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Komatsu HM300-2 Articulated Dump Truck Service Manual

1,368 pages · Publication SEN00237-14

$139.67
Fast free USA shippingShips in 1 business daySave 10% on 2 manuals, 15% on 3 or morePay by credit or debit card or with PayPal. No PayPal account needed.
Models
HM300-2
Serial coverage
2001 and up
Manual type
Service Manual
Pages
1,368
Publication
SEN00237-14
Condition
Brand new
Komatsu HM300-2 Articulated Dump Truck Service Manual, publication SEN00237-14

What's inside

From the manual's own table of contents: 214 sections, 429 entries. See sample pages (PDF, 776 KB)

Composition of shop manual
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table
Specification drawings
Specifications
Weight table
Fuel, coolant and lubricants
Radiator, oil cooler, aftercooler
Output shaft
Power train skeleton
Torque converter and transmission hydraulic piping
Brake cooling oil control valve (BCV)
Power train pump
Torque converter
Transmission
Transmission control valve
Show all 214 sections
ECMV
Main relief, torque converter relief valve
Drive shaft
Axle
Differential
Limited slip differential
Final drive
Steering column
Brake piping
Brake valve
Accumulator charge valve
Accumulator
Slack adjuster
Brake42 topics
  • Proportional reducing valve
  • Brake system tank
  • Parking brake
  • Parking brake solenoid
  • Suspension
  • Suspension cylinder
  • Oscillation hitch
  • Steering, hoist oil pressure piping diagram
  • Dump body control
  • Hydraulic tank and filter
  • Flow amp valve
  • Steering valve
  • Steering cylinder
  • Hoist valve
  • Dump control valve (EPC valve)
  • Hoist cylinder
  • Hydraulic pump
  • ROPS cab
  • Cab tilt
  • Air conditioner
  • Rear view monitor
  • Controller related
  • Machine monitor system
  • Automatic shift control system
  • Retarder control system
  • Auto emergency steering system
  • Battery disconnector switch
  • Dump control lever
  • Payload meter (Card type)
  • Sensors, switches
  • KOMTRAX terminal system (If equipped)
  • Standard value table for engine
  • Standard value table for chassis
  • Tools for testing, adjusting, and troubleshooting
  • Sketches of special tools
  • Testing engine speed
  • Testing intake air pressure (boost pressure)
  • Testing exhaust temperature
  • Testing exhaust gas color
  • Adjusting valve clearance
  • Testing compression pressure
  • Testing blow-by pressure
Testing engine oil pressure
Testing EGR valve and bypass valve drive oil pressure
Handling of fuel system devices
Releasing residual pressure from fuel system
Testing fuel pressure
Handling during cylinder cut-out operation
Handling during no injection cranking operation
Testing fuel return and leak amount
Bleeding air from fuel circuit
Testing fuel circuit for leakage
Testing and adjusting alternator belt tension
Testing and adjusting air conditioner compressor belt tension
Adjusting the shims in the body mount
Testing torque converter stall speed
Testing power train oil pressure
Adjusting transmission speed sensor
Testing and adjusting brake oil pressure
Testing brake performance
Bleeding air from brake circuit
Testing wear of wheel brake disc
Testing wear of parking brake pad
Method for emergency release of parking brake
Testing and adjusting steering circuit oil pressure
Testing and adjusting suspension cylinder
Method of tilting cab up
Testing and adjusting dump circuit oil pressure
Adjusting body positioner sensor
Procedure for adjusting length of spring in body heating spherical joint
Handling engine controller high voltage circuit
Adjusting transmission controller
Method for emergency escape at electrical system failure
Setting and adjusting various equipments
Special function of machine monitor (EMMS)
How to start operation of KOMTRAX terminal
Lamp display of KOMTRAX terminal
Pm Clinic check sheet
Failure codes table
Fuse locations
Points to remember when troubleshooting
Sequence of events in troubleshooting
Checks before troubleshooting
Classification and procedures for troubleshooting
Information in troubleshooting table
Connection table for connector pin numbers
T-branch box and T-branch adapter table
Failure code [1500L0] (Dual engagement)
Failure code [15B0NX] (Transmission oil filter: Clogged)
Failure code [15F0KM] (R o F shifting abuse 1: Operational error or incorrect setting)51 topics
  • Failure code [15F0MB] (R o F shifting abuse 2: Functional deterioration)
  • Failure code [15F7KM] (forward clutch disc abuse)
  • Failure code [15G0MW] (R clutch: Slipping)
  • Failure code [15G7KM] (reverse clutch disc abuse)
  • Failure code [15H0MW] (Hi clutch: Slipping)
  • Failure code [15J0MW] (Lo clutch: Slipping)
  • Failure code [15K0MW] (1st clutch: Slipping)
  • Failure code [15L0MW] (2nd clutch: Slipping)
  • Failure code [15M0MW] (3rd clutch: Slipping)
    • command current is OFF.)
  • Failure code [15SBMA] (R clutch solenoid: Malfunction)
    • command current is OFF.)
  • Failure code [15SCMA] (Hi clutch solenoid: Malfunction)
    • command current is OFF.)
  • Failure code [15SDMA] (Lo clutch solenoid: Malfunction)
    • command current is OFF)
  • Failure code [15SEMA] (1st clutch solenoid: Malfunction)
    • command current is OFF.)
  • Failure code [15SFMA] (2nd clutch solenoid: Malfunction)
    • command current is OFF.)
  • Failure code [15SGMA] (3rd clutch solenoid: Malfunction)
  • Failure code [15SJMA] (Lockup clutch solenoid: Malfunction)
  • Failure code [15SKMA] (Inter-axle differential lockup pressure control valve: Malfunction)
  • Failure code [2F00KM] (Parking brake: Error in operation or setting)
  • Failure code [2G42ZG] (Front accumulator: Oil pressure too low)
  • Failure code [2G43ZG] (Rear accumulator: Oil pressure too low)
  • Failure code [989A00] (Engine over run prevention command signal: Operating)
  • Failure code [989D00] (Rear section tipping over alarm: Alarm is activated.)
  • Failure code [AA10NX] (Air cleaner element: Clogged)
  • Failure code [AB00MA] (Alternator: Malfunction)
  • Failure code [B@BAZG] Lowering of engine oil pressure
  • Failure code [B@BAZK] (Engine oil : Level too low)
  • Failure code [B@BCNS] (Engine: Overheat)
  • Failure code [B@BCZK] (Radiator coolant: Level too low)
  • Failure code [B@BFZK] (Fuel level: Level too low)
  • Failure code [B@C6NS] (Front brake oil: Overheat)
  • Failure code [B@C8NS] (Center brake oil: Overheat)
  • Failure code [B@CENS] (Torque converter: Overheat)
  • Failure code [B@HAZK] (Hydraulic tank oil: Level too low)
  • Failure code [B@JANS] (Steering oil: Overheat)
  • Failure code [CA111] (Abnormality in engine controller)
  • Failure code [CA115] (Abnormal engine Ne and Bkup sensors)
  • Failure code [CA122] (Charge pressure sensor too high)
  • Failure code [CA123] (Charge pressure sensor too low)
  • Failure code [CA131] (Throttle sensor tool high)
  • Failure code [CA132] (Throttle sensor tool low)
  • Failure code [CA135] (Oil pressure sensor too high)
  • Failure code [CA141] (Oil pressure sensor too low)
  • Failure code [CA144] (Coolant temperature sensor too high)
  • Failure code [CA145] (Coolant temperature sensor too low)
  • Failure code [CA153] (Charge temperature sensor too high)
Failure code [CA154] (Charge temperature sensor too low)
Failure code [CA187] (Sensor power source 2 too low)
Failure code [CA221] (Atmospheric sensor too high)
Failure code [CA222] (Atmospheric sensor too low)
Failure code [CA227] (Sensor power source 2 too high)
Failure code [CA234] (Engine over speed)
Failure code [CA238] (Abnormal power source for Ne speed sensor)
Failure code [CA263] (Fuel temperature sensor too high)
Failure code [CA265] (Fuel temperature sensor too low)
Failure code [CA271] (PCV1 short circuit)
Failure code [CA272] (PCV1 disconnection)
Failure code [CA273] (PCV2 short circuit)
Failure code [CA274] (PCV2 disconnection)
Failure code [CA322] Disconnection or short circuit in injector #1 (L#1)
Failure code [CA323] Disconnection or short circuit in injector #5 (L#5)
Failure code [CA324] Disconnection or short circuit in injector #3 (L#3)
Failure code [CA325] Disconnection or short circuit in injector #6 (L#6)
Failure code [CA331] Disconnection or short circuit in injector #2 (L#2)
Failure code [CA332] Disconnection or short circuit in injector #4 (L#4)
Failure code [CA342] (Abnormal engine controller data consistency)
Failure code [CA351] (Abnormal injector drive circuit)
Failure code [CA352] (Sensor power source 1 too low)
Failure code [CA386] (Sensor power source 1 too high)
Failure code [CA431] (Abnormal idle validation switch)
Failure code [CA432] (Abnormal process with idle validation switch)
Failure code [CA441] (Power source voltage too low)
Failure code [CA442] (Power source voltage too high)
Failure code [CA449] (Common rail pressure too high 2)
Failure code [CA451] (Common rail pressure sensor too high)
Failure code [CA452] (Common rail pressure sensor too low)
Failure code [CA553] (Common rail pressure too high 1)
Failure code [CA554] (In-range error of common rail pressure sensor)
Failure code [CA559] (Loss of pressure feed from supply pump 1)
Failure code [CA689] (Abnormal engine Ne speed sensor)
Failure code [CA697] (Engine controller inside temperature sensor too high)
Failure code [CA698] (Engine controller inside temperature sensor too low)
Failure code [CA731] (Abnormal engine Bkup speed sensor phase)
Failure code [CA757] (Loss of all engine controller data)
Failure code [CA778] (Abnormal engine Bkup speed sensor)
Failure code [CA1117] (Loss of partial engine controller data)
Failure code [CA1228] (Abnormal EGR valve servo 1)
Failure code [CA1625] (Abnormal EGR valve servo 2)
Failure code [CA1626] (Short circuit of bypass valve solenoid drive)
Failure code [CA1627] (Disconnection in bypass valve solenoid drive)
Failure code [CA1628] (Abnormal bypass valve servo 1)
Failure code [CA1629] (Abnormal bypass valve servo 2)
Failure code [CA1631] (Bypass valve lift sensor too high)
Failure code [CA1632] (Bypass valve lift sensor too low)
Failure code [CA1633] (Abnormal KOMNET)
Failure code [CA1642] (EGR inlet pressure sensor too low)
Failure code [CA1653] (EGR inlet pressure sensor too high)
Failure code [CA2185] (Throttle sensor power source too high)
Failure code [CA2186] (Throttle sensor power source too low)
Failure code [CA2249] (Loss of pressure feed from supply pump 2)
Failure code [CA2271] (EGR valve lift sensor too high)
Failure code [CA2272] (EGR valve lift sensor too low)
Failure code [CA2351] (EGR valve solenoid drive short circuit)45 topics
  • Failure code [CA2352] (EGR valve solenoid drive disconnection)
  • Failure code [CA2555] (Intake air heater relay disconnection)
  • Failure code [CA2556] (Intake air heater relay short circuit)
  • Failure code [DAF9KM] (Machine monitor connector: Error in operation or setting)
    • Abnormal communication)
  • Failure code [DAQ0KK] (Transmission controller: Power source voltage too low)
  • Failure code [DAQ0KT] (Transmission nonvolatile memory: Abnormality in controller)
  • Failure code [DAQ2KK] (Transmission controller solenoid power source: Voltage too low)
  • Failure code [DAQRKR] (COMMUNICATION LOST: Defective communication)
  • Failure code [DAQRMA] (Transmission controller option setting: Malfunction)
  • Failure code [DB10KT] (Retarder controller nonvolatile memory: Abnormality in controller)
    • Power source voltage too low)
    • Inconsistent model selection signal)
  • Failure code [DB1QMA] (Retarder controller option setting: Malfunction)
    • Communication disabled)
  • Failure code [DD1ML4] Disagreement of accelerator-linked retarder switch signal
  • Failure code [DDTHKA] (Fill switch for Hi clutch: Disconnection)
  • Failure code [DDTJKA] (Fill switch for Lo clutch: Disconnection )
  • Failure code [DDTKKA] (Fill switch for 1st clutch: Disconnection)
  • Failure code [DDTLKA] (Fill switch for 2nd clutch: Disconnection)
  • Failure code [DDTMKA] (Fill switch for 3rd clutch: Disconnection)
  • Failure code [DDTNKA] (Fill switch for R clutch: Disconnection)
  • Failure code [DF10KA] (Gear shift lever: Disconnection)
  • Failure code [DF10KB] (Gear shift lever: Short circuit)
  • Failure code [DGF1KX] (Transmission oil temperature sensor: Input signal out of range)
    • Disconnection or short circuit)
  • Failure code [DGR3L8] (Center brake oil temperature sensor: Inconsistent analog signals)
  • Failure code [DGR4KZ] (Front brake oil temperature sensor: Disconnection or short circuit)
  • Failure code [DGR4L8] (Front brake oil temperature sensor: Inconsistent analog signals)
  • Failure code [DGR6KX] (Steering oil temperature sensor: Input signal out of range)
    • Input signal out of range)
  • Failure code [DHT5KX] (Torque converter oil pressure sensor: Input signal out of range)
    • Inconsistent signals during a travel and stop)
  • Failure code [DHU2KX] (Front accumulator oil pressure sensor: Input signal out of range)
  • Failure code [DHU3KX] (Rear accumulator oil pressure sensor: Input signal out of range)
  • Failure code [DJF1KA] (Fuel level sensor: Disconnection)
    • Potentiometer signal is inconsistent with switch signal)
  • Failure code [DK52KX] (Dump lever potentiometer failure 1: Input signal out of range)
  • Failure code [DK53L8] (Dump lever potentiometer failure 2: Inconsistent analog signal)
  • Failure code [DK54KX] (Body positioner sensor: Input signal out of range)
  • Failure code [DKH0KX] (Pitch angle sensor: Inclination out of range)
  • Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection)
    • Inconsistent rotation speed signal)
  • Failure code [DLF2KA] (Transmission intermediate shaft speed sensor: Disconnection)
  • Inconsistent speed signal)
Failure code [DLF4KA] (Differential speed sensor: Disconnection)
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)
Failure code [DV00KB] (Alarm buzzer output: Short circuit)
Failure code [DW72KZ] (Kick-out solenoid output system: Disconnection or short circuit)
Failure code [DW73KZ] (Hoist selector valve output system: Disconnection or short circuit)7 topics
  • Disconnection or short circuit)
  • Out of control)
  • output circuit: Disconnection)
  • Short circuit)
  • Short circuit to power source line)
  • Malfunction)
  • circuit: Disconnection)
Failure code [DX13KA] (Hoist EPC valve output circuit: Disconnection)
Failure code [DX13KB] (Hoist EPC valve output circuit: Short circuit)
Failure code [DX13KY] (Hoist EPC valve output circuit: Short circuit in power source line)
Failure code [DXH0KA] (Inter-axle differential lock pressure control valve: Disconnection)
Failure code [DXH0KB] (Inter-axle differential lock pressure control valve: Short circuit)
Failure code [DXH1KA] (Lockup clutch solenoid output circuit: Disconnection)
Failure code [DXH1KB] (Lockup clutch solenoid output circuit: Short circuit)
Failure code [DXH2KA] (Hi clutch solenoid output circuit: Disconnection)
Failure code [DXH2KB] (Hi clutch solenoid output circuit: Short circuit)
Failure code [DXH2KY] (Hi clutch solenoid output circuit: Short circuit to power source line)
Failure code [DXH3KA] (Lo clutch solenoid output circuit: Disconnection)
Failure code [DXH3KB] (Lo clutch solenoid output circuit: Short circuit)
Failure code [DXH3KY] (Lo clutch solenoid output circuit: Short circuit in power source line)
Failure code [DXH4KA] (1st clutch solenoid output circuit: Disconnection)
Failure code [DXH4KB] (1st clutch solenoid output circuit: Short circuit)
Failure code [DXH4KY] (1st clutch solenoid output circuit: Short circuit to power source line)
Failure code [DXH5KA] (2nd clutch solenoid output circuit: Disconnection)
Failure code [DXH5KB] (2nd clutch solenoid output circuit: Short circuit)
Failure code [DXH5KY] (2nd clutch solenoid output circuit: Short circuit in power source line)
Failure code [DXH6KA] (3rd clutch solenoid output circuit: Disconnection)
Failure code [DXH6KB] (3rd clutch solenoid output circuit: Short circuit)
Failure code [DXH6KY] (3rd clutch solenoid output circuit: Short circuit to power source line)
Failure code [DXH7KA] (R clutch solenoid output circuit: Disconnection)50 topics
  • Failure code [DXH7KB] (R clutch solenoid output circuit: Short circuit)
  • Failure code [DXH7KY] (R clutch solenoid output circuit: Short circuit to power source line)
  • Information in troubleshooting table
  • Engine does not start
  • Automatic preheating does not operate
  • Machine monitor does not display all, when starting switch is turned ON
  • Machine monitor does not operate when starting switch is OFF
  • Alarm buzzer does not stop sounding
  • Selection of display in character display section cannot be changed
  • Power mode selecting function does not operate properly
  • AISS function does not operate properly
  • Seat belt caution lamp does not display properly
  • Turn signal lamp or turning lamp (hazard lamp) does not work properly
  • Night illumination (lighting) does not work properly
  • Emergency steering does not operate
  • Air conditioner does not operate normally
  • Contents of troubleshooting table
  • Machine does not start
  • Machine does not travel smoothly (machine jerks)
  • Lockup cannot be cancelled
  • Excessive shock when starting or shifting
  • Transmission does not shift up
  • Machine lacks power or speed when traveling
  • Time lag is excessive when starting or shifting gear
  • Torque converter oil temperature is high
  • Torque converter oil pressure is low
  • Front brake is ineffective
  • Center brake is ineffective
  • Steering wheel is heavy
  • Steering wheel does not work
  • Steering wheel vibrates
  • Dump body lifting speed is slow
  • Dump body does not work
  • Excessive hydraulic drift of dump body
  • How to use a troubleshooting chart
  • Engine is hard to start
  • Engine does not pick up smoothly
  • Engine stops during operations
  • Engine does not rotate smoothly
  • Engine lacks output (or lacks power)
  • Exhaust gas color is black (incomplete combustion)
  • Oil consumption is excessive (or exhaust gas color is blue)
  • Oil gets contaminated prematurely
  • Fuel consumption is excessive
  • Oil is in coolant (or coolant spurts back or coolant level goes down)
  • Oil pressure drops
  • Oil level rises (coolant or fuel mixes)
  • Coolant temperature rises too high (overheat)
  • Abnormal noise comes out
  • Vibration is excessive
How to read this manual
Coating materials list
Special tool list
Sketches of special tools
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of cylinder head assembly
Removal and installation of engine front seal
Removal and installation of engine rear seal
Removal and installation of engine assembly
Removal and installation of radiator assembly
Removal and installation of cooling assembly
Removal and installation of output shaft assembly
Disassembly and assembly of output shaft assembly
Removal and installation of transmission and front differential assembly
Disconnection and connection of front differential assembly and transmission assembly
Disassembly and assembly of front differential assembly
Disassembly and assembly of torque converter assembly
Disassembly and assembly of transmission assembly
Removal and installation of center differential assembly
Disassembly and assembly of center differential assembly
Removal and installation of rear differential assembly
Disassembly and assembly of rear differential assembly
Removal and installation of front final drive and brake assembly
Disassembly and assembly of front final drive and brake assembly
Removal and installation of center final drive and brake assembly
Disassembly and assembly of center final drive and brake assembly
Disassembly and assembly of rear final drive assembly
Removal and installation of center axle assembly
Removal and installation of rear axle assembly
Removal and installation of front suspension cylinder assembly
Removal and installation of rear suspension cylinder assembly
Disassembly and assembly of front and rear suspension cylinder assembly
Removal and installation of equalizer bar
Removal and installation of hitch frame assembly
Disassembly and assembly of hitch frame assembly
Removal and installation of flow amp valve
Removal and installation of hoist valve assembly
Disassembly and assembly of steering cylinder assembly
Disassembly and assembly of hoist cylinder assembly
Removal and installation of body assembly
Removal and installation of operator's cab
Removal and installation of operator's cab glass (Stuck glass)20 topics
  • Disassembly and assembly of operator's seat assembly (If equipped)
  • Removal and installation of air conditioner unit assembly
  • Removal and installation of engine controller
  • Removal and installation of retarder controller
  • Removal and installation of transmission controller assembly
  • Power train hydraulic circuit diagram
  • Steering and hoist hydraulic circuit diagram
  • Brake hydraulic circuit diagram
  • Brake cooling hydraulic circuit diagram
  • Electrical circuit diagram for inside cab (1/4)
  • Electrical circuit diagram for inside cab (2/4) (Serial No.: 2001 – 2241)
  • Electrical circuit diagram for inside cab (2/4) (Serial No.: 2242 and up)
  • Electrical circuit diagram for inside cab (3/4) (Serial No.: 2001 – 2241)
  • Electrical circuit diagram for inside cab (3/4) (Serial No.: 2242 and up)
  • Electrical circuit diagram for inside cab (4/4)
  • Electrical circuit diagram for outside cab (1/3)
  • Electrical circuit diagram for outside cab (2/3)
  • Electrical circuit diagram for outside cab (3/3)
  • Electrical circuit diagram for payload meter
  • Connectors table and arrangement drawing

Inside this manual

Real pages from this service manual (1,368 pages). Open the sample pages (PDF, 775 KB)

Sample pages from the Komatsu HM300-2 Articulated Dump Truck Service Manual: Troubleshooting, Diagram, Specifications, Foldout diagram
  • Troubleshooting, page 729: Failure code [CA697] (Engine controller inside temperature sensor too
  • Diagram, page 876: Failure code [DX13KB] (Hoist EPC valve output circuit: Short circuit)
  • Specifications, page 981: H-2 Machine does not travel smoothly (machine jerks)
  • Foldout diagram: Electrical circuit diagram for inside cab (2/4) (Serial No.: 2242 and up)

Other manuals for this machine

Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the HM300-2 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.

This manual: Service Manual SEN00237-14$139.67
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This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 1,368 pages

Quantity one is the manual described above.

Fast free USA shipping

Ships in 1 business day.

60-day returns

Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy

Binder not included

Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.

Other editions and similar models

Komatsu Galeo HM300-2Operation & Maintenance Manual · TEN00112-04 · $69.77Komatsu HM300-2Service Manual · CEBM007700 · $139.93

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