circuit)...696
Failure code [CA352] (Sensor power source 1 too low)...697
Failure code [CA386] (Sensor power source 1 too high)...698
Failure code [CA431] Idle validation switch error...700
Failure code [CA432] (Abnormal process with idle validation switch)...704
Failure code [CA441] (Power source voltage too low)...705
Failure code [CA442] (Power source voltage too high)...705
Failure code [CA449] (Common rail pressure too high 2)...706
Failure code [CA451] (Common rail pressure sensor too high)...708
Failure code [CA452] (Common rail pressure sensor too low)...710
Failure code [CA553] (Common rail pressure too high 1)...710
Failure code [CA554] (In-range error of common rail pressure sensor)...711
Failure code [CA559] (Loss of pressure feed from supply pump 1)...712
Failure code [CA689] (Abnormal engine Ne speed sensor)...716
Failure code [CA731] (Abnormal engine Bkup speed sensor phase)...718
Failure code [CA757] (Loss of all engine controller data)...718
Failure code [CA778] (Abnormal engine Bkup speed sensor)...720
Failure code [CA1633] (Abnormal KOMNET)...722
Failure code [CA2185] (Throttle sensor power source too high)...724
Failure code [CA2186] (Throttle sensor power source too low)...726
Failure code [CA2249] (Loss of pressure feed from supply pump 2)...726
Failure code [CA2555] (Disconnection in intake air heater relay)...727
Failure code [CA2556] (Intake air heater relay short circuit)...728
Failure code [DAF9KM] (Machine monitor connector: Error in operation or setting)...730
Failure code [DAFRKR] (Abnormal CAN communication (machine monitor): Abnormal communication)...732
Failure code [DAQ0KK] (Transmission controller: Power source voltage too low)...734
Failure code [DAQ0KT] (Transmission nonvolatile memory: Abnormality in controller)...736
Failure code [DAQ2KK] (Transmission controller solenoid power source: Voltage too low)...737
Failure code [DAQRKR] (COMMUNICATION LOST: Defective communication)...738
Failure code [DAQRMA] (Transmission controller option setting: Malfunction)...740
Failure code [DB10KT] (Retarder controller nonvolatile memory: Abnormality in controller)...740
Failure code [DB12KK] (Retarder controller solenoid power source: Power source voltage too low)...741
Failure code [DB13KK] (Retarder controller battery direct power source: Power source voltage too low)...742
Failure code [DB19KQ] (Retarder controller model select signal: Inconsistent model selection signal)...743
Failure code [DB1QMA] (Retarder controller option setting: Malfunction)...743
Failure code [DB1RKR] (CAN communication (retarder controller): Communication disabled)...744
Failure code [DB2RKR] (CAN communication (engine controller): Communication disabled)...746
Failure code [DDTHKA] (Fill switch for Hi clutch: Disconnection)...748
Failure code [DDTJKA] (Fill switch for Lo clutch: Disconnection)...750
Failure code [DDTKKA] (Fill switch for 1st clutch: Disconnection)...752
Failure code [DDTLKA] (Fill switch for 2nd clutch: Disconnection)...753
Failure code [DDTMKA] (Fill switch for 3rd clutch: Disconnection)...754
Failure code [DDTNKA] (Fill switch for R clutch: Disconnection)...755
Failure code [DF10KA] (Gear shift lever: Disconnection)...756
Failure code [DF10KB] (Gear shift lever: Short circuit)...759
Troubleshooting by failure code (Display of code), Part 4...763
Failure code [DGF1KX] (Transmission oil temperature sensor: Input signal out of range)...766
Failure code [DGR3KZ] (Center brake oil temperature sensor: Disconnection or short circuit)...768
Failure code [DGR3L8] (Center brake oil temperature sensor: Inconsistent analog signals)...770
Failure code [DGR4KZ] (Front brake oil temperature sensor: Disconnection or short circuit)...772
Failure code [DGR4L8] (Front brake oil temperature sensor: Inconsistent analog signals)...774
Failure code [DGR6KX] (Steering oil temperature sensor: Input signal out of range)...776
Failure code [DGT1KX] (Torque converter oil temperature sensor: Input signal out of range)...778
Failure code [DHT5KX] (Torque converter oil pressure sensor: Input signal out of range)...780