Komatsu hm300 3 Articulated Dump Truck Service Repair

SEN05629-01
ARTICULATED HM300 -3
DUMP TRUCK
SERIAL NUMBERS 3001 and up
00 Index and foreword
Index
Index
00 Index and foreword ....................................................................................................................... 00-1
Index ......................................................................................................................................... 00-2
Foreword, safety and general information ................................................................................... 00-16
Important safety notice ....................................................................................................... 00-16
How to read the shop manual.............................................................................................. 00-21
Explanation of terms for maintenance standard .................................................................... 00-23
Handling of fuel system devices .......................................................................................... 00-25
Handling of intake system parts........................................................................................... 00-26
Handling of hydraulic equipment.......................................................................................... 00-27
Method of disconnecting and connecting push-pull type coupler............................................. 00-29
Handling of electrical equipment.......................................................................................... 00-32
How to read electric wire code............................................................................................. 00-40
Precautions when performing operation ............................................................................... 00-43
Standard tightening torque table.......................................................................................... 00-46
List of abbreviation ............................................................................................................. 00-50
Conversion table ................................................................................................................ 00-54
01 Specification................................................................................................................................. 01-1
Table of contents ........................................................................................................................ 01-2
Specifications............................................................................................................................. 01-3
Specification drawings.......................................................................................................... 01-3
Specifications ...................................................................................................................... 01-4
Weight table ........................................................................................................................ 01-7
Table of fuel, coolant and lubricants ....................................................................................... 01-8
10 Structure and function ................................................................................................................... 10-1
Engine and cooling system .......................................................................................................... 10-4
Engine related parts ............................................................................................................. 10-4
Output shaft......................................................................................................................... 10-6
Cooling system .................................................................................................................... 10-7
Radiator fan pump................................................................................................................ 10-9
Aftercooler in-fan motor ...................................................................................................... 10-19
Radiator in-fan motor.......................................................................................................... 10-29
Power train............................................................................................................................... 10-35
Power train system............................................................................................................. 10-35
Drive shaft ......................................................................................................................... 10-37
Torque converter and transmission hydraulic piping .............................................................. 10-38
Torque converter ................................................................................................................ 10-40
Transmission ..................................................................................................................... 10-45
Transmission control valve.................................................................................................. 10-67
Forward and reverse clutch ECMV and gear speed clutch ECMV ........................................... 10-69
Lockup clutch ECMV .......................................................................................................... 10-76
Differential lock clutch ECMV .............................................................................................. 10-78
Main relief valve, torque converter relief valve, and main flow selector valve............................ 10-82
Axle .................................................................................................................................. 10-87
Differential ......................................................................................................................... 10-90
Final drive ......................................................................................................................... 10-94
Steering system........................................................................................................................ 10-97
Layout of steering devices .................................................................................................. 10-97
Steering column................................................................................................................. 10-98
Flow amplifier valve............................................................................................................ 10-99
Steering valve.................................................................................................................. 10-102
Emergency steering pump ................................................................................................ 10-107
Brake system ......................................................................................................................... 10-108
Layout of brake parts........................................................................................................ 10-108
Parking brake solenoid and accumulator charge valve ........................................................ 10-109
Accumulator .................................................................................................................... 10-114
Brake valve ..................................................................................................................... 10-115
00-2 HM300–3
Index
Proportional pressure reducing valve ................................................................................. 10-120

Slack adjuster .................................................................................................................. 10-121
Brake .............................................................................................................................. 10-125
Brake system tank ........................................................................................................... 10-128
Parking brake .................................................................................................................. 10-129
Undercarriage and frame......................................................................................................... 10-132
Suspension ..................................................................................................................... 10-132
Suspension cylinder ......................................................................................................... 10-138
Oscillation hitch ............................................................................................................... 10-140
Hydraulic system .................................................................................................................... 10-142
Layout of hoist hydraulic parts ........................................................................................... 10-142
Dump body control ........................................................................................................... 10-144
Hydraulic tank.................................................................................................................. 10-145
Steering and hoist control pump ........................................................................................ 10-146
Hoist valve ...................................................................................................................... 10-158
Dump EPC valve ............................................................................................................. 10-164
Brake cooling oil control valve ........................................................................................... 10-166
Cab and its attachments .......................................................................................................... 10-167
ROPS cab ....................................................................................................................... 10-167
Cab tilt ............................................................................................................................ 10-168
Electrical system .................................................................................................................... 10-169
Transmission control system ............................................................................................. 10-169
Retarder and hoist control system ..................................................................................... 10-180
Auto emergency steering system....................................................................................... 10-185
KTCS.............................................................................................................................. 10-187
System component parts .................................................................................................. 10-190
Machine monitor system ................................................................................................... 10-211
Rear view monitor system................................................................................................. 10-230
KOMTRAX system ........................................................................................................... 10-233
Sensor ............................................................................................................................ 10-236
20 Standard value table ..................................................................................................................... 20-1
Standard service value table........................................................................................................ 20-3
Standard value table for engine ............................................................................................. 20-3
Standard value table for machine .......................................................................................... 20-4
30 Testing and adjusting .................................................................................................................... 30-1
General information on testing and adjusting................................................................................. 30-3
Tools for testing and adjusting ............................................................................................... 30-3
Sketch of tools for testing and adjusting ................................................................................. 30-9
Engine and cooling system ........................................................................................................ 30-12
Measuring engine speed .................................................................................................... 30-12
Measuring boost pressure................................................................................................... 30-13
Measuring exhaust gas temperature .................................................................................... 30-15
Measuring exhaust gas color............................................................................................... 30-17
Measuring and adjusting valve clearance ............................................................................. 30-19
Measuring compression pressure ........................................................................................ 30-21
Measuring blowby pressure ................................................................................................ 30-24
Measuring engine oil pressure............................................................................................. 30-26
Measuring EGR valve and KVGT driving oil pressure ............................................................ 30-27
Measuring fuel pressure ..................................................................................................... 30-28
Handling cylinder cutout mode operation.............................................................................. 30-29
Handling no injection cranking operation .............................................................................. 30-30
Measuring fuel return rate and leakage ................................................................................ 30-31
Bleeding air from fuel system .............................................................................................. 30-34
Checking fuel circuit for leakage .......................................................................................... 30-36
Checking and adjusting air conditioner compressor belt tension ............................................. 30-37
Replacing alternator belt ..................................................................................................... 30-38
Procedures for cleaning fuel doser....................................................................................... 30-39
HM300–3 00-3
Index
Writing compensation values at replacement of injector and engine controller ......................... 30-42
Power train............................................................................................................................... 30-46
Testing torque converter stall speed..................................................................................... 30-46
Measuring power train oil pressure ...................................................................................... 30-48
Adjusting transmission speed sensor ................................................................................... 30-58
Adjusting transmission controller ......................................................................................... 30-61
Retrieval of disabled machine that resulted from a trouble in electrical system ......................... 30-62
Retrieval of machine that is disabled due to failure in the traction control system
(KTCS) ................................................................................................................ 30-66
Steering system........................................................................................................................ 30-68
Measuring and adjusting steering circuit oil pressure ............................................................. 30-68
Brake system ........................................................................................................................... 30-70
Measuring and adjusting brake oil pressure.......................................................................... 30-70
Measuring accumulator nitrogen gas pressure and charging procedure for accumulator
nitrogen gas ......................................................................................................... 30-73
Testing braking performance ............................................................................................... 30-77
Testing braking performance ............................................................................................... 30-78
Measuring wear of wheel brake disc .................................................................................... 30-79
Parking brake emergency releasing procedure ..................................................................... 30-80
Measuring wear of parking brake pad and adjusting clearance............................................... 30-81
Hydraulic system ...................................................................................................................... 30-83
Testing and adjusting suspension cylinder............................................................................ 30-83
Measuring and adjusting dump circuit oil pressure ................................................................ 30-89
Work equipment ....................................................................................................................... 30-92
Adjusting dump body positioner sensor ................................................................................ 30-92
Cab and its attachments ............................................................................................................ 30-94
Cab tilt-up procedure .......................................................................................................... 30-94
Electrical system ...................................................................................................................... 30-97
Setting and adjusting each equipment.................................................................................. 30-97
Special functions of machine monitor ................................................................................. 30-107
Handling voltage circuit of engine controller........................................................................ 30-176
Handling battery disconnect switch .................................................................................... 30-177
Pm Clinic ............................................................................................................................... 30-178
Pm Clinic service ............................................................................................................. 30-178
40 Troubleshooting............................................................................................................................ 40-1
General information on troubleshooting ...................................................................................... 40-11
Instruction on troubleshooting ............................................................................................. 40-11
Sequence of events in troubleshooting................................................................................. 40-13
Check before troubleshooting.............................................................................................. 40-14
Testing procedure before troubleshooting............................................................................. 40-16
Classification and procedures for troubleshooting ................................................................. 40-21
Symptom and troubleshooting numbers ............................................................................... 40-22
Information in troubleshooting table ..................................................................................... 40-25
Connector list and layout .................................................................................................... 40-27
Connector contact identification........................................................................................... 40-43
T-branch box and T-branch adapter table ............................................................................. 40-80
Table of fuse locations ........................................................................................................ 40-86
Precautions for cleaning and replacing KDPF (KCSF, KDOC) ................................................ 40-90
Precautions on troubleshooting of machine monitor .............................................................. 40-92
Processing procedure of harness checker for troubleshooting of machine monitor LCD
unit ...................................................................................................................... 40-94
Dummy temperature sensor (for KDOC and KDPF temperature sensors) ............................... 40-99
Short-circuit connector (for CA1883 and CA3135)............................................................... 40-100
Failure codes table........................................................................................................... 40-101
Troubleshooting by failure code (Display of code) ...................................................................... 40-116
Failure code [1500L0] Double Engagement of T/M Clutches ................................................ 40-116
Failure code [15B0NX] Transmission Oil Filter Clogging ...................................................... 40-117
Failure code [15F0KM] Abuse 1 of Gear Shifting from R to F................................................ 40-119
00-4 HM300–3
Index
Failure code [15F0MB] Abuse 2 of Gear Shifting from R to F................................................ 40-120

Failure code [15F7KM] Abuse of TM Forward Clutch Disk ................................................... 40-121
Failure code [15G0MW] Failure of Clutch (Reverse)............................................................ 40-122
Failure code [15G7KM] Abuse of TM Reverse Clutch Disk................................................... 40-125
Failure code [15H0MW] Failure of Clutch (High) ................................................................. 40-126
Failure code [15J0MW] Failure of Clutch (Low) ................................................................... 40-129
Failure code [15K0MW] Failure of Clutch (1st) .................................................................... 40-132
Failure code [15L0MW] Failure of Clutch (2nd) ................................................................... 40-135
Failure code [15M0MW] Failure of Clutch (3rd) ................................................................... 40-138
Failure code [15SBL1] Release Trouble of ECMV (Reverse)................................................ 40-141
Failure code [15SBMA] Malfunction of ECMV (Reverse)...................................................... 40-144
Failure code [15SCL1] Release Trouble of ECMV (High) ..................................................... 40-145
Failure code [15SCMA] Malfunction of ECMV (High) ........................................................... 40-148
Failure code [15SDL1] Release Trouble of ECMV (Low)...................................................... 40-149
Failure code [15SDMA] Malfunction of ECMV (Low)............................................................ 40-152
Failure code [15SEL1] Release Trouble of ECMV (1st)........................................................ 40-153
Failure code [15SEMA] Malfunction of ECMV (1st).............................................................. 40-156
Failure code [15SFL1] Release Trouble of ECMV (2nd)....................................................... 40-157
Failure code [15SFMA] Malfunction of ECMV (2nd)............................................................. 40-160
Failure code [15SGL1] Release Trouble of ECMV (3rd) ....................................................... 40-161
Failure code [15SGMA] Malfunction of ECMV (3rd) ............................................................. 40-164
Failure code [15SJMA] Malfunction of ECMV (Lockup) ........................................................ 40-165
Failure code [15SKMA] Malfunction of ECMV (Inter-Axle Diff.) ............................................. 40-167
Failure code [2F00KM] Dragging of Parking Brake .............................................................. 40-169
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ............................................. 40-171
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) .............................................. 40-172
Failure code [879AKA] A/C Inner Sensor Open Circuit ........................................................ 40-173
Failure code [879AKB] A/C Inner Sensor Short Circuit......................................................... 40-174
Failure code [879BKA] A/C Outer Sensor Open Circuit........................................................ 40-175
Failure code [879BKB] A/C Outer Sensor Short Circuit ........................................................ 40-176
Failure code [879CKA] Ventilating Sensor Open Circuit ....................................................... 40-177
Failure code [879CKB] Ventilating Sensor Short Circuit ....................................................... 40-178
Failure code [879EMC] Ventilation Damper Abnormality ...................................................... 40-179
Failure code [879FMC] Air Mix Damper Abnormality ........................................................... 40-180
Failure code [879GKX] Refrigerant Abnormality .................................................................. 40-181
Failure code [989D00] Tilt Caution ..................................................................................... 40-182
Failure code [989L00] Engine Controller Lock Caution 1...................................................... 40-183
Failure code [989M00] Engine Controller Lock Caution 2..................................................... 40-184
Failure code [989N00] Engine Controller Lock Caution 3 ..................................................... 40-185
Failure code [A1U0N3] HC desorb request 1 ...................................................................... 40-186
Failure code [A1U0N4] HC desorb request 2 ...................................................................... 40-188
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40-190
Failure code [AB00KE] Charge Voltage Low....................................................................... 40-192
Failure code [AB00KY] Hot Short of Alternator R Terminal ................................................... 40-194
Failure code [B@BAZK] Engine Oil Level Low.................................................................... 40-196
Failure code [B@BCZK] Eng Water Level Low ................................................................... 40-197
Failure code [B@C6NS] Retarder Oil Overheat (Front)........................................................ 40-199
Failure code [B@C8NS] Retarder Oil Overheat (Center) ..................................................... 40-200
Failure code [B@CENS] T/C Oil Temp. Overheat................................................................ 40-201
Failure code [B@JANS] Steering Oil Overheat ................................................................... 40-202
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................. 40-203
Failure code [CA122] Chg Air Press Sensor High Error ....................................................... 40-204
Failure code [CA123] Chg Air Press Sensor Low Error ........................................................ 40-206
Failure code [CA131] Throttle Sensor High Error................................................................. 40-208
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40-210
Failure code [CA135] Eng Oil Press Sensor High Error........................................................ 40-213
Failure code [CA141] Eng Oil Press Sensor Low Error ........................................................ 40-215
Failure code [CA144] Coolant Temp Sens High Error .......................................................... 40-217
Failure code [CA145] Coolant Temp Sens Low Error ........................................................... 40-219
HM300–3 00-5
Index
Failure code [CA153] Chg Air Temp Sensor High Error ........................................................ 40-221
Failure code [CA154] Chg Air Temp Sensor Low Error......................................................... 40-223
Failure code [CA187] Sensor 2 Supply Volt Low Error ......................................................... 40-225
Failure code [CA221] Ambient Press Sensor High Error ...................................................... 40-227
Failure code [CA222] Ambient Press Sensor Low Error ....................................................... 40-229
Failure code [CA227] Sensor 2 Supply Volt High Error......................................................... 40-231
Failure code [CA234] Eng Overspeed ................................................................................ 40-232
Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................... 40-233
Failure code [CA239] Ne Speed Sens Supply Volt High Error............................................... 40-234
Failure code [CA271] IMV/PCV1 Short Error ...................................................................... 40-235
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40-236
Failure code [CA273] PCV2 Short Error ............................................................................. 40-237
Failure code [CA274] PCV2 Open Error ............................................................................. 40-238
Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................. 40-239
Failure code [CA343] ECM Critical Internal Failure.............................................................. 40-251
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-252
Failure code [CA352] Sensor 1 Supply Volt Low Error ......................................................... 40-253
Failure code [CA356] Mass Air Flow Sensor High Error ....................................................... 40-255
Failure code [CA357] Mass Air Flow Sensor Low Error ........................................................ 40-257
Failure code [CA386] Sensor 1 Supply Volt High Error......................................................... 40-259
Failure code [CA431] Idle Validation Sw Error..................................................................... 40-260
Failure code [CA432] Idle Validation Process Error ............................................................. 40-263
Failure code [CA441] Battery Voltage Low Error ................................................................. 40-266
Failure code [CA442] Battery Voltage High Error................................................................. 40-268
Failure code [CA449] Rail Press Very High Error................................................................. 40-269
Failure code [CA451] Rail Press Sensor High Error............................................................. 40-270
Failure code [CA452] Rail Press Sensor Low Error ............................................................. 40-272
Failure code [CA515] Rail Press Sens Sup Volt High Error .................................................. 40-274
Failure code [CA516] Rail Press Sens Sup Volt Low Error ................................................... 40-276
Failure code [CA553] Rail Press High Error ........................................................................ 40-278
Failure code [CA555] Crankcase Press High Error 1 ........................................................... 40-279
Failure code [CA556] Crankcase Press High Error 2 ........................................................... 40-280
Failure code [CA559] Rail Press Low Error......................................................................... 40-281
Failure code [CA595] Turbo Speed High Error 2 ................................................................. 40-285
Failure code [CA687] Turbo Speed Low Error ..................................................................... 40-286
Failure code [CA689] Eng Ne Speed Sensor Error .............................................................. 40-288
Failure code [CA691] Intake Air Temp Sens High Error ........................................................ 40-290
Failure code [CA692] Intake Air Temp Sens Low Error......................................................... 40-292
Failure code [CA697] ECM Internal Temp Sensor High Error................................................ 40-294
Failure code [CA698] ECM Int Temp Sensor Low Error........................................................ 40-295
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................... 40-296
Failure code [CA778] Eng Bkup Speed Sensor Error........................................................... 40-297
Failure code [CA1117] Persistent Data Lost Error................................................................ 40-299
Failure code [CA1664] KDOC Malfunction.......................................................................... 40-300
Failure code [CA1691] Regeneration Ineffective ................................................................. 40-302
Failure code [CA1695] Sensor 5 Supply Volt High Error....................................................... 40-305
Failure code [CA1696] Sensor 5 Supply Volt Low Error ....................................................... 40-307
Failure code [CA1843] Crankcase Press Sens High Error.................................................... 40-309
Failure code [CA1844] Crankcase Press Sens Low Error .................................................... 40-311
Failure code [CA1879] KDPF Delta P Sensor High Error ..................................................... 40-313
Failure code [CA1881] KDPF Delta P Sensor Low Error ...................................................... 40-315
Failure code [CA1883] KDPF Delta P Sens In Range Error.................................................. 40-317
Failure code [CA1921] KDPF Soot Load High Error 1.......................................................... 40-321
Failure code [CA1922] KDPF Soot Load High Error 2.......................................................... 40-323
00-6 HM300–3
Index
Failure code [CA1923] Dosing Fuel Valve 1 High Error ........................................................ 40-327
Failure code [CA1924] Dosing Fuel Valve 1 Low Error......................................................... 40-329
Failure code [CA1925] Dosing Fuel Valve 1 In Range Error ................................................. 40-332
Failure code [CA1927] Dosing Fuel Press Sens High Error .................................................. 40-334
Failure code [CA1928] Dosing Fuel Press Sens Low Error................................................... 40-336
Failure code [CA1942] Crankcase Press Sensor In Range Error .......................................... 40-338
Failure code [CA1963] Dosing Fuel Valve 1 Servo Error ...................................................... 40-339
Failure code [CA1977] Fuel Doser Open/Short Error ........................................................... 40-341
Failure code [CA1993] KDPF Delta Pressure Low Error ...................................................... 40-343
Failure code [CA2185] Throt Sensor Sup Volt High Error ..................................................... 40-344
Failure code [CA2186] Throt Sensor Sup Volt Low Error...................................................... 40-346
Failure code [CA2249] Rail Press Very Low Error ............................................................... 40-348
Failure code [CA2265] Fuel Feed Pump Open Error............................................................ 40-349
Failure code [CA2266] Fuel Feed Pump Short Error ............................................................ 40-351
Failure code [CA2271] EGR Valve Pos Sens High Error ...................................................... 40-354
Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................... 40-356
Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................... 40-358
Failure code [CA2353] EGR Valve Solenoid Short Error ...................................................... 40-360
Failure code [CA2357] EGR Valve Servo Error ................................................................... 40-362
Failure code [CA2381] KVGT Pos Sens High Error ............................................................. 40-363
Failure code [CA2382] KVGT Pos Sens Low Error .............................................................. 40-365
Failure code [CA2383] KVGT Solenoid Open Error ............................................................. 40-367
Failure code [CA2386] KVGT Solenoid Short Error ............................................................. 40-369
Failure code [CA2387] KVGT Servo Error .......................................................................... 40-371
Failure code [CA2555] Grid Htr Relay Volt Low Error ........................................................... 40-372
Failure code [CA2556] Grid Htr Relay Volt High Error .......................................................... 40-374
Failure code [CA2637] KDOC Face Plugging ..................................................................... 40-376
Failure code [CA2639] Manual Stationary Regeneration Request......................................... 40-378
Failure code [CA2732] Dosing Fuel Valve 2 High Error ........................................................ 40-381
Failure code [CA2733] Dosing Fuel Valve 2 Low Error......................................................... 40-383
Failure code [CA2741] Dosing Fuel Valve Swap Error ......................................................... 40-385
Failure code [CA2765] Inj Trim Data Error .......................................................................... 40-387
Failure code [CA2878] Dosing Fuel Valve 2 Servo Error ...................................................... 40-388
Failure code [CA2881] Dosing Fuel Pressure Low Error 1.................................................... 40-391
Failure code [CA3133] KDPF Outlet Press Sens High Error ................................................. 40-394
Failure code [CA3134] KDPF Outlet Press Sens Low Error.................................................. 40-396
Failure code [CA3135] KDPF Outlet Press Sens In Range Error .......................................... 40-398
Failure code [CA3251] KDOC Inlet Temp High Error............................................................ 40-402
Failure code [CA3253] KDOC Temp Error - Non Regeneration............................................. 40-405
Failure code [CA3254] KDOC Outlet Temp High Error 1 ...................................................... 40-408
Failure code [CA3255] KDPF Temp Error - Non Regeneration.............................................. 40-411
Failure code [CA3256] KDPF Outlet Temp High Error 1 ....................................................... 40-414
Failure code [CA3311] KDOC Outlet Temp High Error 2....................................................... 40-417
Failure code [CA3312] KDPF Outlet Temp High Error 2 ....................................................... 40-420
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ................................................. 40-423
Failure code [CA3314] KDOC Inlet Temp Sens High Error ................................................... 40-426
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error............................................. 40-430
Failure code [CA3316] KDOC Outlet Temp Sens Low Error ................................................. 40-435
Failure code [CA3317] KDOC Outlet Temp Sens High Error................................................. 40-439
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error .......................................... 40-443
Failure code [CA3319] KDPF Outlet Temp Sens High Error ................................................. 40-448
Failure code [CA3321] KDPF Outlet Temp Sens Low Error .................................................. 40-452
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error........................................... 40-455
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ........................................ 40-460
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ......................................... 40-462
Failure code [D150KB] Ground Fault of Emerg. Steering Relay ............................................ 40-464
Failure code [D150KZ] Failure of Emerg. Steering Relay ..................................................... 40-465
Failure code [D164KY] Hot Short of Head Light High Selector.............................................. 40-466
Failure code [D19HKZ] Failure of Stop Lamp (R&L) ............................................................ 40-467
HM300–3 00-7
Index
Failure code [D19JKZ] Personal Code Relay Abnormality.................................................... 40-469

Failure code [D1EHKA] Disconnection of Engine Start Relay ............................................... 40-470
Failure code [D1EHKB] Ground Fault of Engine Start Relay................................................. 40-471
Failure code [D1EHKY] Hot Short of Engine Start Relay ...................................................... 40-472
Failure code [D1EMKA] Disconnection of Parking Interlock Relay ........................................ 40-473
Failure code [D1EMKB] Ground Fault of Parking Interlock Relay .......................................... 40-474
Failure code [D1EMKY] Hot Short of Parking Interlock Relay ............................................... 40-475
Failure code [D1FBKB] Ground Fault of Sol. Self-Holding Relay........................................... 40-476
Failure code [D5ZHL6] Disconnection of Key SW C ............................................................ 40-477
Failure code [D811MC] KOMTRAX Error............................................................................ 40-479
Failure code [D862KA] GPS Antenna Open Circuit ............................................................. 40-480
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ...................................... 40-481
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ...................................... 40-483
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 .......................................................... 40-485
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ............................................................ 40-486
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ..................................... 40-487
Failure code [DAF0MB] Monitor ROM Abnormality.............................................................. 40-488
Failure code [DAF0MC] Monitor Error ................................................................................ 40-489
Failure code [DAF3KK] Controller Power Source Low (MON)............................................... 40-490
Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................ 40-492
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit .......................................... 40-493
Failure code [DAFGMC] GPS Module Error........................................................................ 40-495
Failure code [DAFLKA] Operating Lamp Open Circuit (MON)............................................... 40-496
Failure code [DAFLKB] Operating Lamp Short Circuit (MON)............................................... 40-498
Failure code [DAFQKR] CAN2 Discon (Monitor) ................................................................. 40-500
Failure code [DAQ0KK] Controller Power Source Low (T/M) ................................................ 40-501
Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) ....................................... 40-503
Failure code [DAQ0MC] T/M Con Error .............................................................................. 40-504
Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M) .............................................. 40-505
Failure code [DAQ2KK] Solenoid Power Source Low (T/M) ................................................. 40-506
Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) .......................................... 40-508
Failure code [DAQLKA] Operating Lamp Open Circuit (T/M) ................................................ 40-509
Failure code [DAQLKB] Operating Lamp Short Circuit (T/M) ................................................ 40-511
Failure code [DAQQKR] CAN2 Discon (Transmission Con) ................................................. 40-513
Failure code [DAQRKR] CAN1 Discon (Transmission Con) ................................................. 40-514
Failure code [DAQRMA] Inconsistency of Option Selection (T/M) ......................................... 40-515
Failure code [DAZ9KQ] A/C Model Selection Abnormality.................................................... 40-516
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ........................................................... 40-517
Failure code [DB10KT] Abnormality of Non-volatile Memory (RHC) ...................................... 40-518
Failure code [DB10MC] RHC Error .................................................................................... 40-519
Failure code [DB11KA] Disconnection of Key SW ACC (RHC) ............................................. 40-520
Failure code [DB12KK] Solenoid Power Source Low (RHC)................................................. 40-522
Failure code [DB13KK] Controller Power Source Low (RHC) ............................................... 40-524
Failure code [DB19KQ] Inconsistency of Model Selection (RHC).......................................... 40-526
Failure code [DB1LKA] Disconnection of System Ope. Lamp (RHC)..................................... 40-527
Failure code [DB1LKB] Short Circuit of System Ope. Lamp (RHC) ....................................... 40-529
Failure code [DB1QKR] CAN2 Discon (Retarder Hoist Con) ................................................ 40-531
Failure code [DB1QMA] Inconsistency of Option Selection (RHC) ........................................ 40-532
Failure code [DB1RKR] CAN1 Discon (Retarder Hoist Con)................................................. 40-533
Failure code [DB2QKR] CAN2 Discon (Engine Con) ........................................................... 40-534
Failure code [DB2RKR] CAN1 Discon (Engine Con) ........................................................... 40-539
Failure code [DD1ML4] Failure of ARAC SW ...................................................................... 40-544
Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch ................................ 40-546
Failure code [DDTHKA] Disconnection of Fill Switch (High) ................................................. 40-548
Failure code [DDTJKA] Disconnection of Fill Switch (Low) ................................................... 40-550
Failure code [DDTKKA] Disconnection of Fill Switch (1st) .................................................... 40-552
Failure code [DDTLKA] Disconnection of Fill Switch (2nd) ................................................... 40-554
Failure code [DDTMKA] Disconnection of Fill Switch (3rd) ................................................... 40-556
Failure code [DDTNKA] Disconnection of Fill Switch (Reverse) ............................................ 40-558
00-8 HM300–3
Index
Failure code [DF10KA] Disconnection of Shift Lever Input ................................................... 40-560

Failure code [DF10KB] Ground Fault of Shift Lever Input ..................................................... 40-563
Failure code [DGF1KX] Out oF Range of T/M Oil Temp. Sensor ........................................... 40-568
Failure code [DGR3KB] Ground Fault of Retarder Oil Temp. S.(C)........................................ 40-570
Failure code [DGR3L8] Failure of Retarder Oil Temp. Sensor (C) ......................................... 40-571
Failure code [DGR4KB] Ground Fault of Retarder Oil Temp. S.(F) ........................................ 40-572
Failure code [DGR4L8] Failure of Retarder Oil Temp. Sensor (F).......................................... 40-573
Failure code [DGR6KB] Ground Fault of Steering Oil Temp. S.............................................. 40-574
Failure code [DGR6L8] Failure of Steering Oil Temp. Sensor ............................................... 40-575
Failure code [DGT1KX] Out of Range of T/C Oil Temp. Sensor ............................................ 40-577
Failure code [DHQ2KX] Out of Range of Main Flow Sel. Valve S. ......................................... 40-579
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor ..................................... 40-581
Failure code [DHT5L6] Failure of T/C Oil Press Sensor ....................................................... 40-583
Failure code [DHT8KX] Out of Range of Steering Oil Press. S.............................................. 40-585
Failure code [DHT8ZG] Steering Oil Pressure Low.............................................................. 40-587
Failure code [DHU2KX] Out of Range of Acc. Oil Press. S. (F) ............................................. 40-588
Failure code [DHU3KX] Out of Range of Acc. Oil Press. S. (R)............................................. 40-590
Failure code [DHUAKX] Out of Range of Retarder Press. S. (CR) ........................................ 40-592
Failure code [DHUBKX] Out of Range of Retarder Press. S. (FR)......................................... 40-594
Failure code [DHUCKX] Out of Range of Parking Brake Press. S. ........................................ 40-596
Failure code [DHUDKX] Out of Range of Emerg. Steering Press. S.1 ................................... 40-598
Failure code [DHUQKX] Out of Range of Retarder Press. S. (FL) ......................................... 40-600
Failure code [DHURKX] Out of Range of Retarder Press. S. (CL)......................................... 40-602
Failure code [DJF1KA] Disconnection of Fuel Level Sensor ................................................. 40-604
Failure code [DK30KX] Out of Range of Steering Angle Pot. ................................................ 40-606
Failure code [DK51L5] Failure of Retarder Lever Pot. and RVS............................................ 40-608
Failure code [DK52KX] Out of Range of Hoist Lever Potentio............................................... 40-611
Failure code [DK53L8] Failure of Hoist Lever Potentio. ........................................................ 40-613
Failure code [DK54KX] Out of Range of Body Potentio. ....................................................... 40-614
Failure code [DK60KX] Out of Range of Acceleration Sensor............................................... 40-616
Failure code [DKH0KX] Out of Range of Inclination Angle Sensor ........................................ 40-618
Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor........................................ 40-620
Failure code [DLF1LC] Failure of T/M Input Speed Sensor................................................... 40-622
Failure code [DLF2KA] Disconnection of T/M Inter. Speed Sensor........................................ 40-624
Failure code [DLF2LC] Failure of T/M Intermediate Speed Sensor........................................ 40-626
Failure code [DLF400] T/M Diff. Overrun Prevention Activated ............................................. 40-628
Failure code [DLF4KA] Disconnection of T/M Diff. Speed Sensor ......................................... 40-629
Failure code [DLF4LC] Failure of T/M Diff. Speed Sensor .................................................... 40-631
Failure code [DLF6LC] Failure of Wheel Speed Sensor (FR)................................................ 40-633
Failure code [DLF7LC] Failure of Wheel Speed Sensor (FL) ................................................ 40-635
Failure code [DLFDLC] Failure of Wheel Speed Sensor (CR)............................................... 40-637
Failure code [DLFELC] Failure of Wheel Speed Sensor (CL) ............................................... 40-639
Failure code [DLFFLC] Failure of Wheel Speed Sensor (Front) ............................................ 40-641
Failure code [DLFGLC] Failure of Wheel Speed Sensor (Center) ......................................... 40-642
Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor.................................. 40-643
Failure code [DLM3MB] Radiator Fan Control Mismatch...................................................... 40-645
Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor............................................. 40-646
Failure code [DLM4KA] Disconnection of CAC Fan Speed Sensor ....................................... 40-648
Failure code [DLM4MB] CAC Fan Control Mismatch ........................................................... 40-649
Failure code [DLM4LC] Failure of CAC Fan Speed Sensor .................................................. 40-650
Failure code [DLT3KA] Disconnection of Output Speed Sens. (Main).................................... 40-652
Failure code [DLT3LC] Failure of Output Speed Sensor (Main)............................................. 40-654
Failure code [DPQ1KR] LIN Discon (Switch Panel) ............................................................. 40-656
Failure code [DPQ2KR] LIN Discon (LED Unit) ................................................................... 40-659
Failure code [DPQ3KR] LIN Discon (Rear View Monitor) ..................................................... 40-662
Failure code [DSJ0KR] CAN2 Discon (Meter Unit) .............................................................. 40-665
Failure code [DV00KB] Ground Fault of Buzzer Output........................................................ 40-666
Failure code [DW2BKA] Disconnection of Main Flow Selector Sol. ....................................... 40-668
Failure code [DW2BKB] Ground Fault of Main Flow Selector Sol. ......................................... 40-669
HM300–3 00-9
Index
Failure code [DW2BKY] Hot Short of Main Flow Selector Sol. .............................................. 40-670
Failure code [DW2BL1] Release Trouble of Main Flow Sel. Valve......................................... 40-671
Failure code [DW2BLH] Malfunction of Main Flow Selector Valve ......................................... 40-672
Failure code [DW4BK4] Release Trouble of Parking Brake Valve ......................................... 40-673
Failure code [DW4BMA] Malfunction of Parking Brake Valve ............................................... 40-675
Failure code [DW72KZ] Failure of Kick out Solenoid............................................................ 40-676
Failure code [DW73KA] Disconnection of Hoist Selector Sol. ............................................... 40-678
Failure code [DW73KB] Ground Fault of Hoist Selector Sol.................................................. 40-680
Failure code [DW73KY] Hot Short of Hoist Selector Sol. ...................................................... 40-682
Failure code [DW78KZ] Failure of Brake Cooling Sol. (Rear)................................................ 40-684
Failure code [DW7BKB] Ground Fault of Radiator Fan Rev. Sol. .......................................... 40-686
Failure code [DW7BKY] Hot Short of Radiator Fan Rev. Sol................................................. 40-688
Failure code [DW7BKZ] Failure of Radiator Fan Rev. Sol..................................................... 40-689
Failure code [DW7LKB] Ground Fault of CAC Fan Rev. Sol. ................................................ 40-691
Failure code [DW7LKY] Hot Short of CAC Fan Rev. Sol....................................................... 40-692
Failure code [DW7LKZ] Failure of CAC Fan Rev. Sol........................................................... 40-693
Failure code [DW7MKB] Ground Fault of Fan/Hoist Selector Sol. ......................................... 40-694
Failure code [DW7MKY] Hot Short of Fan/Hoist Selector Sol. .............................................. 40-696
Failure code [DW7MKZ] Failure of Fan/Hoist Selector Sol. .................................................. 40-697
Failure code [DW7NKZ] Failure of Steering Pump Selector Sol. ........................................... 40-699
Failure code [DWNJKZ] Failure of TCS Shut off Sol. (Front)................................................. 40-701
Failure code [DWNKKZ] Failure of TCS Shut off Sol. (Center) .............................................. 40-703
Failure code [DX13KA] Disconnection of Hoist EPC Solenoid .............................................. 40-705
Failure code [DX13KB] Ground Fault of Hoist EPC Solenoid................................................ 40-707
Failure code [DX13KY] Hot Short of Hoist EPC Solenoid ..................................................... 40-709
Failure code [DX16KA] Disconnection of Rad. Fan Pump EPC Sol....................................... 40-711
Failure code [DX16KB] Ground Fault of Rad. Fan Pump EPC Sol. ....................................... 40-712
Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol. ....................................... 40-714
Failure code [DX29KA] Disconnection of CAC Fan Pump EPC Sol....................................... 40-715
Failure code [DX29KB] Ground Fault of CAC Fan Pump EPC Sol. ....................................... 40-716
Failure code [DX29KY] Hot Short of CAC Fan Pump EPC Sol.............................................. 40-717
Failure code [DX30K4] Release Trouble of Retarder EPC Valve(FL)..................................... 40-718
Failure code [DX30KA] Disconnection of Retarder EPC Sol. (FL) ......................................... 40-720
Failure code [DX30KB] Ground Fault of Retarder EPC Sol. (FL)........................................... 40-722
Failure code [DX30KY] Hot Short of Retarder EPC Sol. (FL) ................................................ 40-724
Failure code [DX30MA] Malfunction of Retarder EPC Valve (FL) .......................................... 40-726
Failure code [DX31K4] Release Trouble of Retarder EPC Valve(CR).................................... 40-728
Failure code [DX31KA] Disconnection of Retarder EPC Sol. (CR) ........................................ 40-730
Failure code [DX31KB] Ground Fault of Retarder EPC Sol. (CR).......................................... 40-732
Failure code [DX31KY] Hot Short of Retarder EPC Sol. (CR) ............................................... 40-734
Failure code [DX31MA] Malfunction of Retarder Valve (CR) ................................................. 40-736
Failure code [DX32K4] Release Trouble of Retarder EPC Valve(CL) .................................... 40-738
Failure code [DX32KA] Disconnection of Retarder EPC Sol. (CL)......................................... 40-740
Failure code [DX32KB] Ground Fault of Retarder EPC Sol. (CL) .......................................... 40-742
Failure code [DX32KY] Hot Short of Retarder EPC Sol. (CL)................................................ 40-744
Failure code [DX32MA] Malfunction of Retarder EPC Valve (CL).......................................... 40-746
Failure code [DX33K4] Release Trouble of Retarder EPC Valve(FR) .................................... 40-748
Failure code [DX33KA] Disconnection of Retarder EPC Sol. (FR)......................................... 40-750
Failure code [DX33KB] Ground Fault of Retarder EPC Sol. (FR) .......................................... 40-752
Failure code [DX33KY] Hot Short of Retarder EPC Sol. (FR) ............................................... 40-753
Failure code [DX33MA] Malfunction of Retarder EPC Valve (FR).......................................... 40-755
Failure code [DXH0KA] Disconnection of ECMV (Inter-Axle Diff.) ......................................... 40-757
Failure code [DXH0KB] Ground Fault of ECMV (Inter-Axle Diff.)........................................... 40-759
Failure code [DXH0KY] Hot Short of ECMV (Inter-Axle Diff.) ................................................ 40-761
Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) ..................................... 40-763
Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) ....................................... 40-765
Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) ............................................ 40-767
Failure code [DXH2KA] Disconnection of ECMV Solenoid (High) ......................................... 40-769
Failure code [DXH2KB] Ground Fault of ECMV Solenoid (High) ........................................... 40-771
00-10 HM300–3
Index
Failure code [DXH2KY] Hot Short of ECMV Solenoid (High) ................................................ 40-773
Failure code [DXH3KA] Disconnection of ECMV Solenoid (Low) .......................................... 40-774
Failure code [DXH3KB] Ground Fault of ECMV Solenoid (Low)............................................ 40-776
Failure code [DXH3KY] Hot Short of ECMV Solenoid (Low) ................................................. 40-778
Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st)............................................ 40-781
Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) ............................................. 40-783
Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st)................................................... 40-785
Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd)........................................... 40-788
Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) ............................................ 40-790
Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd).................................................. 40-792
Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) ........................................... 40-795
Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) ............................................. 40-797
Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) .................................................. 40-799
Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse).................................... 40-802
Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) ..................................... 40-804
Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse)........................................... 40-806
Failure code [DY30MA] Malfunction 1 of Emerg. Steering Motor........................................... 40-809
Failure code [DY30MC] Malfunction 2 of Emerg. Steering Motor .......................................... 40-811
Failure code [DY30ME] Emerg. Steering Long-Time Activated ............................................. 40-814
Troubleshooting of electrical system (E-mode) .......................................................................... 40-816
E-1 Engine does not start (Engine does not rotate).............................................................. 40-816
E-2 Manual preheating system does not work..................................................................... 40-822
E-3 Automatic preheating system does not work................................................................. 40-825
E-4 While preheating is working, preheating monitor does not light up .................................. 40-826
E-5 All of LCD unit, LED unit and meter unit on machine monitor display nothing ................... 40-827
E-6 LCD unit on machine monitor displays nothing.............................................................. 40-829
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or
flickers) .............................................................................................................. 40-831
E-8 LCD on machine monitor does not display properly ....................................................... 40-833
E-9 Meter unit display on machine monitor is abnormal ....................................................... 40-835
E-10 Night lighting lamp of meter unit on machine monitor is abnormal ................................. 40-838
E-11 Caution LED on machine monitor is abnormal............................................................. 40-841
E-12 LED of switch panel on machine monitor is abnormal or switches does not operate
properly ............................................................................................................. 40-843
E-13 2 switches operation of switch panel on machine monitor does not function................... 40-845
E-14 Switch panel buzzer of machine monitor is abnormal................................................... 40-848
E-15 Rear view monitor does not light up or backlight flickers............................................... 40-850
E-16 Rear view monitor images are not displayed clearly..................................................... 40-852
E-17 Rear view monitor brightness cannot be adjusted........................................................ 40-855
E-18 Night lighting lamp of rear view monitor is abnormal .................................................... 40-858
E-19 Rear view monitor does not display images while R-linked display function is
enabled ............................................................................................................. 40-860
E-20 Guide line on rear view monitor is not displayed while guide line is set .......................... 40-863
E-21 Some items of gauges and caution lamps on machine monitor are not displayed
properly ............................................................................................................. 40-865
E-22 Fuel level gauge does not indicate correct level .......................................................... 40-866
E-23 Seat belt caution lamp indication is abnormal.............................................................. 40-868
E-24 Machine monitor cannot be operated when starting switch is in OFF position ................ 40-869
E-25 Alarm buzzer does not sound .................................................................................... 40-870
E-26 Alarm buzzer does not stop sounding......................................................................... 40-872
E-27 Engine mode selector function does not operate properly ............................................ 40-873
E-28 AISS function does not operate properly..................................................................... 40-874
E-29 Hoist lever does not operate properly ......................................................................... 40-875
E-30 Turn signal lamp and winker lamp (hazard lamp) do not operate properly ...................... 40-877
E-31 All of small lamp (clearance lamp and tail lamp) and head lamp do not light up .............. 40-881
E-32 Small lamp (clearance lamp) does not light up ............................................................ 40-883
E-33 Tail lamp does not light up ......................................................................................... 40-885
E-34 "Low beam" head lamp does not light up .................................................................... 40-887
E-35 "High beam" head lamp does not light up ................................................................... 40-889
HM300–3 00-11
Index
E-36 Neither "Low beam" nor "High beam" head lamps lights up .......................................... 40-891
E-37 Passing lamp does not light up .................................................................................. 40-893
E-38 KOMTRAX does not operate properly ........................................................................ 40-895
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................. 40-897
Information mentioned in troubleshooting table (H mode) .................................................... 40-897
System diagram of hydraulic and mechanical systems ........................................................ 40-898
Failure mode and cause table ........................................................................................... 40-900
H-1 Machine does not start ............................................................................................... 40-904
H-2 Machine does not travel smoothly (machine hunts) ....................................................... 40-906
H-3 Lockup is not released................................................................................................ 40-907
H-4 Start shock and gear shift shock are abnormally large ................................................... 40-908
H-5 Gear is not shifted up ................................................................................................. 40-909
H-6 Machine lacks travel speed or power when traveling in lockup drive mode at all gear
speeds............................................................................................................... 40-911
H-7 Machine lacks travel speed or power when traveling in torque converter drive
mode ................................................................................................................. 40-912
H-8 Machine lacks travel speed or power when traveling at some gear speed ....................... 40-913
H-9 Large time lag is observed when machine starts and gear is shifted ............................... 40-914
H-10 Oil temperature of torque converter is high ................................................................. 40-916
H-11 Oil pressure of torque converter is low........................................................................ 40-917
H-12 Front brake does not work enough............................................................................. 40-918
H-13 Center brake does not work enough .......................................................................... 40-919
H-14 Steering wheel is heavy ............................................................................................ 40-920
H-15 Steering wheel does not turn ..................................................................................... 40-921
H-16 Steering wheel waggles............................................................................................ 40-922
H-17 Dump body rising speed is low .................................................................................. 40-923
H-18 Dump body does not move ....................................................................................... 40-924
H-19 Dump body hydraulic drift is large .............................................................................. 40-925
H-20 Radiator fan speed is unusual (excessively high or low, or fan stops)............................ 40-926
H-21 Aftercooler fan speed is unusual (excessively high or low, or fan stops) ........................ 40-927
H-22 Unusual noise is heard from around radiator fan ......................................................... 40-928
H-23 Unusual noise is heard from around aftercooler fan..................................................... 40-929
Troubleshooting of engine (S-mode)......................................................................................... 40-930
Information mentioned in troubleshooting table (S mode)..................................................... 40-930
S-1 When starting switch is turned to START position, engine is not cranked......................... 40-931
S-2 The engine cranks but exhaust smoke does not come out ............................................. 40-932
S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start
but does not) ...................................................................................................... 40-933
S-4 Startability is poor....................................................................................................... 40-934
S-5 Engine does not pick-up smoothly ............................................................................... 40-936
S-6 Engine stops during operation ..................................................................................... 40-938
S-7 Engine runs rough or is unstable ................................................................................. 40-940
S-8 Engine lacks power .................................................................................................... 40-941
S-9 Exhaust gas is black (KDPF gets clogged in a short time) .............................................. 40-943
S-10 Engine oil consumption is excessive .......................................................................... 40-945
S-11 Engine oil becomes contaminated early...................................................................... 40-946
S-12 Fuel consumption is excessive .................................................................................. 40-947
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)...................................... 40-948
S-14 Oil pressure drops .................................................................................................... 40-949
S-15 Fuel mixes into engine oil.......................................................................................... 40-950
S-16 Water mixes into engine oil (milky) ............................................................................. 40-951
S-17 Coolant temperature rises too high (overheating) ........................................................ 40-952
S-18 Unusual noise is made ............................................................................................. 40-953
S-19 Vibration is excessive ............................................................................................... 40-954
S-20 Air cannot be bled from fuel circuit ............................................................................. 40-955
S-21 Active regeneration is executed frequently ................................................................. 40-956
S-22 Active regeneration takes a long time......................................................................... 40-957
S-23 White smoke is exhausted during active regeneration ................................................. 40-958
50 Disassembly and Assembly ........................................................................................................... 50-1
00-12 HM300–3
Index

General information on disassembly and assembly........................................................................ 50-4
How to read this manual ....................................................................................................... 50-4
Coating materials list ............................................................................................................ 50-6
Special tools list ................................................................................................................. 50-10
Sketches of special tools .................................................................................................... 50-15
Engine and cooling system ........................................................................................................ 50-30
Removal and installation of fuel supply pump assembly......................................................... 50-30
Removal and installation of injector assembly....................................................................... 50-37
Removal and installation of cylinder head assembly.............................................................. 50-49
Removal and installation of radiator assembly ...................................................................... 50-61
Removal and installation of radiator fan and fan motor........................................................... 50-64
Removal and installation of aftercooler assembly .................................................................. 50-67
Removal and installation of aftercooler fan and fan motor ...................................................... 50-71
Removal and installation of engine assembly ....................................................................... 50-74
Removal and installation of engine front oil seal .................................................................... 50-81
Removal and installation of engine rear oil seal..................................................................... 50-86
Removal and installation of output shaft assembly ................................................................ 50-91
Disassembly and assembly of output shaft ........................................................................... 50-95
Removal and installation of KDPF assembly......................................................................... 50-98
Disassembly and assembly of KDPF ................................................................................. 50-102
Removal and installation of KCCV assembly .......................................................................50-111
Removal and installation of air cleaner assembly ................................................................ 50-112
Power train............................................................................................................................. 50-114
Removal and installation of transmission and front differential assembly ............................... 50-114
Disconnection and connection of front differential assembly and transmission
assembly ........................................................................................................... 50-126
Disassembly and assembly of front differential.................................................................... 50-127
Disassembly and assembly of torque converter .................................................................. 50-138
Disassembly and assembly of transmission........................................................................ 50-145
Removal and installation of center differential assembly ...................................................... 50-181
Disassembly and assembly of center differential ................................................................. 50-185
Removal and installation of rear differential assembly.......................................................... 50-197
Disassembly and assembly of rear differential .................................................................... 50-199
Removal and installation of front final drive and brake assembly........................................... 50-208
Disassembly and assembly of front final drive and brake ..................................................... 50-214
Removal and installation of center final drive and brake....................................................... 50-224
Disassembly and assembly center final drive and brake ...................................................... 50-226
Disassembly and assemble rear final drive ......................................................................... 50-233
Removal and installation of center axle assembly ............................................................... 50-239
Removal and installation of rear axle assembly................................................................... 50-242
Undercarriage and frame......................................................................................................... 50-244
Removal and installation of front suspension cylinder assembly ........................................... 50-244
Removal and installation of rear suspension assembly ........................................................ 50-249
Disassembly and assembly of suspension cylinder ............................................................. 50-251
Removal and installation of equalizer bar assembly ............................................................ 50-253
Removal and installation of hitch frame assembly ............................................................... 50-256
Disassembly and assembly of hitch frame .......................................................................... 50-265
Hydraulic system .................................................................................................................... 50-270
Removal and installation of flow amplifier valve assembly.................................................... 50-270
Removal and installation of hoist valve assembly ................................................................ 50-273
Disassembly and assembly of steering cylinder .................................................................. 50-275
Disassembly and assembly of hoist cylinder ....................................................................... 50-281
Body...................................................................................................................................... 50-287
Removal and installation of body assembly ........................................................................ 50-287
Cab and its attachments .......................................................................................................... 50-290
Removal and installation of operator's cab assembly........................................................... 50-290
Removal and installation of operator's cab glass (adhered window glass) ............................. 50-294
Removal and installation of operator seat assembly ............................................................ 50-300
HM300–3 00-13
Index
Electrical system .................................................................................................................... 50-302

Removal and installation of machine monitor assembly ....................................................... 50-302
Removal and installation of engine controller assembly ....................................................... 50-304
Removal and installation of retarder and hoist controller assembly ....................................... 50-306
Removal and installation of transmission controller assembly .............................................. 50-307
Removal and installation of mass air flow and temperature sensor ....................................... 50-308
Removal and installation of KOMTRAX terminal assembly .................................................. 50-309
Air conditioner components ..................................................................................................... 50-310
Removal and installation of air conditioner unit assembly..................................................... 50-310
Removal and installation of air conditioner compressor assembly......................................... 50-314
60 Maintenance standard................................................................................................................... 60-1
Engine and cooling system .......................................................................................................... 60-3
Output shaft......................................................................................................................... 60-3
Radiator fan pump................................................................................................................ 60-4
Radiator in-fan motor............................................................................................................ 60-6
Aftercooler in-fan motor ........................................................................................................ 60-8
Power train............................................................................................................................... 60-10
Drive shaft ......................................................................................................................... 60-10
Torque converter ................................................................................................................ 60-11
Transmission ..................................................................................................................... 60-14
Transmission control valve.................................................................................................. 60-23
Forward and reverse clutch ECMV and gear speed clutch ECMV ........................................... 60-24
Lockup clutch ECMV .......................................................................................................... 60-25
Differential lock clutch ECMV .............................................................................................. 60-26
Main relief valve, torque converter relief valve, and main flow selector valve............................ 60-27
Axle .................................................................................................................................. 60-29
Differential ......................................................................................................................... 60-32
Final drive ......................................................................................................................... 60-35
Steering system........................................................................................................................ 60-39
Steering column................................................................................................................. 60-39
Steering cylinder ................................................................................................................ 60-40
Brake system ........................................................................................................................... 60-41
Slack adjuster .................................................................................................................... 60-41
Brake ................................................................................................................................ 60-43
Parking brake .................................................................................................................... 60-45
Undercarriage and frame........................................................................................................... 60-47
Suspension ....................................................................................................................... 60-47
Suspension cylinder ........................................................................................................... 60-51
Oscillation hitch ................................................................................................................. 60-52
Hydraulic system ...................................................................................................................... 60-54
Steering and hoist control pump .......................................................................................... 60-54
Front brake cooling duplex pump and aftercooler fan pump ................................................... 60-59
Center brake cooling pump ................................................................................................. 60-60
Brake charge pump ............................................................................................................ 60-61
Hoist valve ........................................................................................................................ 60-62
Hoist cylinder..................................................................................................................... 60-64
80 Appendix...................................................................................................................................... 80-1
Air conditioner ............................................................................................................................ 80-3
Precautions for refrigerant..................................................................................................... 80-3
Air conditioner component .................................................................................................... 80-4
Configuration and function of refrigeration cycle...................................................................... 80-7
Outline of refrigeration cycle.................................................................................................. 80-8
Air conditioner unit ............................................................................................................. 80-10
Dual pressure switch .......................................................................................................... 80-15
Air conditioner controller ..................................................................................................... 80-16
Air conditioner compressor ................................................................................................. 80-17
Condenser ........................................................................................................................ 80-18
00-14 HM300–3
Index
Receiver drier .................................................................................................................... 80-19

Outside air temperature sensor ........................................................................................... 80-20
Procedure for testing and troubleshooting ............................................................................ 80-21
Circuit diagram and arrangement of connector pins............................................................... 80-23
System diagram................................................................................................................. 80-25
Input and output signals of the air conditioner controller ......................................................... 80-26
Parts and connectors layout................................................................................................ 80-28
Layout of air conditioner related parts and connectors ........................................................... 80-29
Testing air leakage (duct) .................................................................................................... 80-33
Testing with self-diagnosis function ...................................................................................... 80-36
How to enter air conditioner "Electrical Systems" screen in service mode of the machine
monitor ................................................................................................................ 80-37
Testing vent (mode) changeover.......................................................................................... 80-39
Testing FRESH/RECIRC air changeover.............................................................................. 80-40
Testing (dual) pressure switch for refrigerant......................................................................... 80-41
Testing relays .................................................................................................................... 80-43
Troubleshooting chart 1 ...................................................................................................... 80-45
Troubleshooting chart 2 ...................................................................................................... 80-46
Information mentioned in troubleshooting table ..................................................................... 80-49
Failure code list related to air conditioner.............................................................................. 80-50
Failure code [879AKA] A/C Inner sensor Open Circuit ........................................................... 80-51
Failure code [879AKB] A/C Inner sensor Short Circuit ........................................................... 80-52
Failure code [879BKA] A/C Outer sensor Open Circuit .......................................................... 80-53
Failure code [879BKB] A/C Outer sensor Short Circuit .......................................................... 80-55
Failure code [879CKA] Ventilating sensor Open Circuit ......................................................... 80-57
Failure code [879CKB] Ventilating sensor Short Circuit.......................................................... 80-58
Failure code [879EMC] Ventilating Damper Abnormality ........................................................ 80-59
Failure code [879FMC] Air Mix Damper Abnormality ............................................................. 80-60
Failure code [879GKX] Refrigerant Abnormality .................................................................... 80-61
A-1 Troubleshooting for power supply system (Air conditioner does not operate) ..................... 80-63
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ........................ 80-65
A-3 Troubleshooting for blower motor system (No air comes out or air flow is
abnormal) ............................................................................................................ 80-68
A-4 Troubleshooting for FRESH/RECIRC air changeover ...................................................... 80-70
Troubleshooting with gauge pressure................................................................................... 80-72
Connection of service tool................................................................................................... 80-75
Precautions for disconnecting and connecting air conditioner piping ....................................... 80-76
Handling of compressor oil.................................................................................................. 80-78
90 Diagrams and drawings................................................................................................................. 90-1
Hydraulic circuit diagram ............................................................................................................. 90-3
Symbols in hydraulic circuit diagram ...................................................................................... 90-3
Power train hydraulic circuit diagram...................................................................................... 90-7
Steering and hoist hydraulic circuit diagram............................................................................ 90-9
Brake hydraulic circuit diagram............................................................................................ 90-10
Brake cooling system hydraulic circuit diagram ..................................................................... 90-11
Electric circuit diagram .............................................................................................................. 90-13
Symbols in electric circuit diagram ....................................................................................... 90-13
Inside cab electric circuit diagram ........................................................................................ 90-17
Outside cab electric circuit diagram ..................................................................................... 90-31
Index.................................................................................................................................................................... 1
HM300–3 00-15
Foreword, safety and general information

Important safety notice
(Rev. 2011/02)
• Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The
Shop Manual describes the effective and safe servicing and repair methods recommended by Komatsu.
Some of these methods require the use of special tools designed by Komatsu for the specific purpose.
• The symbol mark k is used for such matters that require special precautions during the work. The work
indicated with the warning mark should be performed according to the instructions with special attention to
the precautions. Should a hazardous situation occur or be anticipated during such work, be sure to keep
safe first and take every necessary measure.
General precautions wear welding gloves, apron, shielding goggles,

cap and other clothes suited for welding work.
k Inappropriate handling creates an extreme • Before starting work, warm up your body
danger. Read and understand what is thoroughly to start work under good condition.
described in the Operation and Maintenance • Avoid continuing work for long hours and take
Manual before operating the machine. In rests at proper intervals to keep your body in
addition read this manual carefully and good condition. Take rests in specified safe
understand its contents before starting work. places.
• Before performing any greasing or repairs, read Safety points
all the safety labels stuck to the machine. For 1 Good arrangement
the locations of the safety labels and detailed 2 Correct work clothes
explanation of precautions, see the Operation Following work standard
3
and Maintenance Manual.
4 Making and checking signals
• Locate a place in the repair workshop to keep
Prohibition of operation and handling by
tools and removed parts. Always keep the tools 5
unlicensed workers
and parts in their correct places. Always keep
6 Safety check before starting work
the work area clean and make sure that there is
Wearing protective goggles (for cleaning or
no dirt, water, or oil on the floor. Smoke only in 7 grinding work)
the areas provided for smoking. Never smoke
Wearing shielding goggles and protectors (for
while working. 8 welding work)
• When performing any work, always wear safety
shoes and helmet. Do not wear loose work 9 Good physical condition and preparation
clothes, or clothes with buttons missing. Precautions against work which you are not
10 used to or you are used to too much
1. Always wear the protective eyeglasses when
hitting parts with a hammer. Preparation work
2. Always wear the protective eyeglasses when • Before adding oil or making any repairs, park the
grinding parts with a grinder, etc. machine on a hard and level ground, and apply
• When performing any work with two or more the parking brake and chock the wheels or
workers, always agree on the operating tracks to prevent the machine from moving.
procedure before starting. Always inform your • Before starting work, lower the work equipment
fellow workers before starting any step of the (blade, ripper, bucket, etc.) to the ground. If this
work. During the work, hang UNDER REPAIR is not possible, insert the lock pin or use blocks
warning tag in the operator's compartment. to prevent the work equipment from falling. In
• Only qualified workers must perform the work addition, be sure to lock all the control levers
and operation which require license or and hang warning tag on them.
qualification. • When disassembling or assembling, support the
• Keep all tools in good condition. Learn the machine with blocks, jacks, or stands before
correct way to use them, and use the proper starting the work.
ones of them. Before starting work, thoroughly • Remove all mud and oil from the steps or other
check the tools, machine, forklift truck, service places used to get on and off the machine.
car, etc. Always use the handrails, ladders or steps when
• If welding repairs are needed, always have a getting on or off the machine. Never jump on or
trained and experienced welder perform the off the machine. When a scaffolding is not
work. When performing welding work, always
00-16 HM300–3
provided, use steps or a step ladder to secure When installing hoses and wires, be sure that
your footing. they will not be damaged by contact with other
parts when the machine is operated.
Precautions during work • When installing high pressure hoses and tubes,
• For the machine equipped with a battery make sure that they are not twisted. Damaged
disconnect switch, before starting the work, hoses and tubes are dangerous, so be
check that the system operating lamp is turned extremely careful when installing hoses and
OFF, and then turn the battery disconnect switch tubes for high-pressure circuits. In addition,
to the OFF (Q) position and pull the switch key check that connections of them are correct.
out. For machines without a battery disconnect • When assembling or installing parts, always
switch, before starting the work, remove the tighten them to the specified torques. When
cables from the battery. Always remove the installing protective parts such as guards, or
cable from the negative (–) terminal first. parts which vibrate violently or rotate at high
• Before disconnecting or removing components speeds, be particularly careful to check that they
of the oil, water, or air circuits, first release the are installed correctly.
remaining pressure completely from the circuit. • When aligning two holes, never insert your
When removing the oil filter cap, a drain plug, or fingers or hand. Be careful not to get your
an oil pressure pickup plug, loosen it slowly to fingers caught in a hole.
prevent the oil from spurting out. • When measuring hydraulic pressure, check that
• The coolant and oil in the circuits are hot when the measuring tools are correctly installed.
the engine is shut down. Be careful not to get • Take care when removing or installing the tracks
scalded. Wait for the oil and coolant to cool of track-type machines. When removing the
before performing any work on the oil or water track, the track separates suddenly, so never let
circuits. anyone stand at either end of the track.
• Before starting work, shut down the engine. • If the engine is operated for a long time in a
When working on or around a rotating part, in place which is not ventilated well, you may suffer
particular, shut down the engine. When checking from gas poisoning. Accordingly, open the
the machine without stopping the engine windows and doors to ventilate well.
(measuring oil pressure, revolving speed,
temperature, etc.), take extreme care not to get Precautions for slinging work and making
rolled or caught in rotating parts or moving parts. signals
• When raising a heavy component (heavier than • Only one appointed worker must make signals
25 kg), use a hoist or crane. Before starting work, and co-workers must communicate with each
check that the slings (wire ropes, chains, and other frequently. The appointed signaler must
hooks) are free from damage. Always use slings make specified signals clearly at a place where
which have ample capacity and install them to he (she) is well seen from the operator's seat
proper places. Operate the hoist or crane slowly and where he (she) can see the working
to prevent the component from hitting any other condition easily. The signaler must always stand
part. Do not work with any part still raised by the in front of the load and guide the operator safely.
hoist or crane. 1. Do not stand under the load.
• When removing a cover which is under internal 2. Do not step on the load.
pressure or under reaction force of a spring, • Check the slings before starting sling work.
always leave two bolts in diagonal positions. • Keep putting on gloves during sling work. (Put
Loosen those two bolts gradually and alternately on leather gloves, if available.)
to release the pressure, and then remove the • Measure the weight of the load by the eye and
cover. check its center of gravity.
• When removing components, be careful not to • Use proper sling according to the weight of the
break or damage the electrical wiring. Damaged load and method of slinging. If too thick wire
wiring may cause electrical fires. ropes are used to sling a light load, the load may
• When removing piping, stop the fuel or oil from slip and fall.
spilling out. If any fuel or oil drips onto the floor, • Do not sling a load with one wire rope alone. If it
wipe it off immediately. Fuel or oil on the floor is slung by one wire rope, It may rotate and slip
can cause you to slip and can even cause fires. out of the rope. Install two or more wire ropes
• As a general rule, do not use gasoline to wash symmetrically.
parts. Do not use it to clean electrical parts, in
particular.
• Be sure to assemble all parts again in their
original places. Replace any damaged parts and
parts which must not be reused with new parts.
HM300–3 00-17
50 Disassembly and Assembly
Engine and cooling system
2) Remove tubes (25) and (30). 5) Remove two mounting bolts (55).
3) Disconnect tube (43). [*11] 6) Remove oil filter mounting block (50).
4) Disconnect hose (44).
5) Remove four mounting bolts (45).
6) Remove fuel pre-filter assembly (37).
8. Remove oil filter assembly (46) according to the
following procedure.
1) Disconnect tubes (47) and (48).
3) Remove oil filter assembly (46).
10.Remove fuel pre-filter mounting bracket (56)

according to the following procedure.
1) Disconnect harness clamp (57).
2) Remove brackets (58) and (58a) as a unit.
9. Remove oil filter mounting bracket (50)

1) Remove bracket (51).
2) Remove brackets (52) and (53) as a unit.
3) Release harness connector (59) from the

clip.
4) Disconnect harness connector (60).
5) Release harness connectors (61) to (63)
from clips of bracket (56).
7) Remove fuel pre-filter mounting bracket (56).
3) Remove connector from clip of cover (54).

4) Remove cover (54).
HM300–3 50-39
11.Remove mixing connector and EGR assembly

(65) according to the following procedure.
1) Disconnect radiator overflow hose clamp
(66).
2) Disconnect harness clamps (67a) and (67b).
12)Remove EGR mounting bolts (76) to (78),

two bolts each.
3) Disconnect two harness clamps (67c) and

(67d).
4) Disconnect harness connectors CN-EGR-
SOL (68), and CN-SEGR (69).
5) Disconnect wiring harness (70).
6) Disconnect tube clamp (71).

7) Remove joint bolts (72a) and (72b), and then
remove tube (72). [*12]
8) Remove joint bolts (73a) and (73b), and then
remove tube (73). [*13]
9) Remove four mounting bolts (74a). [*14]
10)Remove two mounting bolts (74b).
11)Remove EGR valve (75).
50-40 HM300–3
2) Move flat-head screwdriver [1] in direction X

to disconnect connector (c).
14.Remove spill tube (87).
13)Lift up and remove mixing connector and

EGR assembly (65).
12.Disconnect following hoses and wiring

harnesses above the cylinder head cover.
15.Remove high-pressure fuel pipes (88) to (93)
1) Disconnect KVGT stroke sensor harnesses according to the following procedure.
(79a) and KVGT rotation sensor harnesses
1) Remove bracket (94).
(79b) from bracket (79).
2) Disconnect turbocharger lubrication tube
(81a) from bracket (81).
3) Remove brackets (79) to (81).
4) Disconnect wiring harness (82a) from
bracket (82).
5) Remove three mounting bolts (82b), and the
disconnect bracket (82).
2) Remove the fuel spray prevention caps.

a Caps on common rail side (95a): six caps
Caps on inlet connector side (95b): six
caps
13.Disconnect harness connector (86).

a Disconnect connectors according to the
1) Insert the tip of flat-head screwdriver [1] into
stepped portion (a) and push stopper (b).
HM300–3 50-41
3) Remove fuel high pressure piping clamps 16.Remove cylinder head cover (106).
(96) and (97).
a Subsequent procedure is common to
• Clamp (96): 1 set removal of No. 1 to No. 6 cylinders, so
a To remove outer clamp (96), be removal procedure of No. 1 cylinder injector
careful not to drop sleeve (96a). assembly is shown below as an example.
• Clamp (97): 4 sets
4) Remove 6 sets of clamp (100) from fuel high
pressure piping brackets (98) and (99).
a It is not necessary to remove fuel high
pressure piping brackets (98) and (99),
but loosen all mounting bolts.
17.Loosen two nuts (107), and then disconnect

injector harness.
a Fully loosen the nuts alternately.
18.Remove mounting bolt (109a) of holder (109)
and then reposition injector harness out of the
way.
5) Fully loosen sleeve nut (105a) on common 19.Remove rocker shaft mounting bolt (110)
rail side and sleeve nut (105b) on injector according to the following procedure.
side. 1) Loosen locknut (111), and then loosen
6) Remove high-pressure fuel pipes (88) to adjustment screw (112).
(93).
50-42 HM300–3
a adjustment screw (112) must be left

loosened to prevent the push rods from
being damaged due to excessive forces
applied to the push rods when the rocker
arms are installed.
2) Remove rocker arm and shaft mounting bolt
(113).
3) Remove rocker arm and shaft assembly
(110).
(Reading order of character string)
20.Remove injector assembly according to the

a Before removing the injector, note the
cylinder number to which the injector is
installed and the character string (M) listed 2) Insert "L" shaped bar [1] into the connector
on the QR code tab (Q) as a set. portion (a) of the injector, and then pry up
injector (114).
a Check that the noted character string is
correct. a Never grip the solenoid valve at the top of
the fuel injector with pliers, etc. to pull out
a Do not remove QR code tab (Q) attached to
the injector.
the injector head.
3) Remove injector assembly (114) and holder
a Do not damage QR code tab (Q) attached to (115) as a unit.
the injector head.
(Reference: The QR code or character string
indicates the offset value for fuel injection of
the injector, which is specific to each
injector.))
1) Remove mounting bolt (116) of holder (115).
Installation
a Wash off and remove dirt and dust attached on
the parts near harness connectors to prevent
them from entering connectors.
a Use clean engine oil when applying engine oil to
O-rings and lubricated portions.
HM300–3 50-43
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a When replacing the injector assembly or engine 1) Install gasket (117) and O-rings (118) and
controller assembly, write the character string (119) to injector assembly (114).
into the engine controller according to the
2 O-ring:
following procedure. For details, see Testing and
adjusting, "Writing offset value when replacing Engine oil (SAE 30 or equivalent)
injector and engine controller". 2) Set holder (115) to injector assembly (114),
and then install the assembly into injector
• Note the number of cylinder to which a new
assembly mounting bore (h).
injector is installed and character string (M)
listed on the QR code tab at the top of the a Pay special attention on following points
injector as a set. when installing injector assemblies to
respective cylinders.
a Be sure to check that the noted character
string is correct. • When reusing the injector assemblies or
• Write the noted character string into the engine engine controller assembly, check the
controller. cylinder numbers and character strings
noted at the time of removal, and install
a Be sure to write the noted character string the injector assemblies to the
into the cylinder number column of the corresponding cylinders.
cylinder to which the injector is installed. • When replacing the injector assemblies
a If the offset values are not written correctly, or engine controller assembly with new
the engine may not operate normally. ones, check the cylinder numbers and
character strings written in the engine
(Reference: The QR code or character string
controller assembly, and install the
indicates the offset value for fuel injection of
injector assemblies to the corresponding
the injector, which is specific to each
cylinders.
injector.))
• When replacing some injector assemblies
with new ones, check the cylinder
numbers and character strings written in
the engine controller assembly, and
install the injector assemblies to the
corresponding cylinders
a Face inlet connector (a) toward high-
pressure fuel pipe insertion portion (v) of
the rocker housing.
a Check that the injector assembly is fitted
to the bottom securely.
3) Finger-tighten bolt (116) with spherical
washer (120) to install holder (115) partially.
(Reading order of character string (M) )
2 Spherical washer:
Engine oil (SAE 30 or equivalent)
1. Install injector assembly (114) according to the

a Check that the injector assembly mounting
bore in the cylinder head is free from dust.
50-44 HM300–3
3) Tighten mounting bolt (113) while checking

following points.
a Check that the push rod is free from
excessive force and can move to the right
and left lightly.
a If the push rod cannot move to the right
and left lightly, excessive force is applied
to the push rod. Stop tightening mounting
bolt (113) and loosen adjustment screw
(112) further.
4) Tighten mounting bolt (113) to the specified
torque.
4) Insert sleeve nut (105b) of the high-pressure
fuel pipe into high-pressure fuel pipe 3 Mounting bolt (113):
insertion portion (P). 58.8 to 73.5 Nm {6.0 to 7.5 kgm}
5) Set sleeve nut (105b) to the threaded portion 3. Adjust the valve clearance. For details, see
of inlet connector (a), and finger-tighten the Testing and adjusting, "Measuring and adjusting
sleeve nut. valve clearance".
a Finger-tighten sleeve nut (105a) on the 3 Lock nut (111):
common rail side.
58.8 to 73.5 Nm {6 to 7.5 kgm}
6) Tighten holder (115) to the specified torque.

4. Install injector harness (108) according to the
a While pulling the tube of high-pressure following procedure.
fuel pipe (88) in the opposite direction of
1) Tighten mounting bolt (109a) of holder (109).
the injector, tighten mounting bolt (116).
3 Holder mounting bolt (109a):
3 Holder mounting bolt:
27 to 34 Nm {2.8 to 3.5 kgm}
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
2) Set the harness terminal to the injector head.
2. Install rocker arm and shaft assembly (110)
3) Tighten two nuts (107) alternately to fix
injector harness (108).
1) Set rocker arm and shaft assembly (110).
3 Nut:
a Install the rocker arm shaft with its larger
2.0 to 2.4 Nm {0.2 to 0.24 kgm}
mounting hole end down and its ball plug
(121) end forward.
2) Check the following points before tightening
mounting bolt (113).
a Clean the oil hole in the mounting bolt
and check that it is free from dirt.
a Check that adjustment screw (112) is
loosened fully.
a Check that the ball of adjustment screw
(112) is fitted in push rod socket (c) and
tighten mounting bolt (113).
HM300–3 50-45
5. Fit O-ring and install cylinder head cover (106).

a When the common rail assembly (123) is
a Fit the O-ring straight removed, tighten its mounting bolts to the
3 Mounting bolt: following torque.
9.8±1 Nm {1.0±0.1 kgm} 3 Common rail mounting bolt:
59 to 74 Nm {6 to 7.5 kgm}
1) Tighten sleeve nuts of high-pressure fuel
pipes (88) to (93) to the specified torque.
3 Sleeve nut (105a) on common rail
side:
39.2 to 44.1 Nm {4 to 4.5 kgm}
3 Sleeve nut (105b) on injector side:
39.2 to 44.1 Nm {4 to 4.5 kgm}
2) Install fuel spray prevention caps.
k Install the cap with its slit facing as

6. Install the high-pressure fuel pipes according to follows.
the following procedure. • Cap (95a) on common rail side:
Toward cylinder block
k Be sure to use genuine high-pressure fuel • Cap (95b) on injector side: Downward
pipe clamps and observe the specified
tightening torque.
k Do not correct the fuel high-pressure pipe by

bending for installation.
k Before installing the high-pressure fuel pipe,

check the following.
High-pressure fuel pipe having any defect
can cause fuel leakage. Accordingly, replace
the high-pressure fuel pipe with a new one.
• Visually check that the taper seal portion of
the connection ((a) portion: 2 mm area from 3) Finger-tighten high-pressure fuel pipe
the tip-end) is free from longitudinal slits (b) clamps (97), (98) and (100).
or dents (c).
• (Check that part d (2 mm from the end of a Check that all of high-pressure fuel pipe
taper seal) is free from the stepped wear brackets (98) and (99) remain loosened.
which can be felt with your fingernail. a Finger-tighten high-pressure fuel pipe
(Namely, this part must be free from fatigue.) brackets (98) and (99) if they have been
removed.
4) Tighten the mounting bolt of high-pressure
fuel pipe clamp (100) to the specified torque.
50-46 HM300–3

Komatsu hm300 3 Articulated Dump Truck Service Repair

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SEN05629-01

Proportional pressure reducing valve ................................................................................. 10-120

Failure code [15F0MB] Abuse 2 of Gear Shifting from R to F................................................ 40-120

Failure code [D19JKZ] Personal Code Relay Abnormality.................................................... 40-469

Failure code [DF10KA] Disconnection of Shift Lever Input ................................................... 40-560

Table of contents ........................................................................................................................ 50-2

Electrical system .................................................................................................................... 50-302

Receiver drier .................................................................................................................... 80-19

Foreword, safety and general information

General precautions wear welding gloves, apron, shielding goggles,

10.Remove fuel pre-filter mounting bracket (56)

9. Remove oil filter mounting bracket (50)

3) Release harness connector (59) from the

3) Remove connector from clip of cover (54).

11.Remove mixing connector and EGR assembly

12)Remove EGR mounting bolts (76) to (78),

3) Disconnect two harness clamps (67c) and

6) Disconnect tube clamp (71).

2) Move flat-head screwdriver [1] in direction X

13)Lift up and remove mixing connector and

12.Disconnect following hoses and wiring

2) Remove the fuel spray prevention caps.

13.Disconnect harness connector (86).

17.Loosen two nuts (107), and then disconnect

a adjustment screw (112) must be left

(Reading order of character string)

20.Remove injector assembly according to the

1. Install injector assembly (114) according to the

3) Tighten mounting bolt (113) while checking

6) Tighten holder (115) to the specified torque.

5. Fit O-ring and install cylinder head cover (106).

k Install the cap with its slit facing as

k Do not correct the fuel high-pressure pipe by

k Before installing the high-pressure fuel pipe,

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