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KOMATSU HM300-2R ARTICULATED DUMP TRUCK SHOP MANUAL SEN02269-08 – PDF DOWNLOAD
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KOMATSU HM300-2R ARTICULATED DUMP TRUCK SHOP MANUAL SEN02269-08 – PDF DOWNLOAD
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KOMATSU HM300-2R ARTICULATED DUMP TRUCK SHOP MANUAL SEN02269-08 – PDF DOWNLOAD
Language : English
Pages : 1376
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU HM300-2R ARTICULATED DUMP TRUCK SHOP MANUAL SEN02269-08 – PDF DOWNLOAD
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 shims in 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................................................................................................ 422 Releasing remaining pressure in brake circuit............................................................................ 423 Bleeding air from brake circuit.......................................................................................... 424 Measuring wear of wheel brake disc....................................................................................... 425 Measuring wear of parking brake pad...................................................................................... 426 Method for emergency release of parking brake............................................................................ 428 Testing and adjusting steering circuit oil pressure...................................................................... 429 Testing and adjusting suspension cylinder................................................................................ 431 Method of tilting cab up................................................................................................. 435 Testing and adjusting dump circuit oil pressure.......................................................................... 437 Adjusting body positioner sensor......................................................................................... 440 Procedure for adjusting length of spring in body heating spherical joint................................................. 441 Adjustment of tilt lock lever of steering wheel.......................................................................... 442 Handling engine controller high voltage circuit.......................................................................... 443 Adjusting transmission controller........................................................................................ 443 Method for emergency escape at electrical system failure................................................................. 444 Testing and adjusting, Part 3................................................................................................ 449 Setting and adjusting various equipments................................................................................. 450 Special function of machine monitor (EMMS)............................................................................... 461 How to start operation of KOMTRAX terminal............................................................................... 495 Lamp display of KOMTRAX terminal......................................................................................... 499 Pm Clinic check sheet.................................................................................................... 502 40 Troubleshooting............................................................................................................... 0 Failure code table and fuse locations........................................................................................ 507 Failure code table....................................................................................................... 508 Before troubleshooting by failure codes.................................................................................. 515 General information on troubleshooting....................................................................................... 519 Points to remember when performing troubleshooting....................................................................... 520 How to proceed in troubleshooting........................................................................................ 522 Checks before troubleshooting............................................................................................ 524 Classification and procedures of troubleshooting......................................................................... 525 Information in troubleshooting table..................................................................................... 529 Troubleshooting method for disconnecting wiring harness of pressure sensor system........................................ 531 Connection table for connector pin numbers............................................................................... 534 T-branch box and T- branch adapter table................................................................................. 570 Troubleshooting by failure code (Display of code), Part 1.................................................................... 575 Failure code [1500L0] (Dual engagement).................................................................................. 577 Failure code [15B0NX] (Transmission oil filter: Clogged)................................................................. 578 Failure code [15F0KM] (R → F shifting abuse 1: Operational error or incorrect setting)................................... 580 Failure code [15F0MB] (R → F shifting abuse 2: Functional deterioration)................................................. 580 Failure code [15F7KM] (forward clutch disc abuse)........................................................................ 581 Failure code [15G0MW] (R clutch: Slipping)............................................................................... 582 Failure code [15G7KM] (reverse clutch disc abuse)........................................................................ 584 Failure code [15H0MW] (Hi clutch: Slipping).............................................................................. 585 Failure code [15J0MW] (Lo clutch: Slipping).............................................................................. 588 Failure code [15K0MW] (1st clutch: Slipping)............................................................................. 590 Failure code [15L0MW] (2nd clutch: Slipping)............................................................................. 592 Failure code [15M0MW] (3rd clutch: Slipping)............................................................................. 594 Failure code [15SBL1] (R clutch solenoid: Fill signal is ON when command current is OFF.)................................ 596 Failure code [15SBMA] (R clutch solenoid: Malfunction)................................................................... 600 Failure code [15SCL1] (Hi clutch solenoid: Fill signal is ON when command current is OFF.)............................... 602 Failure code [15SCMA] (Hi clutch solenoid: Malfunction).................................................................. 606 Failure code [15SDL1] (Lo clutch solenoid: Fill signal is ON when command current is OFF.)............................... 608 Failure code [15SDMA] (Lo clutch solenoid: Malfunction).................................................................. 610 Failure code [15SEL1] (1st clutch solenoid: Fill signal is ON when command current is OFF)............................... 614 Failure code [15SEMA] (1st clutch solenoid: Malfunction)................................................................. 618 Failure code [15SFL1] (2nd clutch solenoid: Fill signal is ON when command current is OFF.).............................. 620 Failure code [15SFMA] (2nd clutch solenoid: Malfunction)................................................................. 624 Failure code [15SGL1] (3rd clutch solenoid: Fill signal is ON when command current is OFF.).............................. 626 Failure code [15SGMA] (3rd clutch solenoid: Malfunction)................................................................. 630 Failure code [15SJMA] (Lockup clutch solenoid: Malfunction).............................................................. 632 Failure code [15SKMA] (Inter-axle differential lockup pressure control valve: Malfunction)............................... 634 Failure code [2F00KM] (Parking brake: Error in operation or setting)..................................................... 636 Failure code [2G42ZG] (Front accumulator: Oil pressure too low).......................................................... 638 Failure code [2G43ZG] (Rear accumulator: Oil pressure too low)........................................................... 638 Troubleshooting by failure code (Display of code), Part 2.................................................................... 641 Failure code [989A00] (Engine over run prevention command signal: Operating)............................................. 643 Failure code [989D00] (Rear section tipping over alarm: Alarm is activated.)............................................. 643 Failure code [AA10NX] (Air cleaner element: Clogged)..................................................................... 644 Failure code [AB00MA] (Alternator: Malfunction).......................................................................... 646 Failure code [B@BAZK] (Engine oil : Level too low)....................................................................... 647 Failure code [B@BCNS] (Eng overheat)..................................................................................... 648 Failure code [B@BCZK] (Radiator coolant: Level too low).................................................................. 649 Failure code [B@BFZK] (Fuel level: Level too low)........................................................................ 650 Failure code [B@C6NS] (Front brake oil: Overheat)........................................................................ 651 Failure code [B@C8NS] (Center brake oil: Overheat)....................................................................... 651 Failure code [B@CENS] (Torque converter: Overheat)....................................................................... 652 Failure code [B@HAZK] (Hydraulic tank oil: Level too low)................................................................ 653 Failure code [B@JANS] (Steering oil: Overheat)........................................................................... 654 Failure code [CA111] Abnormality in engine controller.................................................................... 656 Failure code [CA115] Engine Ne or Bkup speed sensor error................................................................ 658 Failure code [CA122] Charge (boost) pressure sensor high error........................................................... 660 Failure code [CA123] Charge (boost) pressure sensor low error............................................................ 662 Failure code [CA131] Throttle sensor high error.......................................................................... 664 Failure code [CA132] Throttle sensor low error........................................................................... 666 Failure code [CA135] Engine oil pressure sensor high error............................................................... 668 Failure code [CA141] Engine oil pressure sensor low error................................................................ 670 Failure code [CA144] Coolant temperature sensor high error............................................................... 672 Failure code [CA145] Coolant temperature sensor low error................................................................ 674 Failure code [CA153] Charge (boost) temperature sensor high error........................................................ 676 Failure code [CA154] Charge (boost) temperature sensor low error......................................................... 678 Failure code [CA187] Sensor power supply 2 low error..................................................................... 680 Failure code [CA221] Atmospheric pressure sensor high error.............................................................. 682 Failure code [CA222] Atmospheric pressure sensor low error............................................................... 684 Failure code [CA227] Sensor power supply 2 high error.................................................................... 686 Failure code [CA234] Engine overspeed.................................................................................... 687 Failure code [CA238] Ne speed sensor power supply error.................................................................. 688 Failure code [CA263] Fuel Temperature Sensor High Error.................................................................. 690 Failure code [CA265] Fuel Temperature Sensor Low Error................................................................... 692 Failure code [CA271] PCV1 Short circuit.................................................................................. 694 Failure code [CA272] PCV1 Disconnection.................................................................................. 695 Failure code [CA273] PCV2 Short circuit.................................................................................. 696 Failure code [CA274] PCV2 Disconnection.................................................................................. 697 Failure code [CA322] Injector #1 open/short error........................................................................ 698 Failure code [CA323] Injector #5 open/short error........................................................................ 700 Failure code [CA324] Injector #3 open/short error........................................................................ 702 Failure code [CA325] Injector #6 open/short error........................................................................ 704 Failure code [CA331] Injector #2 open/short error........................................................................ 706 Failure code [CA332] Injector #4 open/short error........................................................................ 708 Troubleshooting by failure code (Display of code), Part 3.................................................................... 711 Failure code [CA342] Calibration code inconsistency...................................................................... 714 Failure code [CA351] Injectors drive circuit error....................................................................... 715 Failure code [CA352] Sensor power supply 1 low error..................................................................... 716 Failure code [CA386] Sensor power supply 1 high error.................................................................... 718 Failure code [CA431] Idle validation switch error........................................................................ 719 Failure code [CA432] Idle validation action error........................................................................ 722 Failure code [CA441] Battery voltage low error........................................................................... 725 Failure code [CA442] Battery voltage high error.......................................................................... 726 Failure code [CA449] Common rail pressure high error 2................................................................... 727 Failure code [CA451] Common rail pressure sensor high error.............................................................. 728 Failure code [CA452] Common rail pressure sensor low error............................................................... 730 Failure code [CA553] Common rail pressure high error 1................................................................... 732 Failure code [CA554] Common rail pressure sensor in range error.......................................................... 733 Failure code [CA559] Supply pump pressure very low error 1............................................................... 734 Failure code [CA689] Engine Ne speed sensor error........................................................................ 738 Failure code [CA731] Engine Bkup speed sensor phase error................................................................ 740 Failure code [CA757] All continuous data lost error...................................................................... 741 Failure code [CA778] Engine Bkup speed sensor error...................................................................... 742 Failure code [CA1633] KOMNET datalink timeout error...................................................................... 744 Failure code [CA2185] Throttle sensor power supply voltage high error.................................................... 746 Failure code [CA2186] Throttle sensor power supply voltage low error..................................................... 748 Failure code [CA2249] Supply pump pressure very low error 2.............................................................. 750 Failure code [CA2555] Intake air heater relay open circuit error......................................................... 752 Failure code [CA2556] Intake air heater relay short circuit error........................................................ 754 Failure code [DAF9KM] (Machine monitor connector: Error in operation or setting)......................................... 756 Failure code [DAFRKR] Abnormal CAN communication (machine monitor): Abnormal communication............................... 757 Failure code [DAQ0KK] (Transmission controller: Power source voltage too low)............................................ 758 Failure code [DAQ0KT] (Transmission nonvolatile memory: Abnormality in controller)....................................... 760 Failure code [DAQ2KK] (Transmission controller solenoid power source: Voltage too low)................................... 761 Failure code [DAQRKR] Abnormal CAN communication (Transmission): Abnormal communication.................................. 762 Failure code [DAQRMA] (Transmission controller option setting: Malfunction).............................................. 767 Failure code [DB10KT] (Retarder controller nonvolatile memory: Abnormality in controller)................................ 767 Failure code [DB12KK] (Retarder controller solenoid power source: Power source voltage too low).......................... 768 Failure code [DB13KK] (Retarder controller battery direct power source: Power source voltage too low).................... 769 Failure code [DB19KQ] (Retarder controller model select signal: Inconsistent model selection signal)..................... 770 Failure code [DB1QMA] (Retarder controller option setting: Malfunction).................................................. 770 Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled.................................... 772 Failure code [DB2RKR] CAN communication (engine controller): Communication disabled...................................... 776 Failure code [DDTHKA] (Fill switch for Hi clutch: Disconnection)......................................................... 782 Failure code [DDTJKA] (Fill switch for Lo clutch: Disconnection)......................................................... 784 Failure code [DDTKKA] (Fill switch for 1st clutch: Disconnection)........................................................ 786 Failure code [DDTLKA] (Fill switch for 2nd clutch: Disconnection)........................................................ 787 Failure code [DDTMKA] (Fill switch for 3rd clutch: Disconnection)........................................................ 788 Failure code [DDTNKA] (Fill switch for R clutch: Disconnection).......................................................... 789 Failure code [DF10KA] (Gear shift lever: Disconnection).................................................................. 790 Failure code [DF10KB] (Gear shift lever: Short circuit).................................................................. 793 Troubleshooting by failure code (Display of code), Part 4.................................................................... 797 Failure code [DGF1KX] (Transmission oil temperature sensor: Input signal out of range)................................... 800 Failure code [DGR3KZ] (Center brake oil temperature sensor: Disconnection or short circuit).............................. 802 Failure code [DGR3L8] (Center brake oil temperature sensor: Inconsistent analog signals)................................. 804 Failure code [DGR4KZ] (Front brake oil temperature sensor: Disconnection or short circuit)............................... 806 Failure code [DGR4L8] (Front brake oil temperature sensor: Inconsistent analog signals).................................. 808 Failure code [DGR6KX] (Steering oil temperature sensor: Input signal out of range)....................................... 810 Failure code [DGT1KX] (Torque converter oil temperature sensor: Input signal out of range)............................... 812 Failure code [DHT5KX] (Torque converter oil pressure sensor: Input signal out of range).................................. 814 Failure code [DHT5L6] (Torque converter oil pressure sensor: Inconsistent signals during a travel and stop).............. 816 Failure code [DHU2KX] (Front accumulator oil pressure sensor: Input signal out of range)................................. 818 Failure code [DHU3KX] (Rear accumulator oil pressure sensor: Input signal out of range).................................. 820 Failure code [DJF1KA] (Fuel level sensor: Disconnection)................................................................. 822 Failure code [DK51L5] (Retarder lever potentiometer: Potentiometer signal is inconsistent with switch signal)............ 824 Failure code [DK52KX] (Dump lever potentiometer failure 1: Input signal out of range).................................... 826 Failure code [DK53L8] (Dump lever potentiometer failure 2: Inconsistent analog signal)................................... 828 Failure code [DK54KX] (Body positioner sensor: Input signal out of range)................................................ 830 Failure code [DKH0KX] (Inclination sensor: Inclination out of range)..................................................... 832 Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection)............................................. 834 Failure code [DLF1LC] (Transmission input shaft speed sensor: Inconsistent rotation speed signal)........................ 835 Failure code [DLF2KA] (Transmission intermediate shaft speed sensor: Disconnection)...................................... 836 Failure code [DLF2LC] (Transmission intermediate shaft speed sensor: Inconsistent speed signal).......................... 837 Failure code [DLF4KA] (Differential speed sensor: Disconnection)......................................................... 838 Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)............................................ 839 Failure code [DV00KB] (Alarm buzzer output: Short circuit)............................................................... 840 Failure code [DW72KZ] (Kick-out solenoid output system: Disconnection or short circuit).................................. 842 Failure code [DW73KZ] (Hoist selector valve output system: Disconnection or short circuit)............................... 844 Failure code [DW78KZ] (Rear brake BCV command output system: Disconnection or short circuit)............................. 846 Failure code [DW79KZ] (Front brake BCV command output system: Disconnection or short circuit)............................ 848 Failure code [DX11K4] Trouble in rear wheel proportional solenoid pressure reducing valve 1.............................. 850 Failure code [DX11KA] (Rear brake proportional pressure reducing solenoid valve output circuit: Disconnection)........... 852 Failure code [DX11KB] (Rear brake proportional pressure reducing solenoid valve: Short circuit).......................... 853 Failure code [DX11KY] (Rear brake proportional pressure reducing solenoid valve: Short circuit to power source line)..... 854 Failure code [DX11MA] (Rear brake proportional pressure reducing solenoid valve: Malfunction)............................ 856 Failure code [DX12K4] (Front brake proportional pressure reducing solenoid valve: Out of control)........................ 858 Failure code [DX12KA] (Front brake proportional pressure reducing solenoid valve output circuit: Disconnection).......... 860 Failure code [DX12KB] (Front brake proportional pressure reducing solenoid valve: Short circuit)......................... 861 Troubleshooting by failure code (Display of code), Part 5.................................................................... 863 Failure code [DX12KY] (Front brake proportional pressure reducing solenoid valve: Short circuit to power source line).... 865 Failure code [DX12MA] (Front brake proportional pressure reducing solenoid valve: Malfunction)........................... 866 Failure code [DX13KA] (Hoist EPC valve output circuit: Disconnection).................................................... 868 Failure code [DX13KB] (Hoist EPC valve output circuit: Short circuit).................................................... 869 Failure code [DX13KY] (Hoist EPC valve output circuit: Short circuit in power source line)............................... 870 Failure code [DXH0KA] (Inter-axle differential lock pressure control valve: Disconnection)............................... 871 Failure code [DXH0KB] (Inter-axle differential lock pressure control valve: Short circuit)............................... 872 Failure code [DXH0KY] (Inter-axle differential lockup pressure control valve: Short circuit to power source line)........ 873 Failure code [DXH1KA] (Lockup clutch solenoid output circuit: Disconnection)............................................. 874 Failure code [DXH1KB] (Lockup clutch solenoid output circuit: Short circuit)............................................. 875 Failure code [DXH1KY] (Lockup clutch solenoid output circuit: Short circuit to power source line)........................ 876 Failure code [DXH2KA] (Hi clutch solenoid output circuit: Disconnection)................................................. 878 Failure code [DXH2KB] (Hi clutch solenoid output circuit: Short circuit)................................................. 880 Failure code [DXH2KY] (Hi clutch solenoid output circuit: Short circuit to power source line)............................ 882 Failure code [DXH3KA] (Lo clutch solenoid output circuit: Disconnection)................................................. 886 Failure code [DXH3KB] (Lo clutch solenoid output circuit: Short circuit)................................................. 888 Failure code [DXH3KY] (Lo clutch solenoid output circuit: Short circuit in power source line)............................ 890 Failure code [DXH4KA] (1st clutch solenoid output circuit: Disconnection)................................................ 894 Failure code [DXH4KB] (1st clutch solenoid output circuit: Short circuit)................................................ 896 Failure code [DXH4KY] (1st clutch solenoid output circuit: Short circuit to power source line)........................... 898 Failure code [DXH5KA] (2nd clutch solenoid output circuit: Disconnection)................................................ 902 Failure code [DXH5KB] (2nd clutch solenoid output circuit: Short circuit)................................................ 904 Failure code [DXH5KY] (2nd clutch solenoid output circuit: Short circuit in power source line)........................... 906 Failure code [DXH6KA] (3rd clutch solenoid output circuit: Disconnection)................................................ 910 Failure code [DXH6KB] (3rd clutch solenoid output circuit: Short circuit)................................................ 912 Failure code [DXH6KY] (3rd clutch solenoid output circuit: Short circuit to power source line)........................... 914 Failure code [DXH7KA] (R clutch solenoid output circuit: Disconnection).................................................. 918 Failure code [DXH7KB] (R clutch solenoid output circuit: Short circuit).................................................. 920 Failure code [DXH7KY] (R clutch solenoid output circuit: Short circuit to power source line)............................. 922 Troubleshooting of electrical system (E-mode)................................................................................ 927 Before troubleshooting of electrical system.............................................................................. 929 Contents of troubleshooting table........................................................................................ 932 E-1 Engine does not start................................................................................................ 933 E-2 Automatic preheating does not operate................................................................................ 936 E-3 Machine monitor does not display all, when starting switch is turned ON.............................................. 940 E-4 Machine monitor does not operate when starting switch is OFF......................................................... 942 E-5 Alarm buzzer does not sound.......................................................................................... 944 E-6 Gauges of machine monitor, caution lamps or character display section do not display properly........................ 945 E-7 Selection of display in character display section cannot be changed.................................................. 946 E-8 Power mode selecting function does not operate properly.............................................................. 950 E-9 AISS function does not operate properly.............................................................................. 951 E-10 Seat belt caution lamp does not display properly.................................................................... 952 E-11 Turn signal lamp or turning lamp (hazard lamp) does not work properly............................................... 953 E-12 Night illumination (lighting) does not work properly................................................................ 956 E-13 Emergency steering does not operate................................................................................. 963 E-14 Dump lever does not operate normally................................................................................ 968 E-15 KOMTRAX system does not operate normally............................................................................ 970 E-16 Electric priming pump does not operate or does not stop automatically............................................... 974 E-17 Air conditioner does not operate normally........................................................................... 976 Troubleshooting of hydraulic and mechanical system (H-mode).................................................................. 983 Contents of troubleshooting table........................................................................................ 985 H-1 Machine does not start............................................................................................... 986 H-2 Machine does not travel smoothly (machine jerks)..................................................................... 988 H-3 Lockup cannot be cancelled........................................................................................... 988 H-4 Excessive shock when starting or shifting............................................................................ 989 H-5 Transmission does not shift up....................................................................................... 990 H-6 Machine lacks power or speed when traveling.......................................................................... 991 H-7 Time lag is excessive when starting or shifting gear................................................................. 993 H-8 Torque converter oil temperature is high............................................................................. 994 H-9 Torque converter oil pressure is low................................................................................. 995 H-10 Front brake is ineffective.......................................................................................... 996 H-11 Center brake is ineffective......................................................................................... 997 H-12 Steering wheel is heavy............................................................................................. 998 H-13 Steering wheel does not work........................................................................................ 999 H-14 Steering wheel vibrates.............................................................................................1000 H-15 Dump body lifting speed is slow.....................................................................................1001 H-16 Dump body does not work.............................................................................................1002 H-17 Excessive hydraulic drift of dump body..............................................................................1003 Troubleshooting of engine (S-mode)...........................................................................................1005 How to use a troubleshooting chart.......................................................................................1007 S-1 Engine is hard to start..............................................................................................1010 S-2 Engine does not start................................................................................................1011 S-3 Engine does not pick up smoothly.....................................................................................1014 S-4 Engine stops during operations.......................................................................................1015 S-5 Engine does not rotate smoothly......................................................................................1016 S-6 Engine lacks output (or lacks power).................................................................................1017 S-7 Exhaust gas color is black (incomplete combustion)...................................................................1018 S-8 Oil consumption is excessive (or exhaust gas color is blue)..........................................................1019 S-9 Oil gets contaminated prematurely....................................................................................1020 S-10 Fuel consumption is excessive.......................................................................................1021 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)...............................................1022 S-12 Oil pressure drops..................................................................................................1023 S-13 Oil level rises (coolant or fuel mixes).............................................................................1024 S-14 Coolant temperature rises too high (overheat).......................................................................1025 S-15 Abnormal noise comes out............................................................................................1026 S-16 Vibration is excessive..............................................................................................1027 S-17 Air cannot be bled from fuel circuit...............................................................................1028 50 Disassembly and assembly...................................................................................................... 0 General information on disassembly and assembly..............................................................................1031 How to read this manual..................................................................................................1032 Coating materials list...................................................................................................1034 Special tool list........................................................................................................1037 Sketches of special tools................................................................................................1042 Engine and cooling system (SAA6D125E-5)......................................................................................1057 Removal and installation of fuel supply pump assembly....................................................................1058 Removal and installation of fuel injector assembly.......................................................................1063 Removal and installation of cylinder head assembly.......................................................................1068 Removal and installation of engine front seal............................................................................1080 Removal and installation of engine rear seal.............................................................................1082 Removal and installation of engine assembly..............................................................................1086 Removal and installation of radiator assembly............................................................................1094 Removal and installation of cooling assembly.............................................................................1096 Removal and installation of output shaft assembly........................................................................1099 Disassembly and assembly of output shaft assembly........................................................................1104 Power train, Part 1..........................................................................................................1109 Removal and installation of transmission and front differential assembly.................................................1110 Disconnection and connection of front differential assembly and transmission assembly....................................1116 Disassembly and assembly of front differential assembly..................................................................1118 Disassembly and assembly of torque converter assembly....................................................................1133 Power train, Part 2..........................................................................................................1141 Disassembly and assembly of transmission assembly........................................................................1142 Power train, Part 3..........................................................................................................1185 Removal and installation of center differential assembly.................................................................1186 Disassembly and assembly of center differential assembly.................................................................1190 Removal and installation of rear differential assembly...................................................................1207 Disassembly and assembly of rear differential assembly...................................................................1209 Power train, Part 4..........................................................................................................1225 Removal and installation of front final drive and brake assembly.........................................................1226 Disassembly and assembly of front final drive and brake assembly.........................................................1229 Removal and installation of center final drive and brake assembly........................................................1239 Disassembly and assembly of center final drive and brake assembly........................................................1241 Power train, Part 5..........................................................................................................1251 Disassembly and assembly of rear final drive assembly....................................................................1252 Removal and installation of center axle assembly.........................................................................1259 Removal and installation of rear axle assembly...........................................................................1262 Undercarriage and frame......................................................................................................1265 Removal and installation of front suspension cylinder assembly...........................................................1266 Removal and installation of rear suspension cylinder assembly............................................................1268 Removal and installation of equalizer bar................................................................................1269 Removal and installation of hitch frame assembly.........................................................................1271 Disassembly and assembly of hitch frame assembly.........................................................................1281 Hydraulic system.............................................................................................................1289 Removal and installation of flow amp valve...............................................................................1290 Removal and installation of hoist valve assembly.........................................................................1292 Disassembly and assembly of steering cylinder assembly...................................................................1295 Disassembly and assembly of hoist cylinder assembly......................................................................1299 Body.........................................................................................................................1305 Removal and installation of body assembly................................................................................1306 Cab and its attachments......................................................................................................1309 Removal and installation of operator's cab...............................................................................1310 Removal and installation of operator's cab glass (Stuck glass)...........................................................1315 Disassembly and assembly of operator's seat assembly (If equipped).......................................................1322 Electrical system............................................................................................................1333 Removal and installation of air conditioner unit assembly................................................................1334 Removal and installation of engine controller............................................................................1339 Removal and installation of retarder controller..........................................................................1341 Removal and installation of transmission controller assembly.............................................................1343 90 Diagrams and drawings......................................................................................................... 0 Hydraulic diagrams and drawings..............................................................................................1345 Power train hydraulic circuit diagram....................................................................................1347 Steering and hoist hydraulic circuit diagram.............................................................................1349 Brake hydraulic circuit diagram..........................................................................................1351 Brake cooling hydraulic circuit diagram..................................................................................1353 Electrical diagrams and drawings.............................................................................................1355 Electrical circuit diagram for inside cab (1/4)..........................................................................1357 Electrical circuit diagram for inside cab (2/4)..........................................................................1359 Electrical circuit diagram for inside cab (3/4)..........................................................................1361 Electrical circuit diagram for inside cab (4/4)..........................................................................1363 Electrical circuit diagram for outside cab (1/3).........................................................................1365 Electrical circuit diagram for outside cab (2/3).........................................................................1367 Electrical circuit diagram for outside cab (3/3).........................................................................1369 Electrical circuit diagram for payload meter.............................................................................1371 Connectors table and arrangement drawing ................................................................................1373
DESCRIPTION:
KOMATSU HM300-2R ARTICULATED DUMP TRUCK SHOP MANUAL SEN02269-08 – PDF DOWNLOAD
1. General precautions
1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
A. Always wear safety glasses when hitting parts with a hammer.
B. Always wear safety glasses when grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always 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, forklift, service car, etc.
7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.
8) Before starting work, warm up your body thoroughly to start work under good condition.
9) Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.
S.S 27/12/24
