Komatsu HM300-2 Articulated Dump Truck Shop Manual SEN00237-16 PDF

Description

Komatsu HM300-2 Articulated Dump Truck Shop Manual SEN00237-16  – PDF DOWNLOAD

FILE DETAILS:

Komatsu HM300-2 Articulated Dump Truck Shop Manual SEN00237-16  – PDF DOWNLOAD

Language : English
Pages : 1412
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu HM300-2 Articulated Dump Truck Shop Manual SEN00237-16  – PDF DOWNLOAD

• SERIAL NUMBERS 2001 and up

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
Dump control valve (EPC valve) . 216
Hoist cylinder . 220
Hydraulic pump . 221
Cab and its attachments 225
ROPS cab . 226
Cab tilt . 227
Air conditioner 228
Rear view monitor 236
Controller related . 239
Electrical system, Part 1 241
Machine monitor system . 242
Electrical system, Part 2 263
Automatic shift control system . 264
Retarder control system 296
Auto emergency steering system . 308
Battery disconnector switch 310
Dump control lever . 312
Electrical system, Part 3 317
Payload meter (Card type) 318
Electrical system, Part 4 351
Sensors, switches 352
KOMTRAX terminal system (If equipped) 360
20 Standard value table 0
Standard service value table . 363
Standard value table for engine 364
Standard value table for chassis . 365
30 Testing and adjusting . 0
Testing and adjusting, Part 1 371
Tools for testing, adjusting, and troubleshooting 373
Sketches of special tools 378
Testing engine speed . 379
Testing intake air pressure (boost pressure) . 380
Testing exhaust temperature 381
Testing exhaust gas color 383
Adjusting valve clearance 384
Testing compression pressure . 386
Testing blow-by pressure . 388
Testing engine oil pressure 389
Testing EGR valve and bypass valve drive oil pressure 390
Handling of fuel system devices 391
Releasing residual pressure from fuel system . 391
Testing fuel pressure 392
Handling during cylinder cut-out operation . 393
Handling during no injection cranking operation 393
Testing fuel return and leak amount 394
Bleeding air from fuel circuit . 397
Testing fuel circuit for leakage . 398
Testing and adjusting alternator belt tension 399
Testing and adjusting air conditioner compressor belt tension 399
Adjusting the body mount . 400
Testing and adjusting, Part 2 403
Testing torque converter stall speed . 405
Testing power train oil pressure . 406
Adjusting transmission speed sensor 414
Testing and adjusting brake oil pressure . 416
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas 420
Testing brake performance 428
Releasing remaining pressure in brake circuit 429
Bleeding air from brake circuit 430
Testing wear of wheel brake disc . 431
Testing wear of parking brake pad 432
Method for emergency release of parking brake 434
Testing and adjusting steering circuit oil pressure 435
Testing and adjusting suspension cylinder 437
Method of tilting cab up . 441
Testing and adjusting dump circuit oil pressure 443
Adjusting body positioner sensor . 446
Procedure for adjusting length of spring in body heating spherical joint . 447
Adjustment of tilt lock lever of steering wheel 448
Handling engine controller high voltage circuit 449
Adjusting transmission controller 449
Method for emergency escape at electrical system failure . 450
Testing and adjusting, Part 3 455
Setting and adjusting various equipments . 456
Special function of machine monitor (EMMS) . 468
How to start operation of KOMTRAX terminal . 505
Lamp display of KOMTRAX terminal . 510
Pm Clinic check sheet 513
40 Troubleshooting . 0
Failure code table and fuse locations 517
Failure codes table 518
Fuse locations . 526
General Information on troubleshooting . 533
Points to remember when performing troubleshooting . 534
How to proceed in troubleshooting 536
Checks before troubleshooting 538
Classification and procedures of troubleshooting . 539
Information in troubleshooting table . 543
Troubleshooting method for disconnecting wiring harness of pressure sensor system 545
Connection table for connector pin numbers . 548
T-branch box and T-branch adapter table 584
Troubleshooting by failure code, Part 1 589
Failure code [1500L0] (Dual engagement) 591
Failure code [15B0NX] (Transmission oil filter: Clogged) . 592
Failure code [15F0KM] (R → F shifting abuse 1: Operational error or incorrect setting) . 594
Failure code [15F0MB] (R → F shifting abuse 2: Functional deterioration) . 594
Failure code [15F7KM] (forward clutch disc abuse) 595
Failure code [15G0MW] (R clutch: Slipping) . 596
Failure code [15G7KM] (reverse clutch disc abuse) 598
Failure code [15H0MW] (Hi clutch: Slipping) 599
Failure code [15J0MW] (Lo clutch: Slipping) 602
Failure code [15K0MW] (1st clutch: Slipping) . 604
Failure code [15L0MW] (2nd clutch: Slipping) . 606
Failure code [15M0MW] (3rd clutch: Slipping) . 608
Failure code [15SBL1] (R clutch solenoid: Fill signal is ON when command current is OFF.) 610
Failure code [15SBMA] (R clutch solenoid: Malfunction) . 614
Failure code [15SCL1] (Hi clutch solenoid: Fill signal is ON when command current is OFF.) . 616
Failure code [15SCMA] (Hi clutch solenoid: Malfunction) 620
Failure code [15SDL1] (Lo clutch solenoid: Fill signal is ON when command current is OFF.) . 622
Failure code [15SDMA] (Lo clutch solenoid: Malfunction) 624
Failure code [15SEL1] (1st clutch solenoid: Fill signal is ON when command current is OFF) . 628
Failure code [15SEMA] (1st clutch solenoid: Malfunction) . 632
Failure code [15SFL1] (2nd clutch solenoid: Fill signal is ON when command current is OFF.) 634
Failure code [15SFMA] (2nd clutch solenoid: Malfunction) . 638
Failure code [15SGL1] (3rd clutch solenoid: Fill signal is ON when command current is OFF.) 640
Failure code [15SGMA] (3rd clutch solenoid: Malfunction) . 644
Failure code [15SJMA] (Lockup clutch solenoid: Malfunction) 646
Failure code [15SKMA] (Inter-axle differential lockup pressure control valve: Malfunction) . 648
Failure code [2F00KM] (Parking brake: Error in operation or setting) . 650
Failure code [2G42ZG] (Front accumulator: Oil pressure too low) 652
Failure code [2G43ZG] (Rear accumulator: Oil pressure too low) . 652
Failure code [989A00] (Engine over run prevention command signal: Operating) . 653
Failure code [989D00] (Rear section tipping over alarm: Alarm is activated.) . 653
Failure code [AA10NX] (Air cleaner element: Clogged) . 654
Failure code [AB00MA] (Alternator: Malfunction) 656
Failure code [B@BAZG] Lowering of engine oil pressure 657
Failure code [B@BAZK] (Engine oil : Level too low) . 658
Failure code [B@BCNS] (Engine: Overheat) . 659
Failure code [B@BCZK] (Radiator coolant: Level too low) 660
Failure code [B@BFZK] (Fuel level: Level too low) 661
Failure code [B@C6NS] (Front brake oil: Overheat) 662
Failure code [B@C8NS] (Center brake oil: Overheat) . 662
Failure code [B@CENS] (Torque converter: Overheat) . 663
Failure code [B@HAZK] (Hydraulic tank oil: Level too low) 664
Failure code [B@JANS] (Steering oil: Overheat) . 665
Troubleshooting by failure code, Part 2 667
Failure code [CA111] Abnormality in engine controller 670
Failure code [CA115] Engine Ne or Bkup speed sensor error 672
Failure code [CA122] Charge (boost) pressure sensor high error . 674
Failure code [CA123] Charge (boost) pressure sensor low error 676
Failure code [CA131] Throttle sensor high error 678
Failure code [CA132] Throttle sensor low error . 681
Failure code [CA135] Engine oil pressure sensor high error . 684
Failure code [CA141] Engine oil pressure sensor low error 686
Failure code [CA144] Coolant temperature sensor high error . 688
Failure code [CA145] Coolant temperature sensor low error 690
Failure code [CA153] Charge (boost) temperature sensor high error 692
Failure code [CA154] Charge (boost) temperature sensor low error . 694
Failure code [CA187] Sensor power supply 2 low error . 696
Failure code [CA221] Atmospheric pressure sensor high error 698
Failure code [CA222] Atmospheric pressure sensor low error . 700
Failure code [CA227] Sensor power supply 2 high error 702
Failure code [CA234] Engine overspeed 703
Failure code [CA238] Ne speed sensor power supply error 704
Failure code [CA263] Fuel Temperature Sensor High Error 706
Failure code [CA265] Fuel Temperature Sensor Low Error . 708
Failure code [CA271] PCV1 Short circuit 710
Failure code [CA272] PCV1 Disconnection 711
Failure code [CA273] PCV2 Short circuit 712
Failure code [CA274] PCV2 Disconnection 713
Failure code [CA322] Injector #1 open/short error 714
Failure code [CA323] Injector #5 open/short error 716
Failure code [CA324] Injector #3 open/short error 718
Failure code [CA325] Injector #6 open/short error 720
Failure code [CA331] Injector #2 open/short error 722
Failure code [CA332] Injector #4 open/short error 724
Failure code [CA342] Calibration code inconsistency 726
Failure code [CA351] Injectors drive circuit error . 727
Failure code [CA352] Sensor power supply 1 low error . 728
Failure code [CA386] Sensor power supply 1 high error 730
Failure code [CA431] Idle validation switch error 732
Failure code [CA432] Idle validation action error 735
Failure code [CA441] Battery voltage low error . 738
Failure code [CA442] Battery voltage high error 739
Failure code [CA449] Common rail pressure high error 2 . 740
Failure code [CA451] Common rail pressure sensor high error 742
Failure code [CA452] Common rail pressure sensor low error . 744
Failure code [CA553] Common rail pressure high error 1 . 746
Failure code [CA554] Common rail pressure sensor in range error 747
Failure code [CA559] Supply pump pressure very low error 1 . 748
Failure code [CA689] Engine Ne speed sensor error 752
Failure code [CA731] Engine Bkup speed sensor phase error 754
Failure code [CA757] All continuous data lost error 755
Failure code [CA778] Engine Bkup speed sensor error 756
Failure code [CA1117] Loss of partial engine controller data . 758
Failure code [CA1228] EGR valve servo error 1 759
Failure code [CA1625] EGR valve servo error 2 760
Failure code [CA1626] Bypass valve solenoid current high error . 762
Failure code [CA1627] Bypass valve solenoid current low error 764
Failure code [CA1628] Bypass Valve Servo Error 1 . 766
Failure code [CA1629] Bypass Valve Servo Error 2 . 767
Troubleshooting by failure code, Part 3 769
Failure code [CA1631] Bypass valve lift sensor high error 772
Failure code [CA1632] Bypass valve lift sensor low error . 774
Failure code [CA1633] KOMNET datalink timeout error 776
Failure code [CA1642] EGR inlet pressure sensor low error 778
Failure code [CA1653] EGR inlet pressure sensor high error . 780
Failure code [CA2185] Throttle sensor supply voltage high error 782
Failure code [CA2186] Throttle sensor power supply low error . 784
Failure code [CA2249] Supply pump pressure very low error 2 786
Failure code [CA2271] EGR valve lift sensor high error . 788
Failure code [CA2272] EGR valve lift sensor low error 790
Failure code [CA2351] EGR valve solenoid operation short circuit . 792
Failure code [CA2352] EGR valve solenoid operation disconnect 794
Failure code [CA2555] Intake air heater relay open circuit error . 796
Failure code [CA2556] Intake air heater relay short circuit error 798
Failure code [DAF9KM] Machine monitor connector: Error in operation or setting . 800
Failure code [DAFRKR] Abnormal CAN communication (machine monitor): Abnormal communication . 801
Failure code [DAQ0KK] Transmission controller: Power source voltage too low 802
Failure code [DAQ0KT] Transmission nonvolatile memory: Abnormality in controller . 804
Failure code [DAQ2KK] Transmission controller solenoid power source: Voltage too low . 805
Failure code [DAQRKR] Abnormal CAN communication (Transmission): Abnormal communication 806
Failure code [DAQRMA] Transmission controller option setting: Malfunction 811
Failure code [DB10KT] Retarder controller nonvolatile memory: Abnormality in controller 811
Failure code [DB12KK] Retarder controller solenoid power source: Power source voltage too low 812
Failure code [DB13KK] Retarder controller battery direct power source: Power source voltage too low 813
Failure code [DB19KQ] Retarder controller model select signal: Inconsistent model selection signal . 814
Failure code [DB1QMA] Retarder controller option setting: Malfunction 814
Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled 815
Failure code [DB2RKR] CAN communication (engine controller): Communication disabled 819
Failure code [DD1ML4] Disagreement of accelerator-linked retarder switch signal 824
Failure code [DDTHKA] Fill switch for Hi clutch: Disconnection . 826
Failure code [DDTJKA] Fill switch for Lo clutch: Disconnection . 828
Failure code [DDTKKA] Fill switch for 1st clutch: Disconnection 830
Failure code [DDTLKA] Fill switch for 2nd clutch: Disconnection 831
Failure code [DDTMKA] Fill switch for 3rd clutch: Disconnection 832
Failure code [DDTNKA] Fill switch for R clutch: Disconnection 833
Failure code [DF10KA] Gear shift lever: Disconnection 834
Failure code [DF10KB] Gear shift lever: Short circuit 837
Failure code [DGF1KX] Transmission oil temperature sensor: Input signal out of range . 840
Failure code [DGR3KZ] Center brake oil temperature sensor: Disconnection or short circuit 842
Failure code [DGR3L8] Center brake oil temperature sensor: Inconsistent analog signals . 843
Failure code [DGR4KZ] Front brake oil temperature sensor: Disconnection or short circuit . 844
Failure code [DGR4L8] Front brake oil temperature sensor: Inconsistent analog signals 845
Failure code [DGR6KX] Steering oil temperature sensor: Input signal out of range . 846
Failure code [DGT1KX] Torque converter oil temperature sensor: Input signal out of range . 848
Failure code [DHT5KX] Torque converter oil pressure sensor: Input signal out of range 850
Failure code [DHT5L6] Torque converter oil pressure sensor: Inconsistent signals during a travel and stop 852
Failure code [DHU2KX] Front accumulator oil pressure sensor: Input signal out of range . 854
Failure code [DHU3KX] Rear accumulator oil pressure sensor: Input signal out of range 856
Failure code [DJF1KA] Fuel level sensor: Disconnection . 858
Failure code [DK51L5] (Retarder lever potentiometer : Potentiometer signal is inconsistent with switch signal) . 860
Failure code [DK52KX] Dump lever potentiometer failure 1: Input signal out of range 862
Failure code [DK53L8] Dump lever potentiometer failure 2: Inconsistent analog signal . 864
Failure code [DK54KX] Body positioner sensor: Input signal out of range 866
Troubleshooting by failure code, Part 4 869
Failure code [DKH0KX] (Inclination sensor: Inclination out of range) . 872
Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection) . 874
Failure code [DLF1LC] (Transmission input shaft speed sensor: Inconsistent rotation speed signal) 875
Failure code [DLF2KA] (Transmission intermediate shaft speed sensor: Disconnection) 876
Failure code [DLF2LC] (Transmission intermediate shaft speed sensor: Inconsistent speed signal) 877
Failure code [DLF4KA] (Differential speed sensor: Disconnection) . 878
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection) 879
Failure code [DV00KB] (Alarm buzzer output: Short circuit) . 880
Failure code [DW72KZ] (Kick-out solenoid output system: Disconnection or short circuit) 882
Failure code [DW73KZ] (Hoist selector valve output system: Disconnection or short circuit) . 884
Failure code [DW78KZ] (Rear brake BCV command output system: Disconnection or short circuit) . 886
Failure code [DW79KZ] (Front brake BCV command output system: Disconnection or short circuit) 888
Failure code [DX11K4] (Rear brake proportional pressure reducing solenoid valve: Out of control) . 890
Failure code [DX11KA] (Rear brake proportional pressure reducing solenoid valve output circuit: Disconnection) . 892
Failure code [DX11KB] (Rear brake proportional pressure reducing solenoid valve: Short circuit) 893
Failure code [DX11KY] (Rear brake proportional pressure reducing solenoid valve: Short circuit to power source line) . 894
Failure code [DX11MA] (Rear brake proportional pressure reducing solenoid valve: Malfunction) 896
Failure code [DX12K4] (Front brake proportional pressure reducing solenoid valve: Out of control) 898
Failure code [DX12KA] (Front brake proportional pressure reducing solenoid valve output circuit: Disconnection) 900
Failure code [DX12KB] (Front brake proportional pressure reducing solenoid valve: Short circuit) . 901
Failure code [DX12KY] (Front brake proportional pressure reducing solenoid valve: Short circuit to power source line) 902
Failure code [DX12MA] (Front brake proportional pressure reducing solenoid valve: Malfunction) . 904
Failure code [DX13KA] (Hoist EPC valve output circuit: Disconnection) 906
Failure code [DX13KB] (Hoist EPC valve output circuit: Short circuit) 907
Failure code [DX13KY] (Hoist EPC valve output circuit: Short circuit in power source line) . 908
Failure code [DXH0KA] (Inter-axle differential lock pressure control valve: Disconnection) . 909
Failure code [DXH0KB] (Inter-axle differential lock pressure control valve: Short circuit) . 910
Failure code [DXH0KY] (Inter-axle differential lockup pressure control valve: Short circuit to power source line) 911
Failure code [DXH1KA] (Lockup clutch solenoid output circuit: Disconnection) . 912
Failure code [DXH1KB] (Lockup clutch solenoid output circuit: Short circuit) . 913
Failure code [DXH1KY] (Lockup clutch solenoid output circuit: Short circuit to power source line) 914
Failure code [DXH2KA] (Hi clutch solenoid output circuit: Disconnection) . 916
Failure code [DXH2KB] (Hi clutch solenoid output circuit: Short circuit) . 918
Failure code [DXH2KY] (Hi clutch solenoid output circuit: Short circuit to power source line) 920
Failure code [DXH3KA] (Lo clutch solenoid output circuit: Disconnection) . 924
Failure code [DXH3KB] (Lo clutch solenoid output circuit: Short circuit) . 926
Failure code [DXH3KY] (Lo clutch solenoid output circuit: Short circuit in power source line) 928
Failure code [DXH4KA] (1st clutch solenoid output circuit: Disconnection) 932
Failure code [DXH4KB] (1st clutch solenoid output circuit: Short circuit) 934
Failure code [DXH4KY] (1st clutch solenoid output circuit: Short circuit to power source line) . 936
Failure code [DXH5KA] (2nd clutch solenoid output circuit: Disconnection) 940
Failure code [DXH5KB] (2nd clutch solenoid output circuit: Short circuit) 942
Failure code [DXH5KY] (2nd clutch solenoid output circuit: Short circuit in power source line) . 944
Failure code [DXH6KA] (3rd clutch solenoid output circuit: Disconnection) 948
Failure code [DXH6KB] (3rd clutch solenoid output circuit: Short circuit) 950
Failure code [DXH6KY] (3rd clutch solenoid output circuit: Short circuit to power source line) . 952
Failure code [DXH7KA] (R clutch solenoid output circuit: Disconnection) 956
Failure code [DXH7KB] (R clutch solenoid output circuit: Short circuit) 958
Failure code [DXH7KY] (R clutch solenoid output circuit: Short circuit to power source line) . 960
Troubleshooting of electrical system (E-mode) 965
Information in troubleshooting table . 966
E-1 Engine does not start 967
E-2 Automatic preheating does not operate 970
E-3 Machine monitor does not display all, when starting switch is turned ON 973
E-4 Machine monitor does not operate when starting switch is OFF . 975
E-5 Alarm buzzer does not stop sounding 977
E-6 Gauges of machine monitor, caution lamps or character display section do not display properly 978
E-7 Selection of display in character display section cannot be changed 979
E-8 Power mode selecting function does not operate properly 983
E-9 AISS function does not operate properly 984
E-10 Seat belt caution lamp does not display properly 985
E-11 Turn signal lamp or turning lamp (hazard lamp) does not work properly . 986
E-12 Night illumination (lighting) does not work properly 989
E-13 Emergency steering does not operate . 996
E-14 Air conditioner does not operate normally .1000
Troubleshooting of hydraulic and mechanical system (H-mode) 1007
Contents of troubleshooting table 1009
H-1 Machine does not start .1010
H-2 Machine does not travel smoothly (machine jerks) .1012
H-3 Lockup cannot be cancelled .1012
H-4 Excessive shock when starting or shifting 1013
H-5 Transmission does not shift up .1014
H-6 Machine lacks power or speed when traveling 1015
H-7 Time lag is excessive when starting or shifting gear .1017
H-8 Torque converter oil temperature is high .1018
H-9 Torque converter oil pressure is low .1019
H-10 Front brake is ineffective 1020
H-11 Center brake is ineffective .1021
H-12 Steering wheel is heavy .1022
H-13 Steering wheel does not work 1023
H-14 Steering wheel vibrates .1024
H-15 Dump body lifting speed is slow .1025
H-16 Dump body does not work .1026
H-17 Excessive hydraulic drift of dump body 1027
Troubleshooting of engine (S-mode) .1029
How to use a troubleshooting chart .1031
S-1 Engine is hard to start 1034
S-2 Engine does not start 1036
S-3 Engine does not pick up smoothly .1040
S-4 Engine stops during operations .1041
S-5 Engine does not rotate smoothly 1042
S-6 Engine lacks output (or lacks power) .1043
S-7 Exhaust gas color is black (incomplete combustion) .1044
S-8 Oil consumption is excessive (or exhaust gas color is blue) 1046
S-9 Oil gets contaminated prematurely 1047
S-10 Fuel consumption is excessive .1048
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) .1049
S-12 Oil pressure drops 1050
S-13 Oil level rises (coolant or fuel mixes) .1052
S-14 Coolant temperature rises too high (overheat) .1054
S-15 Abnormal noise comes out 1055
S-16 Vibration is excessive 1056
50 Disassembly and assembly 0
General information on disassembly and assembly 1059
How to read this manual 1060
Coating materials list .1062
Special tool list 1065
Sketches of special tools 1069
Engine and cooling system, Part 1 1083
Removal and installation of fuel supply pump assembly 1084
Removal and installation of fuel injector assembly .1089
Removal and installation of cylinder head assembly .1094
Removal and installation of engine front seal 1107
Removal and installation of engine rear seal .1109
Engine and cooling system, Part 2 1115
Removal and installation of engine assembly 1116
Removal and installation of radiator assembly 1124
Removal and installation of cooling assembly .1126
Removal and installation of output shaft assembly 1129
Disassembly and assembly of output shaft assembly 1134
Power train, Part 1 1139
Removal and installation of transmission and front differential assembly .1140
Disconnection and connection of front differential assembly and transmission assembly 1146
Disassembly and assembly of front differential assembly 1148
Disassembly and assembly of torque converter assembly 1163
Power train, Part 2 1171
Disassembly and assembly of transmission assembly 1172
Power train, Part 3 1215
Removal and installation of center differential assembly .1216
Disassembly and assembly of center differential assembly .1220
Removal and installation of rear differential assembly .1237
Disassembly and assembly of rear differential assembly .1239
Power train, Part 4 1255
Removal and installation of front final drive and brake assembly .1256
Disassembly and assembly of front final drive and brake assembly .1259
Removal and installation of center final drive and brake assembly 1269
Disassembly and assembly of center final drive and brake assembly 1271
Power train, Part 5 1281
Disassembly and assembly of rear final drive assembly 1282
Removal and installation of center axle assembly .1289
Removal and installation of rear axle assembly .1292
Undercarriage and frame 1295
Removal and installation of front suspension cylinder assembly .1296
Removal and installation of rear suspension cylinder assembly 1298
Disassembly and assembly of front and rear suspension cylinder assembly 1299
Removal and installation of equalizer bar 1301
Removal and installation of hitch frame assembly .1303
Disassembly and assembly of hitch frame assembly .1313
Hydraulic system .1321
Removal and installation of flow amp valve .1322
Removal and installation of hoist valve assembly .1324
Disassembly and assembly of steering cylinder assembly .1327
Disassembly and assembly of hoist cylinder assembly 1331
Body .1337
Removal and installation of body assembly 1338
Cab and its attachments 1341
Removal and installation ofoperator’s cab 1342
Removal and installation ofoperator’s cab glass (Stuck glass) 1347
Disassembly and assembly of operator’s seat assembly (If equipped) .1354
Electrical system 1365
Removal and installation of air conditioner unit assembly 1366
Removal and installation of engine controller 1371
Removal and installation of retarder controller 1373
Removal and installation of transmission controller assembly .1375
90 Diagrams and drawings . 0
Hydraulic diagrams and drawings 1377
Power train hydraulic circuit diagram 1379
Steering and hoist hydraulic circuit diagram .1381
Brake hydraulic circuit diagram 1383
Brake cooling hydraulic circuit diagram 1385
Electrical diagrams and drawings .1387
Electrical circuit diagram for inside cab (1/4) 1389
Electrical circuit diagram for inside cab (2/4) (Serial No.: 2001 – 2241) 1391
Electrical circuit diagram for inside cab (2/4) (Serial No.: 2242 and up) .1393
Electrical circuit diagram for inside cab (3/4) (Serial No.: 2001 – 2241) 1395
Electrical circuit diagram for inside cab (3/4) (Serial No.: 2242 and up) 1397
Electrical circuit diagram for inside cab (4/4) 1399
Electrical circuit diagram for outside cab (1/3) .1401
Electrical circuit diagram for outside cab (2/3) .1403
Electrical circuit diagram for outside cab (3/3) 1405
Electrical circuit diagram for payload meter .1407
Connectors table and arrangement drawing .1409

DESCRIPTION:

Komatsu HM300-2 Articulated Dump Truck Shop Manual SEN00237-16  – PDF DOWNLOAD

• SERIAL NUMBERS 2001 and up

1. Composition of shop manual:
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly
and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution
Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.

G.B 29/12/24