HM 300 PDF

SEBM024815
Machine model Serial number
HM300-1 1001 and up
• This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may
require. Materials and specifications are subject to change without notice.
• HM300-1 mount the SAA6D125E-3 engine.

For details of the engine, see the 125-3 Series Engine Shop Manual.
© 2012
All Rights Reserved 00-1
Printed in Japan 08-12 (02) (15)
00
CONTENTS
No. of page
01 GENERAL ......................................................................................... 01-1
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ...... 10-1
20 TESTING AND ADJUSTING ............................................................. 20-1
30 DISASSEMBLY AND ASSEMBLY ................................................... 30-1
90 OTHERS ............................................................................................ 90-1
00-2 HM300-1
2
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LIST OF REVISED PAGES
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20-462 (4) 20-521 (9) 20-635 (1) 20-730 (9) 30- 1 (10)
20-463 (1) 20-522 (9) 20-636 (9) 20-731 (9) 30- 2 (14)
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20-486 (9) 20-545 (10) 20-659 (4) 20-808 (9) 30- 19 (9)
20-487 (9) 20-546 (10) 20-660 (9) 20-809 (1) 30- 20 (2)
20-488 (1) 20-547 (10) 20-661 (9) 20-810 (9) 30- 21 (9)
20-489 (1) 20-601 (9) 20-662 (1) 20- 811 (1) 30- 22 (9)
20-490 (9) 20-602 (9) 20-663 (1) 20-812 (4) 30- 23 (9)
20-491 (9) 20-604 (1) 20-664 (9) 20-813 (9) 30- 24 (2)
20-492 (9) 20-605 (9) 20-701 (9) 20-814 (9) 30- 25 (10)
20-493 (9) 20-606 (1) 20-702 (1) 20-815 (9) 30- 26 (10)
20-494 (9) 20-607 (1) 20-703 (1) 20-816 (1) 30- 27 (10)
20-495 (9) 20-608 (1) 20-704 (1) 20-817 (9) 30- 28 (10)
20-496 (9) 20-610 (9) 20-705 (1) 20-818 (9) 30- 29 (10)
20-497 (9) 20- 611 (9) 20-706 (9) 20-819 (9) 30- 30 (10)
HM300-1 00-2-3
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30- 31 (9) 30- 89 (10) 30-148 (2) 30-205 (9) 90- 7 (5)
30- 32 (9) 30- 90 (2) 30-149 (9) 30-206 (9) 90- 9 (5)
30- 33 (10) 30- 91 (2) 30-150 (9) 30-207 (2) 90- 11 (5)
30- 34 (10) 30- 92 (2) 30-151 (2) 30-208 (9) 90- 13 (5)
30- 35 (10) 30- 93 (9) 30-152 (2) 30-209 (2) 90- 15 (11)
30- 35-1 (10) 30- 94 (2) 30-153 (2) 30-210 (9) 90- 17 (11)
30- 36 (2) 30- 95 (9) 30-154 (9) 30- 211 (9) 90- 19 (11)
30- 37 (9) 30- 96 (2) 30-155 (2) 30-212 (2) 90- 21 (11)
30- 38 (2) 30- 97 (9) 30-156 (2) 30-213 (2) 90- 22 (12)
30- 39 (9) 30- 98 (10) 30-157 (2) 30-214 (2) (90- 23)
30- 40 (9) 30- 99 (2) 30-158 (2) 30-215 (2)
30- 41 (5) 30-100 (2) 30-159 (9) 30-216 (7)
30- 42 (9) 30-101 (2) 30-160 (2) 30-217 (2)
30- 43 (9) 30-102 (2) 30-161 (9) 30-218 (2)
30- 44 (9) 30-103 (2) 30-162 (9) 30-219 (2)
30- 45 (9) 30-104 (2) 30-163 (2) 30-220 (7)
30- 46 (9) 30-105 (2) 30-164 (9) 30-221 (7)
30- 47 (2) 30-106 (2) 30-165 (2) 30-222 (2)
30- 48 (2) 30-107 (2) 30-166 (2) 30-223 (2)
30- 49 (2) 30-108 (2) 30-167 (2) 30-224 (2)
30- 50 (2) 30-109 (2) 30-168 (9) 30-225 (2)
30- 51 (2) 30- 110 (2) 30-169 (2) 30-226 (2)
30- 52 (2) 30- 111 (9) 30-170 (2) 30-227 (9)
30- 53 (2) 30- 112 (2) 30-171 (9) 30-228 (2)
30- 54 (9) 30- 113 (9) 30-172 (2) 30-229 (2)
30- 55 (2) 30- 114 (2) 30-173 (2) 30-230 (2)
30- 56 (2) 30- 115 (9) 30-174 (2) 30-231 (2)
30- 57 (2) 30- 116 (9) 30-175 (2) 30-232 (2)
30- 58 (2) 30- 117 (2) 30-176 (2) 30-233 (10)
30- 59 (9) 30- 118 (9) 30-177 (2) 30-234 (10)
30- 60 (5) 30- 119 (9) 30-178 (9) 30-235 (10)
30- 61 (9) 30-120 (9) 30-179 (9) 30-235-1 (10)
30- 62 (2) 30-121 (9) 30-180 (2) 30-236 (2)
30- 63 (10) 30-122 (2) 30-181 (9) 30-237 (2)
30- 64 (10) 30-123 (9) 30-182 (2) 30-238 (2)
30- 65 (2) 30-124 (2) 30-183 (2) 30-239 (2)
30- 66 (9) 30-125 (9) 30-184 (2) 30-240 (2)
30- 67 (9) 30-126 (2) 30-185 (2) 30-241 (2)
30- 68 (2) 30-127 (9) 30-186 (2) 30-242 (2)
30- 69 (2) 30-128 (2) 30-187 (2) 30-243 (2)
30- 70 (2) 30-129 (2) 30-188 (9) q 30-244 (15)
30- 71 (2) 30-130 (2) 30-189 (2) q 30-245 (15)
30- 72 (2) 30-131 (2) 30-190 (9) 30-246 (5)
30- 73 (2) 30-132 (9) 30-191 (2) 30-247 (5)
30- 74 (2) 30-133 (2) 30-192 (2) 30-248 (5)
30- 75 (2) 30-134 (2) 30-193 (2) 30-249 (5)
30- 76 (2) 30-135 (2) 30-194 (2) 30-250 (5)
30- 77 (2) 30-136 (2) 30-195 (2) 30-251 (5)
30- 78 (2) 30-137 (2) 30-196 (9) 30-252 (5)
30- 79 (2) 30-138 (2) 30-197 (9) 30-253 (5)
30- 80 (2) 30-139 (2) 30-198 (9) 30-254 (5)
30- 81 (2) 30-140 (2) 30-199 (9) 30-255 (5)
30- 82 (2) 30-141 (2) 30-200 (9) 90- 1 (12)
30- 83 (2) 30-142 (9) 30-201 (9) 90- 2
30- 84 (2) 30-143 (9) 30-202 (9) 90- 3 (12)
30- 85 (2) 30-144 (2) 30-203 (9) 90- 5 (12)
30- 86 (9) 30-145 (2) 30-203-1 (14) 90- 5-2 (12)
30- 87 (9) 30-146 (9) 30-203-2 (14) 90- 5-4 (12)
30- 88 (10) 30-147 (2) 30-204 (9) 90- 5-6 (11)
00-2-4 HM300-1
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SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.
TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
VOLUMES When a manual is revised, an edition mark

Shop manuals are issued as a guide to carrying out ((1)(2)(3)....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Each issued as one Revised pages are shown in the LIST OF REVISED
Electrical volume:
}
Attachments volume: · volume to cover all
models
PAGES next to the CONTENTS page.
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
k
Special safety precautions
Safety are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order. tions or other precautions
2. Following examples show how to read the page a Caution for preserving standards
number. are necessary when per-
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
4
10 - 3 tems. Caution necessary
Weight when selecting hoisting
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
3
Places that require special
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine)
5
Places where oil, water or
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
6
item. Places where oil or water
Drain must be drained, and
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
k Heavy parts (25 kg or more) must be lifted

Slinging near the edge of the hook may cause
the rope to slip off the hook during hoisting, and
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol 4
• If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.
but sling with two or more ropes symmetrically
k Slinging with one rope may cause turning

wound onto the load.
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to of the load during hoisting, untwisting of
the table below: the rope, or slipping of the rope from its
original winding position on the load, which
Wire ropes can result in a dangerous accident.
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
Rope diameter Allowable load
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
mm kN tons with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6
vertically, at various hanging angles.
14 21.6 2.2
16 27.5 2.8
When two ropes sling a load vertically, up to
18 35.3 3.6 19.6 kN {2000 kg} of total weight can be sus-
20 43.1 4.4 pended. This weight becomes 9.8 kN {1000 kg}
22.4 54.9 5.6 when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.
★ The allowable load value is estimated to be one-

sixth or one-seventh of the breaking strength of
the rope used.
2) Sling wire ropes from the middle portion of the

hook.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
k Before carrying out the following work, release Type 1

the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.
k Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
★ The adapter can be pushed in about 3.5
mm.
★ Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
★ Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
★ Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter

perfectly, pull it back to check its connecting
condition. (See Fig. 5)
★ When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q’ty Container Main applications, features
• Used to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube
cushions, and cock plug from coming out.
• Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethylene,
LT-1B 790-129-9050
(2 pcs.) container polyprophylene, tetrafluoroethlene and
vinyl chloride), rubber, metal and non-
metal.
• Features:
Polyethylene Resistance to heat and chemicals
LT-2 09940-00030 50 g
container • Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for metal,
790-129-9060
1 kg glass and plastic.
(Set of adhesive
LT-3 Hardening Can
and hardening
agent:
agent)
Adhesives 500 g
Polyethylene • Used as sealant for machined holes.
LT-4 790-129-9040 250 g
container
Holtz • Used as heat-resisting sealant for
790-126-9120 75 g Tube
MH 705 repairing engine.
• Quick hardening type adhesive
Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of metals,
rubbers, plastics and woods.
• Quick hardening type adhesive
• Quick cure type
Aron-alpha Polyethylene
790-129-9130 2g (max. strength after 30 minutes)
201 container
• Used mainly for adhesion of rubbers,
plastics and metals.
• Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc • Used at joint portions subject to high
648-50 container
temperatures.
• Used as adhesive or sealant for gaskets
LG-1 790-129-9010 200 g Tube
and packing of power train case, etc.
• Used as sealant for various threads, pipe
joints, flanges.
LG-5 790-129-9080 1 kg Can
• Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
• Features: Silicon based, resistance to
heat, cold
LG-6 790-129-9020 200 g Tube • Used as sealant for flange surface, tread.
• Used as sealant for oil pan, final drive
Gasket case, etc.
sealant • Features: Silicon based, quick hardening
type
LG-7 790-129-9070 1 kg Tube • Used as sealant for flywheel housing,
intake manifold, oil pan, thermostat
housing, etc.
Three bond • Used as heat-resisting sealant for
790-129-9090 100 g Tube
1211 repairing engine.
• Features: Silicone type, heat resistant,
Three bond vibration resistant, and impact resistant
419-15-18131 100 g Tube
1207B sealing material
• Used as sealing material for transfer case
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q’ty Container Main applications, features
• Used as lubricant for sliding portion (to
LM-G 09940-00051 60 g Can
prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuffling of the
lubricant thread when press fitting or shrink fitting.
LM-P 09940-00040 200 g Tube
• Used as lubricant for linkage, bearings,
etc.
SYG2-400LI • General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature, light load
SYG2-350CA bearing at places in contact with water or
G2-CA SYG2-400CA-A Various Various steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum • Used for heavy load portion
SYG2-400M 400 g × 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g × 20 Bellows type
grease
SYGA-16CNM 16 kg Can
LM-G (G2-M)
Hyper White • Seizure resistance and heat resistance
SYG2-400T-A
Grease G2-T higher than molybdenum disulfide grease
SYG2-16CNT 400 g Bellows type
G0-T (*) • Since this grease is white, it does not
SYG0-400T-A (*) 16 kg Can
*: For use in stand out against machine body.
SYG0-16CNT (*)
cold district
Biogrease G2B • Since this grease is decomposed by
SYG2-400B
G2-BT (*) bacteria in short period, it has less effects
SYGA-16CNB 400 g Bellows type
*: For high on microorganisms, animals, and plants.
SYG2-400BT (*) 16 kg Can
temperature
SYGA-16CNBT (*)
and large load
SUNSTAR • Used as primer for cab side
Glass
PAINT PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
417-926-3910
SUNSTAR • Used as primer for glass side
Glass
GLASS PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
SUNSTAR • Used as primer for painted surface on
Glass
PAINT PRIMER 22M-54-27230 20 ml cab side
Primer container
435-95 (Using limit: 4 months)
• Used as primer for black ceramic-
SUNSTAR
coated surface on glass side and for
GLASS PRIMER 22M-54-27240 150 ml Can
hard polycarbonate-coated surface
435-41
(Using limit: 4 months)
SUNSTAR • Used as primer for sash (Alumite).
Adhesive for cab glass
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months)
container
GP-402
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months)
SUPER 560 container)
SUNSTAR • “S” is used for high-temperature
PENGUINE season (April - October) and “W” for
Adhesive Polyethylene
SEAL 580 417-926-3910 320 ml low-temperature season (November -
container
SUPER “S” or April) as adhesive for glass.
“W” (Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml
Sikaflex 256HV container (Using limit: 6 months)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months)
container
SEAL No. 2505
SEKISUI • Used to seal front window.
Caulking Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months)
material container
SEALANT
GE TOSHIBA • Used to seal joint of glasses.
SILICONES 22M-54-27220 333 ml Cartridge Translucent white seal.
TOSSEAL 381 (Using limit: 12 months)
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5

8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5

18 27 320 – 400 33 – 41
20 30 455 – 565 46.5 – 58
22 32 610 – 765 62.5 – 78
24 36 785 – 980 80 – 100
27 41 1150 – 1440 118 – 147

30 46 1520 – 1910 155 – 195
33 50 1960 – 2450 200 – 250
36 55 2450 – 3040 250 – 310
39 60 2890 – 3630 295 – 370
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0

8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

★ In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below. SAD00483
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 24.5 ± 4.9 2.5 ± 0.5

18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

03, 04 20 Varies depending 84 – 132 {8.5 – 13.5} 103 {10.5}
05, 06 24 on type of 128 – 186 {13.0 – 19.0} 157 {16.0}
10, 12 33 connector. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1010 {76.0 – 103} 883 {90.0}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 {9.5 – 12.5} 107.8 {11.0}
33 33 — 107.8 – 147.0 {11.0 – 15.0} 124.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 — 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 — 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
00-13
TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
10 0 2 1.02 0 0.20
24 0 4 2.45 0 0.41
6
43 0 6 4.38 0 0.61
8
77 0 12 7.85 0 1.22
10
12
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
802 0.81 0 0.20
10 0 2 1.02 0 0.20
6
12 0 2 1.22 0 0.20
8
24 0 4 2.45 0 0.41
10
36 0 5 3.67 0 0.51
12
14
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
301 0.31 0 0.10
802 0.81 0 0.20
1 / 16
12 0 2 1.22 0 0.20
1/8
15 0 2 1.53 0 0.20
1/4
24 0 4 2.45 0 0.41
3/8
36 0 5 3.67 0 0.51
1/2
60 0 9 6.12 0 0.92
3/4
1
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) Face seal type
type
Nominal size Width across
of hose flats Nominal thread
Thread size size Root diameter
Range Target - Threads per
(mm) inch, Thread series (mm) (Reference)
9
34 – 54 {3.5 – 5.5} 44 {4.5} – — – 18UN 14.3
02 19 16
34 – 63 {3.5 – 6.5} 44 {4.5} 14 – –
11
22 54 – 93 {5.5 – 9.5} 74 {7.5} – — – 16UN 17.5
03 16
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 – –
13
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 — – 16UN 20.6
16
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
3
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1 — – 12UN 30.2
16
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
00-14
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White
Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL — BR RY YG GY LY
4 Auxi-
liary Yellow & Green &
Color White & Blue — Black & Red Red & Yellow Blue & Yellow
Green Yellow
Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black
Code — — — RL YW GL n
n
6
Color — — — Red & Blue Yellow & White Green & Blue
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line
from (A).
(2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
(3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
(B)
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
(A) 50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-16
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

1l = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 0 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22 04-05
GENERAL
01 GENERAL
Specification drawings................................................................................................................................... 01-2

Specifications ................................................................................................................................................ 01-3
Weight table................................................................................................................................................... 01-6
Fuel, coolant and lubricants........................................................................................................................... 01-7
HM300-1 01-1
GENERAL SPECIFICATION DRAWINGS
SPECIFICATION DRAWINGS
01-2 HM300-1
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model HM300-1 HM300-1 E-SPEC
Serial Numbers 1001 and up 1001 and up
Unloaded kg 23,545
Max. payload kg 27,300
Overall weight kg 50,920
Unloaded (front wheel) kg 13,125

Weight
(center wheel) kg 5,345

(rear wheel) kg 5,075
Weight
Fully loaded (front wheel) kg 15,220
(center wheel) kg 18,125
(rear wheel) kg 17,575
Struck m3 12.9
Dump body capacity
Heaped (2:1) m 3 16.6
Performance
Max. travel speed km/h 59

Gradeability (sin θ) 0.45
Min. turning radius mm 8,110
Dumping angle (angle to ground) deg 70
Overall length mm 10,095

Overall width mm 3,195
Overall height mm 3,500
Wheelbase (front wheel - center wheel) mm 4,100
Dimensions
Wheelbase (center wheel - rear wheel) mm 1,710
Front tires mm 2,435

Tread Center tires mm 2,435
Rear tires mm 2,435
Ground Clearance mm 510
Model Komatsu SAA6D125E-3
Type 4-cycle, water-cooled, in-line 6 cylinder, direct

injection, with turbocharger and air-cooled
after-cooler
No. of cylinders - Bore x stroke mm
l {cc}
6-125 x 150
Piston displacement 11.04{11,040}
Engine
Flywheel horsepower kW/rpm{HP/rpm} 238/2,000 {319/2,000}

Max. torque Nm/rpm{kgm/rpm} 1,569/1,400 {160/1,400}
Fuel consumption (rated) g/kWh{g/HPh} 194 {145}
Starting motor 7.5kW
Alternator 24V 50A
Battery 12V 112Ah x 2
HM300-1 01-3
4
(9)
3-element, 1-stage, 2-phase

Type
Torque converter Hydraulically-actuated, wet-type, single-disc
Lock-up clutch
clutch
TORQFLOW multiple-axle transmission, fully

Type automatic, electrically-hydraulically actuated,
Transmission
Power train
No. of speeds force-feed type pump lubrication type

F6, R2
Type Spiral bevel gear, splash lubrication

Reduction gear Reduction ratio 3.154
Differential type Straight bevel gear, splash lubrication
Type Planetary gear, splash lubrication

Final drive
Reduction ratio 4.667
Travel system
Type Fully hydraulic
Front axle Full floating suspension (De Dion type)

Suspension
Axle type Center axle Full floating suspension

Rear axle Full floating suspension
Front axle Hydropneumatic type

Suspension method
Rear axle Hydropneumatic type
Front tire 23.5 R25 x 2

Size and no. Center tire 23.5 R25 x 2
Tires
Rear tire 23.5 R25 x 2
kPa
Tire inflation pressure 440 {4.5}
{kg/cm2}
Independent front and center system brake, sealed,

Front wheel wet- type, multiple disc, hydraulically operated type
Main brake
Center wheel Independent front and center system brake, sealed,
wet- type, multiple disc, hydraulically operated type
Brakes
Parking brake Spring-boosted, caliper disc type
Independent front and

center system brake,
Retarder sealed, wet- type, multi-
ple disc, hydraulically
operated type
01-4 HM300-1
4
For steering, hoist

Type Gear pump
Discharge amount (l /min) 137 + 137
(when engine is at rated speed of 2000 rpm)
For hoist control
Type Gear pump
Discharge amount (l /min) 14.1
Hydraulic pump, motor
For transmission, brake cooling

Type Gear pump
Discharge amount (l /min) 204
For brake cooling
Hydraulic system
Type Gear pump

For brake
Type Gear pump
Hoist cylinder
Type 2-stage piston type
(only 2nd stage double-acting)
Cylinders
No. - bore (1st-2nd) x stroke 2-(140mm-100mm) x 2,897mm

Steering cylinder
Type Piston type, double acting
No. - bore x stroke 2-110mm x 420mm
HM300-1 01-5
4
(9)
GENERAL WEIGHT TABLE
WEIGHT TABLE
This weight table is a guide for use when transporting or handling components.
Unit: kg
Engine assembly 1,200

Output shaft assembly 65
Cooling assembly 229
Fuel tank (individual part) 205
Torque converter assembly 112
Transmission assembly 935
Drive shaft assembly 178
Front axle assembly 1,139
Differential 302
Final drive 779
Center axle assembly 1,394
Differential 300
Final drive 813
Rear axle assembly 894
Differential 194
Final drive 423
Front suspension cylinder 70.1
Rear suspension cylinder 54.2
Oscillation hitch assembly 634
Front frame 1,362
Rear frame 1,596
ROPS cab (including platform, interior components) 1,300
Operator’s seat 56.1
Steering cylinder (one side) 56.2
Hoist cylinder (one side) 182
Flow amp valve 29
Hoist valve 33.6
Hydraulic tank 185
Hydraulic pump (SAR(3) 63 + 63 + (1)6) 38.6
Hydraulic pump (SAR(3)90) 17.2
Hydraulic pump (SAR(3)80+(1)18) 24.8
Hydraulic pump (SBL(1)26) 7.9
Emergency steering motor 13
Body assembly 3,454
01-6 HM300-1
(12)
GENERAL FUEL, COOLANT AND LUBRICANTS
FUEL, COOLANT AND LUBRICANTS
• ASTM: American Society of Testing and Material
HM300-1 01-7
(11)
Reservoir Transmission
Front Rear Front
Engine oil case Hydraulic
suspension suspension differential
pan (Incl. brake tank
(each) (each) Case
Capacity oil tank)
Specified Liters 45 165 171 3 2.2 14
Refill Liters 35 77.5 120 3 2.2 14
Reservoir
Front final Center Center final Rear Rear final
Cooling
drive case differential drive case differential drive case Fuel tank
system
(each) case (each) case (each)
Capacity
Specified Liters 4.5 25 4.0 25 5.0 386 57
Refill Liters 4.0 24.5 3.5 25 4.5 – 51
NOTICE
Use only diesel fuel.
The engine mounted on this machine employs electronic control and a high-pressure fuel injection
device to obtain good fuel consumption and good exhaust gas characteristics. For this reason, it
requires high precision for the parts and good lubrication. If kerosene or other fuel with low lubricating
ability is used, there will be a big drop in durability.
Note 1: HTHS (High-Temperature High-Shear Viscosity 150°C), specified by ASTM D4741 must be equal to or
higher than 3.5 m Pa-S. Komatsu EOS0W30 and EOS5W40 are the most suitable oils.
Note 2: Powertrain oil has different properties from engine oil. Be sure to use the recommended oils.
Note 3: When the ambient temperature is higher than 45°C (113°F) and the machine operation hour is longer
than 12 hours/day, then the use of TO50 instead of AXO80 is recommended.
Squealing of the brakes may occur with TO50, but there is no problem with the brake performance or
durability.
Note 4: Hyper grease (G2-T, G2-TE) has a high performance.

When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking of
pins and bushings, the use of G2-T or G2-TE is recommended.
Note 5: Supercoolant (AF-NAC)

1) The coolant has the important function of preventing corrosion as well as preventing freezing.
Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential.
Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC)
has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or
4000 hours.
Komatsu Supercoolant (AF-NAC) is strongly recommended wherever available.
2) For details of the ratio when diluting super coolant with water, see "Mixing rate water and antifreeze".
When the machine is shipped from the factory, it may be filled with coolant containing 30% or more Super-
coolant (AF-NAC). In this case, no adjustment is needed for temperatures down to -10°C (14°F). (never
dilute with water)
3) To maintain the anticorrosion properties of Supercoolant (AF-NAC), always keep the density of Supercool-
ant between 30% and 68%.
01-8 HM300-1
(11)
Mixing rate of water and antifreeze
Min. atmospheric °C -10 -15 -20 -25 -30

temperature °F 14 5 -4 -13 -22
Amount of antifreeze Liters 15.3 18.4 21.0 23.5 25.5
Amount of water Liters 35.7 32.6 30.0 27.5 25.5
Volume ratio % 30 36 41 46 50
HM300-1 01-9
(11)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
10 STRUCTURE, FUNCTION AND

MAINTENANCE STANDARD
RADIATOR, OIL COOLER, AFTERCOOLER ............................................................................................. 10-2
POWER TRAIN SKELETON ....................................................................................................................... 10-4
OUTPUT SHAFT ......................................................................................................................................... 10-6
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING ...................................................... 10-8
TORQUE CONVERTER ............................................................................................................................ 10-10
TRANSMISSION ....................................................................................................................................... 10-16
TRANSMISSION VALVE ........................................................................................................................... 10-36
ECMV (Electronic Control Modulation Valve) ............................................................................................ 10-37
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE ........................................................................ 10-44
DRIVE SHAFT .......................................................................................................................................... 10-46
AXLE ......................................................................................................................................................... 10-47
DIFFERENTIAL ......................................................................................................................................... 10-50
LIMITED SLIP DIFFERENTIAL ................................................................................................................. 10-56
FINAL DRIVE ............................................................................................................................................ 10-62
STEERING COLUMN ................................................................................................................................ 10-67
BRAKE PIPING ......................................................................................................................................... 10-68
BRAKE VALVE ......................................................................................................................................... 10-70
ACCUMULATOR CHARGE VALVE .......................................................................................................... 10-73
ACCUMULATOR ....................................................................................................................................... 10-77
SLACK ADJUSTER ................................................................................................................................... 10-78
BRAKE ...................................................................................................................................................... 10-80
PROPORTIONAL REDUCING VALVE ..................................................................................................... 10-85
BRAKE SYSTEM TANK ............................................................................................................................ 10-86
PARKING BRAKE ..................................................................................................................................... 10-88
PARKING BRAKE CALIPER ..................................................................................................................... 10-90
SPRING CYLINDER .................................................................................................................................. 10-91
PARKING BRAKE SOLENOID .................................................................................................................. 10-92
SUSPENSION ........................................................................................................................................... 10-94
SUSPENSION CYLINDER ...................................................................................................................... 10-100
OSCILLATION HITCH ............................................................................................................................. 10-102
STEERING, HOIST OIL PRESSURE PIPING DIAGRAM ....................................................................... 10-106
DUMP BODY CONTROL ........................................................................................................................ 10-107
HYDRAULIC TANK AND FILTER ........................................................................................................... 10-108
FLOW AMP VALVE ................................................................................................................................. 10-109
STEERING VALVE .................................................................................................................................. 10-112
STEERING CYLINDER ........................................................................................................................... 10-116
HOIST VALVE ......................................................................................................................................... 10-118
EPC VALVE ............................................................................................................................................. 10-124
PILOT CHECK VALVE ........................................................................................................................... 10-124-1
HOIST CYLINDER .................................................................................................................................. 10-125
HYDRAULIC PUMP ................................................................................................................................ 10-126
CAB TILT ................................................................................................................................................. 10-130
AIR CONDITIONER ................................................................................................................................ 10-131
HEATER ................................................................................................................................................ 10-135-1
MACHINE MONITOR SYSTEM .............................................................................................................. 10-136
AUTOMATIC SHIFT CONTROL SYSTEM .............................................................................................. 10-149
TRANSMISSION CONTROLLER ............................................................................................................ 10-151
AUTO EMERGENCY STEERING SYSTEM ........................................................................................... 10-157
SENSORS, SWITCHES .......................................................................................................................... 10-158
RETARDER CONTROL SYSTEM .......................................................................................................... 10-166
BRAKE CONTROL SYSTEM (E-SPEC) ................................................................................................ 10-175-1
DUMP CONTROL LEVER ........................................................................................................................ 10-176
HM300-1 10-1
(11)
RADIATOR, OIL COOLER,
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AFTERCOOLER
RADIATOR, OIL COOLER, AFTERCOOLER
1. Reservoir tank Specifications

2. Radiator Radiator
3. Aftercooler • Core type: CF4-4
4. Torque converter oil cooler • Total heat dissipation area: 50.61m2
5. Steering oil cooler Torque converter oil cooler
6. Upper tank • Core type: PTO-LS
7. Lower tank • Total heat dissipation area: 4.065m2
A. To intake manifold Steering oil cooler
B. From turbocharger • Core type: PTO-LS
C. From thermostat • Total heat dissipation area: 0.497m2
D. To water pump
10-2 HM300-1
(9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN SKELETON
POWER TRAIN SKELETON
10-4 HM300-1
(4
9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN SKELETON
1. Engine
2. Output shaft
3. Front drive shaft
4. Brake cooling and brake system pump (SAR(3)80+(1)18)
5. Torque converter, transmission, front brake cooling pump (SAR(3)90)
6. PTO
7. Torque converter
8. Steering, hoist control pump (SAR(3)63+63+(1)6)
9. Transmission
11. Oscillation hitch
12. Center drive shaft
13. Front differential
14. Front limited slip differential
16. Tire
17. Final drive (front)
18. Brake (front)
19. Rear drive shaft (front)
20. Center differential
21. Center limited slip differential
22. Tire
23. Final drive (center)
24. Brake (center)
25. Rear drive shaft (rear)
26. Rear differential
27. Rear limited slip differential
28. Tire
29. Final drive (rear)
30. Interaxle differential lock
HM300-1 10-5
(9)
4
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD OUTPUT SHAFT
OUTPUT SHAFT
1. Rubber cushion FUNCTION

2. Outer body The output shaft is installed to the engine fly-
3. Inner body wheel,and absorbs the twisting vibration caused by
4. Breather changes in the engine torque.
5. Coupling shaft
6. Flange
7. Cover
10-6 HM300-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD OUTPUT SHAFT
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance

Clearance between bearing size Shaft Hole clearance limit
1
and inner body
+0.025 0 -0.045 –
85 –
+0.003 -0.020 -0.013
Clearance between bearing 0 -0.020 -0.045 –
2 130 –
and flange -0.018 -0.045 -0.002
Clearance between retainer +0.006 +0.060 -0.014 –
3 130 –
and flange -0.034 +0.020 -0.094
Standard size Tolerance Repair limit
Wear of shaft and oil seal con- Replace
4 0
tact surface 70 -0.12
-0.074
Backlash at spline Standard backlash Clearance limit

5
portion 0.071 – 0.177 0.35
Standard clearance Clearance limit
Deterioration and cracks in
6 At min. width: Min. 63 mm
rubber 70
There must be no cracks
Deterioration and cracks in At min. width: Min. 48 mm
7 50
rubber There must be no cracks
HM300-1 10-7
(9)
TORQUE CONVERTER AND TRANSMISSION
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PIPING
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC

PIPING
10-8 HM300-1
TORQUE CONVERTER AND TRANSMIS-
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SION HYDRAULIC PIPING
1. Engine
2. Oil cooler
3. Rear brake cooling and brake system pump (SAR(3)80+(1)18)
4. Torque converter
5. Transmission
6. Hydraulic tank
7. Brake system tank
8. Torque converter, transmission, front brake cooling pump (SAR(3)90)
9. Transmission line filter
HM300-1 10-9
4
(9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TORQUE CONVERTER
TORQUE CONVERTER
1. PTO gear (No. of teeth: 66)

Unit: mm

Clearance between PTO gear size Shaft Hole clearance limit
2
and bearing
+0.018 0 -0.030 – Replace
ø 50 –
+0.002 -0.012 -0.002
Clearance between bearing 0 +0.016 -0.006 –
3 ø 90 –
and case -0.015 -0.006 0.031
SPECIFICATIONS
Type: 3 element, 1-stage, 2-phase
with modulation and lock-up
clutch
Lock-up clutch: Multiple-disc clutch
Hydraulic control
(with modulation valve)
Stall torque ratio: 2.46
10-10 HM300-1
(9)
1. Coupling 8. Stator shaft

2. Input shaft 9. One way clutch
(No. of teeth: 78) 10. Stator
3. Case 11. Disc
4. Drive case 12. Piston
5. Turbine 13. Clutch housing
6. Race 14. Retainer
7. Pump
HM300-1 10-11
(9)
10-12 HM300-1
Unit: mm

Outside diameter of coupling
1 0
and oil seal sliding portion ø 95 ø 94.8
-0.087
Inside diameter of seal ring
+0.025
2 sliding portion of input shaft ø 35 ø 35.1
0
sliding portion
Inside diameter of seal ring +0.089
3 ø 365 ø 365.5
sliding portion of clutch housing 0
4 ø 260 ø 260.1
sliding portion of clutch piston 0
5 ø 140 ø 140.5
sliding portion of pump housing 0
6 ø 60 ø 60.1
sliding portion of input shaft 0
-0.01
Wear of clutch Width 5 4.5
7 -0.04
housing seal ring
Thickness 6 ± 0.15 5.85 Replace
0
Wear of stator shaft Width 4.45
-0.1
4.05
8
seal ring
Thickness 5.2 ± 0.1 4.7
Inside diameter of outer race
9 one-way clutch transmission ø 102.555 ± 0.008 ø 102.585
surface
Outside diameter of inner race
+ 0.004
10 one-way clutch transmission ø 83.6 ø 83.57
- 0.009
surface
Inside diameter of sliding por- +0.015
11 ø 83.71 ø 83.79
tion of bushing 0
Thickness of sliding portion of
12 6 ± 0.05 5.5
bushing
13 Thickness of clutch disc 5 ± 0.1 4.4
Backlash between input shaft
14 0.18 – 0.46
and PTO gear
HM300-1 10-13
(9)
PATH FOR TRANSMISSION OF POWER 2. When lock-up clutch is engaged

When the lock-up clutch is engaged, drive case
1. When lock-up clutch is disengaged (1) and turbine (2) are engaged and form one
When the lock-up clutch is disengaged, drive unit. Stator (8) is rotated by the rotation of pump
case (1) and turbine (2) are separated, and the (6) and turbine (2).
torque converter functions as normal. The power generated by the engine goes from
The power generated by the engine goes from the damper through the drive shaft, is transmit-
the damper through the drive shaft, is transmitted to coupling (3), input shaft (4) and clutch
ted to coupling (3), input shaft (4) and clutch housing (5), and rotates drive case (1) and pump
housing (5), and rotates drive case (1) and pump (6) as one unit.
(6) as one unit. In addition, drive case (1) and turbine (2) are en-
The power from pump (6) uses oil as a medium, gaged by the clutch, so the power is transmitted
rotates turbine (2), and is transmitted from tur- directly from turbine (2) to transmission input
bine (2) to transmission input shaft (7). shaft (7) without using oil as a medium.
10-14 HM300-1
(9)
FLOW OF OIL
The oil passes through the main relief valve, is ad-

justed by the torque converter relief valve to a pres-
sure less than the set pressure, and enters inlet port
A. It then passes through the oil passage in stator
shaft (1) and flows from between pump (2) and sta-
tor (3) to pump (2). The oil is given centrifugal force
by pump (2), enters turbine (4), and transmits the en-
ergy of the oil to the turbine.
The oil from turbine (4) is sent to stator (3), and en-
ters the pump again. However, part of the oil passes
between turbine (4) and stator (3) and is sent from
outlet port B to the oil cooler to be cooled. It is then
used to lubricate the transmission.
HM300-1 10-15
(9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
1. Transmission case (front)

2. Transmission case (rear)
3. Oil filler pipe mount
4. Transmission control valve
5. Main relief, torque converter relief valve
10-16 HM300-1
1. R clutch 9. Lower shaft

2. Idler gear (No. of teeth: 53) 10. 3rd clutch
3. 1st clutch 11. Upper shaft
4. 2nd clutch 12. FH clutch
5. Differential lock clutch 13. Input shaft
6. Rear output shaft 14. FL clutch
7. Rear coupling 15. Torque converter
8. Front output shaft
HM300-1 10-17
10-18 HM300-1
Unit: mm
Tolerance
Standard Standard Clearance
size clearance limit
1 Clearance (F) between FL, R clutch Shaft Hole
bearing and case
ø 130 0 +0.026 -0.014 – –
-0.018 -0.014 0.044
2 Clearance (R) between FL, R clutch ø 130 0 -0.012 -0.052 – –

bearing and case -0.018 -0.052 0.006
3 Clearance (F) between FH, 1st clutch ø 130 0 +0.026 -0.014 – –

bearing and case -0.018 -0.014 0.044
4 Clearance (R) between FH, 1st clutch ø 130 0 -0.012 -0.052 – –

bearing and case -0.018 -0.052 0.006
5 Clearance (R) between FH. 1st clutch ø 60 +0.054 0 -0.069 – –

bearing and upper shaft +0.044 -0.015 0.044
6 Clearance (F) between 2nd, 3rd ø 120 0 -0.010 -0.045 – –

clutch bearing and case -0.015 -0.045 0.005
7 Clearance (R) between 2nd, 3rd ø 125 0 -0.012 -0.052 – –

clutch bearing and case -0.018 -0.052 0.006
8 Clearance (F) between differential ø 230 0 -0.014 -0.060 – –

lock clutch bearing and case -0.030 -0.060 0.016
9 Clearance (R) between differential ø 205.583 +0.025 + 0.013 -0.058 – –

lock clutch bearing and case 0 -0.033 -0.013

Width of input shaft seal ring groove
2.5 +0.18 2.7
+0.10
10
Width 2.4 ± 0.05 2.2
Wear of input shaft
seal ring 0
Thickness 1.7 -0.10 1.5
Width of input shaft seal ring groove 3.2 +0.076 3.5

0 Replace
11 Width 3.1 0 2.8

Wear of input shaft - 0.05
seal ring
Thickness 2.05 ± 0.10 1.8
Inside diameter of seal ring sliding +0.050

portions of input and upper shafts ø 60 0 ø 60.1
(Rear side)
Width of seal ring grooves of input 3.2 +0.076 3.5

12 and upper shafts (Rear side) 0
Wear of seal ring Width 3.1 0 2.8

grooves of input and -0.05
upper shafts (Rear
side) Thickness 2.05 ± 0.10 1.8
Inside diameter of seal ring sliding ø 50 +0.050 ø 50.1

portion of lower shaft (Rear side) 0
Width of seal ring groove of lower 3.2 +0.076 3.5

shaft (Rear side) 0
13
Width 3.1 0 2.8
Wear of seal ring -0.05
groove of lower shaft
(Rear side)
Thickness 2.05 ± 0.10 1.8
Inside diameter of seal ring sliding ø 80 +0.030 ø 80.1

portion of front output shaft 0
Width of seal ring groove of front out- 3.2 +0.076 3.5

put shaft 0
14
Width 3.1 ± 0.05 2.8
Wear of seal ring of
front output shaft 0
Thickness 2.29 -0.1 2.1
15 Outside diameter of rear coupling oil ø 95 0 ø 94.8

seal sliding portion -0.087
HM300-1 10-19
(9)
1. R idler gear (No. of teeth : 33)

2. Strainer
3. Lubrication oil relief valve
Unit: mm

Clearance between bearing size Shaft Hole clearance limit
4
and case
+0.032 0 -0.047 – Replace
± 70 –
+0.002 -0.015 -0.002
Clearance between R idler gear 0 -0.038 -0.073 –
5 ± 100 –
and bearing -0.015 -0.073 -0.023
Outline Clutch combination and reduction ratio

• The transmission is installed to the rear of the
torque converter. The power from the torque Speed range Clutch used Reduction ratio
converter passes through the transmission input
shaft and enters the transmission. F1 FL x 1st 6.522
• The transmission uses combinations of the FL,
F2 FH x 1st 4.243
FH, and R clutches and the three speed clutches
to shift the power from the input shaft and se- F3 FL x 2nd 2.717
lects a speed range from FORWARD 1st - 6th or
REVERSE 1st - 2nd. This is then transmitted to F4 FH x 2nd 1.768
the output shaft. F5 FL x 3rd 1.130
• Gearshifting is carried out automatically by the
automatic transmission according to the chang- F6 FH x 3rd 0.735
es in the engine speed.
R1 R x 1st 5.829
R2 R x 2nd 2.429
10-20 HM300-1
(9)
FL - R CLUTCH
A: R clutch oil port C: Lubricating oil port

B: FL clutch oil port D: Lock-up clutch oil port
1. Input shaft 5. FL, R cylinder (No. of teeth: 78)

2. Idler gear (No. of teeth: 45) 6. R clutch
3. FL gear (No. of teeth: 34) 7. R gear (No. of teeth: 28)
4. FL clutch
Unit: mm

Clearance (F) between FL, R size Shaft Hole clearance limit
8
shaft and bearing
+0.033 0 -0.048 –
ø 60 –
+0.022 -0.015 -0.022
Clearance (R) between FL, R +0.033 0 -0.048 –
9 ø 60 –
shaft and bearing +0.022 -0.015 -0.022
10 Thickness 1.7 ± 0.05 1.5
Separator plate
Distortion – 0.05 0.15
Thickness 2.2 ± 0.08 1.75 Replace
11 Friction plate
Load of wave spring (height: 712 N 101 N 605 N
12
2.2 mm) {72.6 kg} {10.3 kg} {61.7 kg}
Thickness of FL clutch thrust
13 3 ± 0.1 2.7
washer
Thickness of R clutch thrust
14 3 ± 0.1 2.7
washer
15 End play of FL gear 0.28 – 1.10
16 End play of R gear 0.08 – 0.90
HM300-1 10-21
(9)
FH - 1ST CLUTCH
A: 1st clutch oil port C: Lubricating oil port

B: FH clutch oil port
1. FH gear (No. of teeth: 62) 4. 1st clutch

2. FH clutch 5. 1st gear (No. of teeth: 24)
3. FH, 1st cylinder, idler gear (No. of teeth: 72) 6. Upper shaft
Unit: mm

Clearance (F) between FH, 1st size Shaft Hole clearance limit
7
shaft and bearing
+0.030 0 -0.045 –
ø 60 –
+0.011 -0.015 -0.011
8 Thickness 1.7 ± 0.05 1.5
Separator plate
Friction plate Thickness 2.2 ± 0.08 1.75

9
(FH clutch) Distortion – 0.10 0.25
Replace
10
(1st clutch) Distortion – 0.10 0.25
11
2.2 mm) {72.6 kg} {10.3 kg} {61.7 kg}
Thickness of FH clutch thrust
12 3 ± 0.1 2.7
washer
Thickness of 1st clutch thrust
13 3 ± 0.1 2.7
washer
14 End play of FH gear 0.07 – 0.93
15 End play of 1st gear 0.23 – 1.37
10-22 HM300-1
(9)
2ND - 3RD CLUTCH
A: 2nd clutch oil port C: Lubricating oil port

B: 3rd clutch oil port
1. 3rd gear (No. of teeth: 26) 5. 2nd gear (No. of teeth: 46)
2. 3rd clutch 6. Lower shaft
3. 2nd, 3rd cylinder, idler gear (No. of teeth: 50, 46)
4. 2nd clutch
10-24 HM300-1
Unit: mm

Clearance (F) between 2nd, size Shaft Hole clearance limit
7
3rd shaft and bearing
+0.030 0 -0.045 –
ø 55 –
+0.011 -0.015 -0.011
Clearance (R) between 2nd, +0.030 0 -0.045 –
8 ø 70 –
3rd shaft and bearing +0.011 -0.015 -0.011
Separator plate
9 Thickness 1.7 ± 0.05 1.5
(3rd clutch)

10
(2nd Clutch) Distortion – 0.05 0.15

11 Replace
(3rd Clutch) Distortion – 0.10 0.25

12
(2nd Clutch) Distortion – 0.10 0.25
13
2.2 mm) (3rd clutch) {72.6 kg} {10.3 kg} {61.7 kg}
Load of wave spring (height: 1,274 N 115 N 1,088 N
14
3.8 mm) (2nd clutch) {130 kg} {11.7 kg} {111 kg}
Thickness of 3rd clutch thrust
15 3 ± 0.1 2.7
washer
Thickness of 2nd clutch thrust
16 4 ± 0.1 3.6
washer
17 End play of 3rd gear 0.07 – 0.93
18 End play of 2nd gear 0.07 – 0.93
HM300-1 10-25
DIFFERENTIAL LOCK CLUTCH
A: Lubricating oil port

B: Differential lock clutch oil port
1. Front output shaft 7. Planetary gear (No. of teeth: 22)

2. Front housing 8. Sun gear (No. of teeth: 44)
3. Clutch hub (No. of teeth: 38) 9. Ring gear (No. of teeth: 88)
4. Differential lock clutch 10. Rear housing
5. Carrier 11. Rear output shaft
6. Output gear (No. of teeth: 68)
10-26 HM300-1
(9)
Unit: mm

Clearance between front size Shaft Hole clearance limit
12
housing and bearing
+0.040 0 -0.065 –
ø170 –
+0.015 -0.025 -0.015
Clearance between rear +0.068 +0.025 -0.068 –
13 ø 158.750 –
housing and bearing +0.043 0 -0.018
Clearance between front 0 -0.020 -0.045 –
14 ø 140 –
housing and bearing -0.018 -0.045 -0.002
Clearance (F) between front +0.030 0 -0.045 –
15 ø 80 –
output shaft and bearing +0.011 -0.015 -0.011
Clearance between carrier and 0 -0.024 -0.059 –
16 ø 115 –
bearing -0.015 -0.059 -0.009
Clearance (R) between front +0.030 0 -0.045 –
17 ø 75 –
Clearance between rear 0 -0.036 -0.061 –
18 ø 140 –
housing and bearing -0.018 -0.061 -0.018
Clearance between rear +0.030 0 -0.045 – Replace
19 ø 80 –
20 Thickness 2.0 ± 0.05 1.8
Separator plate
Thickness 3.2 ± 0.10 2.75
21 Friction plate
Load of wave spring (height: 1,480 N 440 N 1,255 N
22
3.2 mm) {151 kg} {45 kg} {128 kg}
ø 90 90.1
sliding portion of front housing 0
Width of seal ring groove of +0.15
3.0 2.3
23 front output shaft +0.10
Wear of seal ring -0.01

Width 3.0 2.7
of front output -0.03
shaft Thickness 3.7 ± 0.12 3.3
HM300-1 10-27
(9)
OPERATION OF CLUTCHES
Clutch engaged (fixed) Clutch disengaged (free)

• The oil sent from the transmission valve passes • The oil sent from the transmission valve is shut
through the oil passage inside shaft (1), reaches off, so the pressure of the oil acting on the back
the back face of piston (6) and acts on piston (6). face of piston (6) goes down.
• When piston (6) is actuated, separator plate (2) • Piston (6) is returned to its original position by
and friction plate (3) are pressed together, shaft wave spring (7), and shaft (1) and clutch gear (4)
(1) and clutch gear (4) form one unit, and the are separated.
power is transmitted. • When the clutch is disengaged, centrifugal force
When this happens, the oil is drained from oil is used to drain the oil at the back face of the pis-
drain hole (5), but the drain amount is less than ton through oil drain hole (5). This acts to pre-
the amount of oil supplied, so there is no influ- vent the clutch from being partially applied.
ence on the actuation of the clutch.
★ Oil drain hole (5) forms part of the structure

of only the 2nd and differential lock clutches.
10-28 HM300-1
FORWARD 1ST
Operation
• In the case of FORWARD 1st, FL clutch (3) and • 1st clutch (11) is engaged, so the power trans-
1st clutch (11) are engaged. The power from the mitted to FH, 1st cylinder gear (8) passes
torque converter is transmitted to input shaft (1), through 1st clutch (11), and goes from 1st gear
and then transmitted to front and rear output (12) to 2nd, 3rd cylinder gear (14). It then goes
shafts (27) and (28). through output gear (19), and is transmitted to
• FL clutch (3) and 1st clutch (11) hold each clutch differential lock carrier (20).
disc in position with the oil pressure applied to • When the differential lock switch is OFF, the
the piston. front output force passes from planet gear (24)
• The power from the torque converter is transmit- through sun gear (25), and is transmitted to front
ted from input shaft (1) through FL clutch (3), output shaft (27). The rear output force passes
goes to FL gear (5), and is then transmitted to from planet gear (24) through ring gear (26),
FH, 1st cylinder gear (8). and is transmitted to rear output shaft (28).
★ If the differential lock is ON, see FORWARD
2ND.
HM300-1 10-29
(9)
FORWARD 2ND
Operation
• In the case of FORWARD 2nd, FH clutch (10) • 1st clutch (11) is engaged, so the power trans-
and 1st clutch (11) are engaged. The power mitted to FH, 1st cylinder gear (8) passes
from the torque converter is transmitted to input through 1st clutch (11), and goes from 1st gear
shaft (1), and then transmitted to front and rear (12) to 2nd, 3rd cylinder gear (14). It then goes
output shafts (27) and (28). through output gear (19), and is transmitted to
• FH clutch (10) and 1st clutch (11) hold each differential lock carrier (20).
clutch disc in position with the oil pressure ap- • When the differential lock switch is ON, the
plied to the piston. front output force passes from front housing (21)
• The power from the torque converter is transmit- through differential lock clutch (22) and clutch
ted from input shaft (1) to idler gear (2) and goes hub (23), and is transmitted to front output shaft
to FH gear (9), passes through FH clutch (10), (27). The rear output force passes from planet
and is then transmitted to FH, 1st cylinder gear gear (24) through ring gear (26), and is transmit-
(8). ted to rear output shaft (28).
★ If the differential lock is OFF, see FORWARD
1ST.
10-30 HM300-1
FORWARD 3RD
Operation
• In the case of FORWARD 3rd, FL clutch (3) and • 2nd clutch (17) is engaged, so the power trans-
2nd clutch (17) are engaged. The power from mitted to 2nd gear (15) passes through 2nd
the torque converter is transmitted to input shaft clutch (17), and goes to 2nd, 3rd cylinder gear
(1), and then transmitted to front and rear output (14). It then goes through output gear (19), and
shafts (27) and (28). is transmitted to differential lock carrier (20).
• FL clutch (3) and 2nd clutch (17) hold each ★ The diagram above shows the situation when
clutch disc in position with the oil pressure ap- the differential lock is OFF.
plied to the piston. ★ For details of the actuation when the differential
• The power from the torque converter is transmit- lock is OFF, see FORWARD 1ST; for details of
ted from input shaft (1) through FL clutch (3), the actuation when the differential lock is ON,
goes to FL gear (5), and is then transmitted see FORWARD 2ND.
through FH, 1st cylinder gear (8) and idler gear
(13), and goes to 2nd gear (15).
HM300-1 10-31
FORWARD 4TH
Operation
• In the case of FORWARD 4th, FH clutch (10) • 2nd clutch (17) is engaged, so the power trans-
and 2nd clutch (17) are engaged. The power mitted to 2nd gear (15) passes through 2nd
from the torque converter is transmitted to input clutch (17), and goes to 2nd, 3rd cylinder gear
shaft (1), and then transmitted to front and rear (14). It then goes through output gear (19), and
output shafts (27) and (28). is transmitted to differential lock carrier (20).
• FH clutch (10) and 2nd clutch (17) hold each ★ The diagram above shows the situation when
clutch disc in position with the oil pressure ap- the differential lock is ON.
plied to the piston. ★ For details of the actuation when the differential
ted from input shaft (1), goes to idler gear (2) the actuation when the differential lock is ON,
and FH gear (9), passes through FH clutch (10), see FORWARD 2ND.
and is then transmitted through FH, 1st cylinder
gear (8) and idler gear (13), and is transmitted
to 2nd gear (15).
10-32 HM300-1
FORWARD 5TH
Operation
• In the case of FORWARD 5th, FL clutch (3) and • 3rd clutch (18) is engaged, so the power trans-
3rd clutch (18) are engaged. The power from mitted to 3rd gear (16) passes through 3rd clutch
the torque converter is transmitted to input shaft (18), and goes to 2nd, 3rd cylinder gear (14). It
(1), and then transmitted to front and rear output then goes through output gear (19), and is trans-
shafts (27) and (28). mitted to differential lock carrier (20).
• FL clutch (3) and 3rd clutch (18) hold each clutch ★ The diagram above shows the situation when
disc in position with the oil pressure applied to the differential lock is OFF.
the piston. ★ For details of the actuation when the differential
ted from input shaft (1) through FL clutch (3), the actuation when the differential lock is ON,
goes to FL gear (5), and is then transmitted see FORWARD 2ND.
through FH, 1st cylinder gear (8) to 3rd gear
(16).
HM300-1 10-33
FORWARD 6TH
Operation • 3rd clutch (18) is engaged, so the power trans-

• In the case of FORWARD 6th, FH clutch (10) mitted to 3rd gear (16) passes through 3rd clutch
and 3rd clutch (18) are engaged. The power (18), and goes to 2nd, 3rd cylinder gear (14). It
from the torque converter is transmitted to input then goes through output gear (19), and is
shaft (1), and then transmitted to front and rear transmitted to differential lock carrier (20).
output shafts (27) and (28). ★ The diagram above shows the situation when
• FH clutch (10) and 3rd clutch (18) hold each the differential lock is ON.
clutch disc in position with the oil pressure ap- ★ For details of the actuation when the differential
plied to the piston. lock is OFF, see FORWARD 1ST; for details of
• The power from the torque converter is transmit- the actuation when the differential lock is ON,
ted from input shaft (1), goes to idler gear (2) see FORWARD 2ND.
and FH gear (9), passes through FH clutch (10),
and is then transmitted through FH, 1st cylinder
gear (8) to 3rd gear (16).
10-34 HM300-1
REVERSE 1ST
Operation
• In the case of REVERSE 1st, R clutch (4) and • 1st clutch (11) is engaged, so the power trans-
1st clutch (11) are engaged. The power from the mitted to FH, 1st cylinder gear (8) passes
torque converter is transmitted to input shaft (1), through 1st clutch (11), and goes from 1st gear
and then transmitted to front and rear output (12) to 2nd, 3rd cylinder gear (14). It then goes
shafts (27) and (28). through output gear (19), and is transmitted to
• R clutch (4) and 1st clutch (11) hold each clutch differential lock carrier (20).
disc in position with the oil pressure applied to ★ The diagram above shows the situation when
the piston. the differential lock is OFF.
• The power from the torque converter is trans- ★ For details of the actuation when the differential
mitted from input shaft (1) through R clutch (4), lock is OFF, see FORWARD 1ST; for details of
goes to R gear (6), is rotated in the opposite di- the actuation when the differential lock is ON,
rection by R idler gear (7), passes through idler see FORWARD 2ND.
gear (13), and is then transmitted to FH, 1st
cylinder gear (8).
HM300-1 10-35
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION VALVE
TRANSMISSION VALVE
ECMV clutch operation table

A. Differential lock clutch oil pressure detection port
ECMV
B. FH clutch oil pressure detection port
C. 1st clutch oil pressure detection port FL FH R 1st 2nd 3rd
Speed
D. FL clutch oil pressure detection port Range
E. R clutch oil pressure detection port
F. 3rd clutch oil pressure detection port F1 O O
G. 2nd clutch oil pressure detection port
H. Lock-up clutch oil pressure detection port F2 O O
1. ECMV (for differential lock clutch) F3 O O
2. ECMV (for FH clutch)
3. ECMV (for 1st clutch)
F4 O O
4. ECMV (for FL clutch)
5. ECMV (for R clutch)
F5 O O
6. ECMV (for 3rd clutch)
7. ECMV (for 2nd clutch)
F6 O O
8. ECMV (for lock-up clutch) R1 O O
9. Seat
10. Last chance filter R2 O O
N
10-36 HM300-1
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ECMV (Electronic Control Modulation Valve)
ECMV (Electronic Control Modulation Valve)
A: To clutch 1. Connector for fill switch

P: From pump 2. Connector for proportional solenoid
T: Drain 3. Oil pressure detection valve
Dr: Drain 4. Fill switch
P1: Clutch oil pressure detection port 5. Proportional solenoid
P2: Pilot oil pressure detection port 6. Pressure control valve
HM300-1 10-37
ECMV FOR LOCK-UP CLUTCH
Outline Operation
• This valve acts to set the lock-up clutch oil pres- During torque converter travel
sure to the set pressure, and also to switch the • When the transmission is in torque converter
lock-up clutch. travel, no current flows to proportional solenoid
It forms a modulation wave pattern, so the lock- (1).
up clutch is engaged smoothly to reduce the Pressure control valve (3) drains the oil at clutch
shock when shifting gear. In addition, it prevents port A through drain port Dr and cancels the
generation of peak torque in the power train. As lock-up clutch.
a result, it provides a comfortable ride for the op- When this happens, there is no oil pressure act-
erator and greatly increases the durability of the ing on oil pressure detection valve (4), so fill
power train. switch (6) is OFF.
10-38 HM300-1
(9)
DURING DIRECT TRAVEL

(torque converter travel ➔ direct travel)
1. When filling 2. Adjusting pressure

When the transmission is in direct travel (lock- When electric current flows to proportional sole-
up), if electric current is applied to proportional noid (1), the solenoid generates a propulsion
solenoid (1) by the electric signal, a hydraulic force proportional to the current. The pressure
force balancing with the force of the solenoid is adjusted so that the total of this propulsion
acts on chamber B, and pressure control valve force of the solenoid, the propulsion force of the
spool (3) moves to the left. As a result, the oil pressure at the clutch port, and the reaction
circuit between pump port P and clutch port A force of pressure control valve spring (2) is bal-
opens, and oil starts to fill the clutch. When the anced.
clutch is filled with oil, fill switch (6) is turned To reduce the shock when shifting gear, the oil
ON. pressure of the lock-up clutch is temporarily
lowered during the gearshifting operation.
The oil pressure at this point is an oil pressure
which balances the pushing force of the lock-up
piston and the pressure inside the torque con-
verter.
HM300-1 10-39
(9)
ECMV FOR SPEED CLUTCH ECMV and proportional solenoid

• There is one proportional solenoid installed to
Outline of ECMV each ECMV.
• The ECMV (Electronic Control Modulation It generates propulsion as shown in the dia-
Valve) consists of two components: the pressure gram below according to the command current
control valve and the fill switch. from the controller.
• Pressure control valve The propulsion generated by the proportional
The proportional solenoid receives the flow of solenoid acts on the pressure control valve
electricity sent from the transmission controller, spool and generates oil pressure as shown in
and the pressure control valve converts this into the diagram below. In this way, the command
hydraulic pressure. current is controlled and the propulsion force
• Fill switch varies to actuate the pressure control valve
This detects when oil has filled the clutch. It and control the oil flow and oil pressure.
has the following functions.
1) When the clutch is filled with oil, it sends a
signal (fill signal) to the controller to inform
the controller that the filling is completed.
2) While oil pressure is applied to the clutch, it
outputs a signal (fill signal) to the controller
to inform the controller of the existence of
the oil pressure.
A range: Before gear shifting (drained)

B range: Filling starts (trigger issued)
C range: Filling completed
D range: Regulation
E range: Filling
ECMV and fill switch

• There is one fill switch installed to each ECMV.
When the filling of the clutch is completed, the fill
switch is turned on by the clutch pressure. With
this signal, the oil pressure starts to build up.
10-40 HM300-1
(9)
OPERATION OF ECMV
• The ECMV is controlled by the command current 1. When gear shifting (during draining)
from the transmission controller to the propor- (Range A in graph)
tional solenoid and the fill switch output signal. When no current is flowing to proportional sole-
The relationship between the ECMV propor- noid (1), pressure control valve spool (3) drains
tional solenoid command current and the clutch the oil at clutch port A through drain port Dr.
input pressure and fill switch output signal is as When this happens, there is no hydraulic force
shown in the diagram below. acting on pressure detection valve (4), so fill
switch (6) is turned OFF.
A range: Before gear shifting (drained)
B range: Filling starts (trigger issued)
C range: Filling completed
D range: Regulation
E range: Filling
HM300-1 10-41
2. When filling (when trigger command is input 3. Adjusting pressure (Range D in graph)
to pressure control valve) When electric current flows to proportional sole-
(Ranges B and C in graph) noid (1), the solenoid generates a propulsion
When there is no oil inside the clutch, if electric force proportional to the current. The pressure
current is applied to proportional solenoid (1), a is adjusted so that the total of this propulsion
hydraulic force balancing the force of the sole- force of the solenoid, the propulsion force of the
noid acts on chamber B, and pressure control oil pressure at the clutch port, and the reaction
valve spool (3) moves to the left. As a result, force of pressure control valve spring (2) is bal-
the circuit between pump port P and clutch port anced.
A opens, and oil starts to fill the clutch. When
the clutch is filled with oil, fill switch (6) is turned
ON.
10-42 HM300-1
(9)
MAINTENANCE STANDARD ECMV (Electronic Control
ECMV (Electronic
ModulationControl
Valve)
ECMV FOR DIFFERENTIAL LOCK
Operation
1. When differential lock switch is turned ON ➔ 2. When differential lock switch is turned OFF
OFF ➔ ON
When the differential lock switch is turned OFF, When the differential lock switch is turned ON, and
there is no electric current flowing from the electric signal is sent from the controller to
controller to proportional solenoid (1) of the proportional solenoid (1) of the ECMV, and oil starts
ECMV, so the oil at clutch port A passes through to fill clutch port A. As a result, piston (2) is actuated,
drain port Dr and is drained. As a result, the presses separator plate (3) and friction plate (4)
force of the oil pressure at clutch port A goes together, so carrier (6) and front output shaft (7) form
down and piston (2) is returned to its original one unit and transmit the power.
position by wave spring (5). Carrier (6) and front
output shaft (7) are separated, and the power is
transmitted by the planetary gear.
The proportion of the torque at this point is as The proportion of the torque at this point is as
follows: follows:
Front 1: Rear 2 Front 1: Rear 1
HM300-1 10-43
(9)
MAINTENANCE STANDARD MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
A: Drain (torque converter relief) 1. Body

B: Drain 2. Piston
C: From pump 3. Torque converter relief valve
D: Drain 4. Piston
E: To torque converter 5. Main relief valve
P1: Main relief oil pressure detection port
P2: Torque converter relief oil pressure detection
port
Unit: mm

Clearance between main relief size Shaft Hole clearance limit
6 valve and valve body
-0.035 +0.013 0.035 –
ø 28 0.078
-0.045 0 0.058
Clearance between torque con-
7 -0.035 +0.013 0.035 –
verter relief valve and valve ø 22 0.078
-0.045 0 0.058
body
Standard size Repair limit Replace
Free Installed Installed Free Installed
Main relief valve spring (out-
8 length length load length load
side)
275 N 261 N
108 79.5 104.8
{28.0 kg} {26.6 kg}
326 N 309 N
9 Main relief valve spring (inside) 108 79.5 104.8
{33.2 kg} {31.5 kg}
Torque converter relief valve 173 N 164 N
10 50 41 48.5
spring {17.6 kg} {16.7 kg}
10-44 HM300-1
(9)
MAINTENANCE STANDARD MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
OUTLINE Operation of main relief valve

• The oil from the hydraulic pump passes through
Torque converter relief valve the filter and enters port A of the relief valve. It
The torque converter relief valve protects the torque then passes through orifice a of spool (6) and
converter from abnormally high pressure. It is in- enters chamber B.
stalled in the torque converter inlet port circuit to hold When the oil from the pump fills the circuit, the
the oil pressure in the torque converter inlet port cir- oil pressure starts to rise.
cuit below the set pressure.
Set pressure: 0.91 MPa {9.31 kg/cm2}
(Cracking pressure)
Main relief valve

The main relief valve holds the oil pressure in the
transmission and brake at the set pressure.
Set pressure: 2.55 MPa {26.0 kg/cm2}
(Engine at rated speed)
OPERATION
Operation of torque converter relief valve • As the oil pressure in the circuit rises, the oil en-
• The oil relieved by the main relief valve flows tering chamber B pushes piston (4). The reac-
from port C into the torque converter, and at the tion force compresses valve spring (7) and
same time, passes through orifice b of spool (2) moves spool (6) to the left to open the circuit be-
and enters chamber D. tween port A and port C.
When the circuit leading to the torque converter When this happens, the oil at port A is relieved
becomes filled with oil, the oil pressure starts to to port C and flows from port C to the torque
rise. converter.
The oil pressure at port A at this point is 2.55
• As the oil pressure going to the torque converter MPa {26.0 kg/cm2} (engine at rated speed).
rises, the oil entering chamber D pushes piston
(9). The reaction force compresses valve spring
(3) and moves spool (2) to the right to open the
circuit between port C and port E.
When this happens, the oil at port C is relieved
to port E and drains to the oil tank.
The oil pressure at port C at this point is 0.91
MPa {9.31 kg/cm2} (cracking pressure).
HM300-1 10-45
(9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DRIVE SHAFT
DRIVE SHAFT
1. Drive shaft (right) Outline

2. Front drive shaft • The power from the engine goes from the output
3. Drive shaft (left) shaft through front drive shaft (2), the transmis-
4. Center drive shaft sion, and the front axle, and is transmitted by
5. Rear drive shaft (front) right and left drive shafts (1) and (3).
6. Rear drive shaft (rear) The rest of the power passes through center
drive shaft (4) and the oscillation hitch, and is
transmitted by rear drive shafts (5) and (6) to
the rear axles.
• The drive shaft does not only transmit the power
but also has the following function.
When the machine articulates or receives
impacts from the ground and other things during
travel and operation, the positions of the
engine, transmission, and each axle change.
The drive shaft has the universal joints and slid-
ing joints to absorb the change of angles and
lengths and transmit the power without damag-
ing the parts even when the positions of the com-
ponents change and impacts are given to the
machine.
10-46 HM300-1
(9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AXLE
AXLE
FRONT
1. Drive shaft
2. Front differential
3. Brake
4. Final drive
HM300-1 10-47
CENTER
1. Center differential
2. Center axle housing
3. Brake
4. Final drive
5. Drain plug
10-48 HM300-1
REAR
1. Drain plug
2. Rear differential
3. Rear axle housing
4. Final drive
HM300-1 10-49
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DIFFERENTIAL
DIFFERENTIAL
FRONT
1. Bevel gear (No. of teeth: 41) 6. Shaft

2. Bevel pinion (No. of teeth: 13) 7. Shaft
3. Limited slip differential 8. Disc
4. Side gear (No. of teeth: 24) 9. Plate
5. Pinion gear (No. of teeth: 12)
10-50 HM300-1
(9)
Unit: mm

Wear of coupling oil seal con-
10 0
tact surface 95 94.9 Repair or
-0.087
replace
Wear of coupling oil seal con- 0
11 90 89.9
tact surface -0.087
Backlash between bevel gear
12 0.36 – 0.55 (in circumferential direction at outside diameter) Adjust
and pinion
HM300-1 10-51
CENTER
1. Bevel pinion (No. of teeth: 13) 8. Shaft

2. Disc 9. Gear (No. of teeth: 27)
3. Plate 10. Shaft
4. Pinion gear (No. of teeth: 12) 11. Coupling
5. Limited slip differential 12. Shaft
6. Bevel gear (No. of teeth: 41) 13. Gear (No. of teeth: 27)
7. Side gear (No. of teeth: 24)
10-52 HM300-1
Unit: mm

Wear of coupling oil seal con- Repair or
14 0
tact surface 95 94.9 replace
-0.087
Wear of coupling oil seal 0 Repair or
15 90 89.9
contact surface -0.087 replace
and pinion
HM300-1 10-53
REAR
1. Bevel pinion (No. of teeth: 13)

2. Plate
3. Disc
4. Bevel gear (No. of teeth: 41)
5. Shaft
6. Limited slip differential
7. Pinion gear (No. of teeth: 12)
8. Side gear (No. of teeth: 24)
10-54 HM300-1
Unit: mm

Wear of coupling oil seal con- Repair or
9 0
tact surface 90 89.9 replace
-0.087
and pinion
HM300-1 10-55
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LIMITED SLIP DIFFERENTIAL
LIMITED SLIP DIFFERENTIAL
1. Washer Operation of limited slip differential

2. Disc The power transmitted from the transmission goes
3. Plate from bevel gear (5) to case (9), pressure ring (4),
4. Pressure ring shaft (8), pinion gear (7), side gear (6), and is then
5. Bevel gear divided and sent to left and right shafts (11). A brake
6. Side gear mechanism consisting of disc (2) and plate (3) is as-
7. Pinion gear sembled at the rear face of side gear (6), and the
8. Shaft brake torque is generated in proportion to the torque
9. Case transmitted from pressure ring (4) to shaft (8).
10. Cover In order for this brake torque to act to suppress the
11. Shaft rotation in relation to side gear (6) and case (9), it is
made difficult for left and right side gears (6) to rotate
mutually, and the action of the differential is sup-
pressed.
10-56 HM300-1
(9)
Unit: mm

1 Plate thickness 3
0.02 2.9
3.1
+0.04
2 Disc thickness 3 2.95
-0.03
Clearance between disc and
3 0.2 - 0.75
plate (Total on both sides)
4 Replace
4 Washer thickness ± 0.05 3.8
4.1
End play of side gear in axial
5 0.15 - 0.35
direction (Each side)
Backlash between case and
6 0.4
plate
Backlash between side gear
7 0.13 – 0.36
and disc
HM300-1 10-57
<Mechanism for generation of brake torque of

left and right side gears (6)>
Shaft (8) is supported by the cam surface cut into the
mating surfaces of left and right pressure rings (4).
The power (= torque) transmitted from pressure ring
(4) to shaft (8) is transmitted by the cam surface, but
force Fa to separate left and right pressure rings (4)
is generated in proportion to the torque transmitted
by the angle of this cam surface.
This separation load Fa acts as a brake on the rear
face of left and right side gears (6) and generates
brake torque.
<When travelling in a straight line >

1. When there in a no imbalance between drive
force of left and right wheels.
(The road surface condition (friction coeffident)
for the left and right wheels and the load on the
wheels are uniform.)
The power from the transmission is divided uni-
formly to the left and right by the side gear. Un-
der these conditions, the limit for wheel slip for
the left and right wheels is the same, so even if
the power from the transmission exceeds the
wheel slip limit, the wheels on both sides slip
and the differential is not actuated.
No load is applied to the brake at the rear sur-
face of the side gear.
10-58 HM300-1
(9)
2. When there is imbalance between drive force

of left and right wheels
(The road surface condition (friction coefficient)
for the left and right wheels and the load on the
wheels are not uniform and the wheel on one
side tends to slip more than the wheel on the
other side.)
• When wheel on one side is on soft ground sur-

face.
• The power from the transmission is divided uni-

formly to the left and right by the side gear.
However, if the divided drive force exceeds the
wheel slip limit on the side where the wheel is
slipping, a drive force equal to the excess is sent
through the brake at the rear face of the side
gear and the case to the brake on the opposite
side (side where wheel is locked), and is sup-
plied to the wheel on the side which is locked.
If this excess drive force becomes greater than
the braking force, the differential starts to be ac-
tuated.
Difference in wheel drive force for each type of differ-

ential when wheel on one side is slipping
Wheel drive force (taken as 1 for wheel

that is slipping)
Slipping Locked Total

wheel wheel (proportional)
Limited slip 1 2.64 3.64 (1.82)

differential
Normal 1 1 2 (1)
differential
On road surfaces where the wheel on one side is

likely to slip, the limited slip differential increases the
drive force 1.82 times that of the normal differential
supplied as standard.
<When turning>
The side gear built into the limited slip differential is
the same as the gear used on the normal differential,
so the difference in rotation of the inside and outside
wheels generated when turning can be generated
smoothly.
HM300-1 10-59
(9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
FRONT
1. Axle shaft
2. Ring gear (No. of teeth: 66)
3. Planetary gear (No. of teeth: 23)
4. Planetary carrier
5. Sun gear (No. of teeth: 18)
6. Drain plug
7. Brake
10-62 HM300-1
(9)
Unit: mm
Backlash between planetary

8 0.17 – 0.41
gear and sun gear
Replace
9 0.20 – 0.55
gear and ring gear
10 Curvature of drive shaft Repair limit: 0.7TIR Repair or replace
11 Thickness of spacer Replace
14 ± 0.1 13.5
Wear of outside diameter of
+0.040
12 portion of ring gear hub 170 170
+0.015
inserted into bearing
Repair
-0.030
13 portion of axle tube inserted 140 139.83
-0.055
into bearing

Clearance between shaft (out- size Shaft Hole clearance limit
14 Replace
side diameter) and bushing
0 +0.337 0.251 –
65 0.4
-0.013 +0.251 0.350
HM300-1 10-63
(9)
CENTER
1. Axle shaft 5. Sun gear (No. of teeth: 18)

2. Ring gear (No. of teeth: 66) 6. Drain plug
3. Planetary gear (No. of teeth: 23) 7. Brake
4. Planetary carrier
Unit: mm

8 0.17 – 0.41
gear and sun gear
Replace
9 0.20 – 0.55
gear and ring gear
28 ± 0.1 27.5
+0.040
+0.015
Repair
-0.030
-0.055
into bearing
10-64 HM300-1
(9)
REAR
1. Axle shaft 4. Planetary carrier

2. Ring gear (No. of teeth: 66) 5. Sun gear (No. of teeth: 18)
3. Planetary gear (No. of teeth: 23) 6. Drain plug
Unit: mm

7 0.17 – 0.41
gear and sun gear
Replace
8 0.20 – 0.55
gear and ring gear
28 ± 0.1 27.5
+0.040
+0.015
Repair
-0.030
-0.055
into bearing
HM300-1 10-65
(9)
Function
• The final drive uses a planetary gear mechanism
to reduce the speed in order to give a large drive
force, and transmits this drive force to the tires.
Operation
• The power from the differential passing through
axle shaft (1) is transmitted to sun gear (5) and
then goes to planetary gear (3).
The planetary gear rotates on the inside of fixed
ring gear (2) and transmits the reduced speed
to planetary carrier (4). This power is then
transmitted to the wheels that are installed to
the planetary carrier.
10-66 HM300-1
(9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING COLUMN
STEERING COLUMN
1. Steering shaft
2. Steering column
3. Lock lever
4. Yoke
5. Join shaft
6. Steering valve
HM300-1 10-67
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE PIPING
BRAKE PIPING
10-68 HM300-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE PIPING
1. Slack adjuster (Front)

2. Shuttle valve
3. Slack adjuster (center)
4. Proportional reducing valve
5. Accumulator (for center)
6. Accumulator (for front)
7. Parking brake solenoid
8. Brake system tank
9. Accumulator charge valve
10. Brake valve
11. Brake filter
HM300-1 10-69
4
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE VALVE
BRAKE VALVE
1. Pilot piston A. To center brake

2. Rod B. To front brake
3. Lower cylinder C. To brake system tank
4. Spool D. From front accumulator
5. Upper cylinder E. From center accumulator
6. Spool
10-70 HM300-1
OPERATION Applying brake when upper valve fails

• Even if there is leakage of oil in the upper piping,
Upper portion spool (5) is moved down mechanically when
• When brake pedal (1) is depressed, the operat- pedal (1) is depressed, and the lower portion is
ing force is transmitted to spool (3) through rod actuated normally.
(2) and spring (4). When spool (3) goes down, The upper portion brake is not actuated.
drain port a is closed, and the oil from the pump
and accumulator flows from port A to port C and Applying brake when lower valve fails
actuates the center brake cylinder. • Even if there is leakage of oil in the lower piping,
the upper portion is actuated normally.
Lower portion
• When brake pedal (1) is depressed, the operat-
ing force is transmitted to spool (3) through rod
(2) and spring (4). When spool (3) goes down,
spool (5) is also pushed down by plunger (6).
When this happens, drain port b is closed, and
the oil from the pump and accumulator flows
from port B to port D and actuates the front
brake cylinders.
When actuation is balanced

Upper portion
• When oil fills the center brake cylinders and the
pressure between port A and port C becomes
high, the oil entering port H from orifice e of
spool (3) pushes against spring (4). It pushes up
spool (3) and shuts off the circuit between port A
and port C. When this happens, drain port a
stays closed, so the oil entering the brake cylin-
der is held and the brake remains applied.
HM300-1 10-71
(9)
Lower portion Brake released

• When spool (3) in the upper portion moves up
and the circuit between port A and port C is shut Upper portion
off, oil also fills the front brake cylinder at the • When pedal (1) is released and the operating
same time, so the pressure in the circuit force is removed from the top of the spool, the
between port B and port D rises. The oil entering back pressure from the brake cylinder and the
port J from orifice f of spool (5) pushes up spool force of the spool return spring move spool (3)
(5) by the same amount that spool (3) moves, up. Drain port a is opened and the oil from the
and shuts off port B and port D. Drain port b is brake cylinder flows to the brake system tank
closed, so the oil entering the brake cylinder is return circuit to release the center and rear
held, and the brake is applied. brakes.
• The pressure in the space in the upper portion is
balanced with the operating force of the pedal,
and the pressure in the space in the lower Lower portion
portion is balanced with the pressure in the • When the pedal is released, spool (3) in the
space in the upper portion. When spools (3) and upper portion moves up. At the same time, the
(5) move to the end of their stroke, the circuits back pressure from the brake cylinder and the
between ports A and C and between ports B and force of the spool return spring move spool (5)
D are fully opened, so the pressure in the space up. Drain port b is opened and the oil from the
in the upper and lower portions and the pressure brake cylinder flows to the brake system tank
in the left and right brake cylinders is the same return circuit to release the front brake.
as the pressure from the pump.
Therefore, up to the point where the piston
moves to the end of its stroke, the effect of the
brake can be adjusted by the amount that the
pedal is depressed.
10-72 HM300-1
4
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ACCUMULATOR CHARGE VALVE
ACCUMULATOR CHARGE VALVE
ACC. To accumulator Function

P. From hydraulic pump • The accumulator charge valve is actuated to
PP. To accumulator maintain the oil pressure from the pump at the
T. To brake system tank specified pressure and to store it in the accumu-
lator.
• When the oil pressure reaches the specified
pressure, the oil from the pump is connected to
the drain circuit to reduce the load of the pump.
HM300-1 10-73
4
(9)
1. \Main relief valve (R3) 4. Relief valve (H1)

2. Valve body 5. Filter
3. Relief valve (R1) 6. Filter
10-74 HM300-1
OPERATION 2. When oil supplied to accumulator

1) Cut-in condition
1. When no oil is being supplied to accumulator • When the pressure at port B is lower than the set
(cut-out condition) pressure of the relief valve (R1), piston (8) is
• The pressure at port B is higher than the set pushed back down by spring (5).
pressure of the relief valve (R1), so piston (8) is Valve seat (7) and poppet (6) are brought into
forcibly pushed up by the oil pressure at port B. tight contact, and port C and port T are shut off.
Poppet (6) is opened, so port C and port T are • The spring chamber at the right end of spool (15)
short circuited. is also shut off from port T, so the pressure rises,
• The spring chamber at the right end of spool (15) and the pressure at port P also rises in the same
is connected to port C of the relief valve (R1), so way.
the pressure becomes the oil tank pressure. The • When the pressure at port P goes above the
oil from the pump enters port P, pushes spool pressure at port B (accumulator pressure), the
(15) to the right at a low pressure equivalent to supply of oil to the accumulator starts immedi-
the load on spring (14). ately. In this case, it is decided by the size (area)
It also passes through orifices (17), (18) and of orifice (17) and the pressure difference
(16), and flows to the oil tank. (equivalent to the load on spring (14)) generated
on both sides of the orifice. A fixed amount is
supplied regardless of the engine speed.
HM300-1 10-75
(9)
2) When cut-out pressure is reached 3. Main relief valve (R3)

• When the pressure at port B (accumulator pres- • If the pressure at port P (pump pressure) goes
sure) reaches the set pressure of the relief valve above the set pressure of the relief valve (R3),
(R1), poppet (6) separates from valve seat (7), the oil from the pump pushes spring (3). Ball (11)
so an oil flow is generated and the circuit is re- is pushed up and the oil flows to the brake oil
lieved. tank circuit, so this set the maximum pressure in
• When the circuit is relieved, a pressure differ- the brake circuit and protects the circuit.
ence is generated above and below piston (8),
so piston (8) moves up, poppet (6) is forcibly
opened, and port C and port T are short
circuited.
• The spring chamber at the right end of spool (15)
is connected to port C of the relief valve (R1), so
the pressure becomes the brake oil tank pres-
sure.
• The pressure at port P drops in the same way to
a pressure equivalent to the load on spring (14),
so the supply of oil to port B is stopped.
10-76 HM300-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ACCUMULATOR
ACCUMULATOR
1. Valve
2. Top cover
3. Cylinder
4. Piston
Function
• The accumulator is installed between the accu-
mulator charge valve and the brake valve. It is
charged with nitrogen gas between cylinder (3)
and free piston (4), and uses the compressibility
of the gas to absorb the pulse of the hydraulic
pump or to maintain the braking force and to
make it possible to operate the machine if the
engine should stop.
Specifications
Gas used: Nitrogen gas
Gas capacity: 4,000 cc
Charging pressure: 4.4 ± 0.15MPa
{45 ± 1.5kg/cm2} (at 20 °C ± 5 °C)
HM300-1 10-77
(9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SLACK ADJUSTER
SLACK ADJUSTER
1. Breather
2. Cylinder
3. Check valve
4. Spring
5. Piston
A. Inlet port
B. Outlet port
Unit: mm

size Shaft Hole clearance limit
Clearance Front
6 between body and -0.030 +0.074 0.030 –
55 0.25
piston -0.076 0 0.150
-0.030 +0.074 0.030 –
Center 55 0.25
-0.076 0 0.150
Standard size Repair limit Replace
Free Installed Installed Free Installed
Front length length load length load
Slack adjuster
7 118 N
spring 230 88 – –
{12 kg}
39.2 N
Center 198 60 – –
{4.0 kg}
10-78 HM300-1
(9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SLACK ADJUSTER
Specifications • If the brake pedal is depressed further, and the

Piston actuation oil pressure: oil pressure discharged from the brake valve
0.01 + 0.01 MPa {0.1 + 0.1 kg/cm2} goes above to set pressure, check valve (3)
Check valve cracking pressure: opens and the pressure is applied to port C to
0.93 ± 0.05 MPa {9.5 ± 0.5 kg/cm2} act as the braking force.
Check valve closing pressure: Therefore, when the brake is applied, the time
0.6 ± 0.05 MPa {6.0 ± 0.5 kg/cm2} lag is a fixed valve.
FUNCTION
• The slack adjuster is installed in the brake oil line
from the brake valve to the brake piston. It acts
to keep a constant time lag when the brake is
operated.
OPERATION
1. When brake pedal is depressed

• Before the brake is depressed, piston (4) is re-
turned by the distance of stoke S (full stroke).
When the brake pedal is depressed, the oil dis-
charged from the brake valve flows from port P 2. When brake pedal is released
of the slack adjuster and is divided to left and • When the brake is released, piston (4) returns
right cylinders (2), where it moves piston (4) by because of lowering of the brake oil pressure by
stroke S to the left and right. an amount equivalant to the oil for stroke S, and
the brake is released again.
In other words, return stroke T of brake piston
(7) is determined by the amount of oil for stroke
S of the slack adjuster. The time lag of the
brake is always kept constant regardless of the
wear of the brake disc.
• As a result, brake piston (7) moves by an

amount equal to stroke S. When this happens,
the relationship between the brake piston and
disc is simply that the clearance becomes 0. No
braking force is generated.
HM300-1 10-79
(9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE
BRAKE
FRONT
1. Stud bolt
2. Cylinder
3. Brake piston
4. Disc
5. Plate
6. Hub gear (No. of teeth: 96)
7. Outer gear (No. of teeth: 148)
10-80 HM300-1
(9)
Unit: mm
Backlash between outer gear Standard backlash Repair limit
1
and plate 0.22 – 0.56 1.1
Backlash between hub gear
2 0.17 – 0.52 1.1
and plate
Standard size Repair limit
3 Thickness of plate
2.4 2.15
4 Thickness of disc 5.2 4.7
Replace
5 Thickness of damper 6.9 5.1
Distortion of disc friction sur- Standard distortion Repair limit
6
face Max 0.45 0.7
Distortion of plate and damper
7 Max 0.50 0.7
friction surface
Assemble thickness of plate Standard size Repair limit
8
and disc 61.2 56.7
Wear of lip contact surface of Correct or
9 401 400.9
oil seal ring replace
HM300-1 10-81
(9)
CENTER
1. Bolt
2. Cylinder
3. Brake piston
4. Disc
5. Plate
6. Hub gear (No. of teeth: 96)
7. Outer gear (No. of teeth: 148)
10-82 HM300-1
Unit: mm
Backlash between outer gear Standard backlash Repair limit
1
and plate 0.22 – 0.56 1.1
Backlash between hub gear
2 0.17 – 0.52 1.1
and plate
3 Thickness of plate
2.4 2.15
4 Thickness of disc 5.2 4.7
5 Thickness of damper 6.9 5.1
Replace
Distortion of disc friction sur- Standard distortion Repair limit
6
face Max 0.45 0.7
Distortion of plate and damper
7 Max 0.50 0.7
friction surface
Assemble thickness of plate Standard size Repair limit
8
and disc 76.4 70.9
Wear of lip contact surface of
9 401 400.9
oil seal ring
HM300-1 10-83
(9)
Function
• There are wet-type multiple disc brakes installed
to the front and center wheels.
Operation
• When the brake pedal is depressed, pressure oil
from the brake valve moves brake piston (3) to
the right in the direction of the arrow. This press-
es disc (7) and plate (6) together and generates
friction between the disc and plate. The wheel is
rotating together with the disc, so this friction re-
duces the travel speed and stops the machine.
• When the brake pedal is released, the pressure

at the back face of brake piston (3) is released,
so the piston is moved to the left in the direction
of the arrow by the internal pressure, and this re-
leases the brake.
10-84 HM300-1
(9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PROPORTIONAL REDUCING VALVE
PROPORTIONAL REDUCING VALVE
1. Filter Function
2. Connector • The proportional reducing valve is a valve used
3. Solenoid assembly for retarder control. It is installed between the
brake valve and the system tank in the brake cir-
A. To brake valve cuit.
P. From accumulator It varies the discharge pressure of the pressure
T. To brake system tank oil in accordance with the turning angle of the
retarder control lever, so the retarder control
can be carried out as desired.
HM300-1 10-85
4
(9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE SYSTEM TANK
BRAKE SYSTEM TANK
1. Plug
2. Return tube
3. Valve
4. Suction tube
A. From accumulator charge valve, brake valve

B. To transmission
C. To hydraulic pump
10-86 HM300-1
4
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PARKING BRAKE
PARKING BRAKE
1. Spring cylinder Function

2. Parking brake disc • The parking brake is the disc type and installed
3. Parking brake caliper to the rear of the oscillation hitch.
• It is actuated mechanically by the force of the
spring inside the spring cylinder and is released
by hydraulic pressure.
• The parking brake calipers are fixed to the oscil-
lation hitch.
The disc is installed to the oscillation hitch shaft
output coupling and rotates together with the
coupling.
10-88 HM300-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PARKING BRAKE
Unit: mm
Standard size Repair limit Repair or

4 Face runout of disc
0.4 0.8 replace
Rebuid
(Thickness of
Min. 20
5 Thickness of disc 25 disc must not be
under 20 mm)
Max. 20
Thickness of pad (including Replace
6 20 10
thickness of plate)
Standard dimen- Standard Clearance
Tolerance
sion of blade clearance limit
0
22.3
-0.3
Clearance between blade and Repair or
7 Standard
brake assembly Tolerance replace
dimension of 1.0 ± 0.4 1.5
brake assembly
+0.4
23
-0.1
HM300-1 10-89
(9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PARKING BRAKE CALIPER
PARKING BRAKE CALIPER
1. Adjuster Outline
2. Piston • A piston guide is installed to caliper (5). Piston
3. Piston shaft (2) and piston shaft (3) are inserted, and the ro-
4. Pad tation of piston shaft (3) moves piston (2) in the
5. Caliper axial direction to bring pad (4) into tight contact.
• The adjuster (1) is joined by a spline to the spline
side of piston shaft (3).
Pad (4) is inserted together with caliper (5) into
the caliper mounting plate and is held in posi-
tion.
10-90 HM300-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SPRING CYLINDER
SPRING CYLINDER
1. Outer spring OUTLINE

2. Inner spring • The oil pressure from the parking brake solenoid
3. Piston valve pushes the spring and releases the park-
4. Cylinder ing brake.
5. Boot When the engine is stopped, the parking brake
6. Rod is applied by springs (1) and (2), so the machine
is prevented from moving.
HM300-1 10-91
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PARKING BRAKE SOLENOID
PARKING BRAKE SOLENOID
1. Solenoid valve assembly Function

2. Relief valve • The parking brake solenoid valve is installed on
3. Block the right inner side of the front frame. When the
parking brake switch is turned ON, the solenoid
A: Outlet port valve is energized. This sends the brake oil to
P: Inlet port the parking brake spring cylinder and sets the
T: Drain port parking brake to the PARKING position. When
the parking brake is turned OFF, the solenoid
valve is de-energized, and the brake oil pressure
is removed from the parking brake spring cylin-
der to set the machine to the TRAVEL condition.
• Parking brake solenoid energized: TRAVEL
de-energized : PARKING
10-92 HM300-1
(4
9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SUSPENSION
SUSPENSION
FRONT
10-94 HM300-1
1. Front suspension cylinder

2. Arm
3. Lateral rod
4. Dust cover
Unit: mm

Clearance between pin and size Shaft Hole clearance limit
5
bushing
45 -0.025 +0.039 0.025 – 0.3 Replace
-0.064 0 0.103
Clearance between pin and -0.025 +0.039 0.025 –
6 bushing 45 -0.064 0 0.103 0.3
HM300-1 10-95
REAR
10-96 HM300-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SUSPENSHION
1. Arm
2. Equalizer bar
3. Lateral rod (center)
4. Spring
5. Rear suspension
6. Lateral rod (rear)
10-98 HM300-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SUSPENSHION
Unit: mm

Clearance between pin and size Shaft Hole clearance limit
7
bushing
60 -0.030 +0.046 0.030 – 0.3
-0.076 0 0.122 Replace
Clearance between pin and -0.030 +0.046 0.030 –
8 bushing 60 -0.076 0 0.122 0.3
9 Clearance between pin and 60 -0.030 +0.046 0.030 – 0.3

bushing -0.076 0 0.122
Outline 2. Center, rear suspension

• The suspension supports the weight of the ma- The center axle and rear axle are both fixed to arms.
chine. It also reduces any impact caused by un- The center axle is joined to the equalizer bar through
evenness in the road surface and provides a a spring, and the rear axle is joined through the rear
comfortable ride for the operator. By ensuring suspension cylinder. The arm and equalizer bar os-
that all the tires are always in contact with the cillate in accordance with the condition
road surface, it maintains the stability of the ma- of the road surface to keep the wheels in contact with
chine, and also fulfills the operating perform- the road surface.
ance by ensuring that the machine can carry out The main frame and arm are connected by a lateral
acceleration, braking, and turning. rod and receive the lateral load.
• The suspension cylinders reducing the impact
from the road surface are a hydropneumatic
type. The inside of the suspension cylinder is
charged (sealed) with oil and nitrogen gas. In
this way, the compression and expansion of the
nitrogen gas and oil act as a spring and shock
absorber, and is used to absorb the load from
the road surface.
Function
1. Front suspension
The front suspension cylinder has the function of a
shock absorber and spring. It is joined to the arm
and main frame by a spherical bearing, and the arm
oscillates according to the extension and retraction
of the front suspension cylinder.
The main frame and arm are joined by a lateral rod
and receive the lateral load.
HM300-1 10-99
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SUSPENSION CYLINDER
SUSPENSION CYLINDER
1. Feed valve
2. Oil level valve
3. Flange
4. Rod
5. Cylinder
6. Piston
10-100 HM300-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SUSPENSION CYLINDER
Unit: mm

Clearance between piston rod size Shaft Hole clearance limit
7 and bushing
-0.036 +0.235 0.096 – Replace
110 0.4
-0.090 +0.060 0.325
Clearance between cylinder 0 +0.100
8 150 0 – 0.22 0.8
and wear ring -0.21 0
Structure and operation

The suspension cylinder has the function of both a
shock absorber and spring.
When a fixed amount of oil is sent from oil chamber
(1) through orifices (4) and (5) to cavity (3), the oil is
throttled by the orifices and a shock-absorbing effect
is obtained.
1. Retracting action
When the machine is traveling and it hits a
bump or object on the road, the wheels are
pushed up, and the cylinder rod is pushed
inside the cylinder.
When this happens, the nitrogen gas inside
chamber (2) is compressed, the oil in chamber
(1) is sent through both orifices (4) and (5) to
cavity (3), and cavity (3) is filled more quickly
than when extending.
2. Extending action
When the machine has passed any bump or
object on the road surface, the cylinder rod is
pushed up by the weight of the wheels and axle
and the pressure of the nitrogen inside chamber
(2).
As a result, the amount of oil in cavity (3) is
reduced, and pressure is applied to the oil
remaining in cavity (3).
This pressurized oil closes orifice (4) with check 1. Oil chamber
ball (6), and is sent to chamber (1) through only 2. Nitrogen gas chamber
orifice (5), so the flow of oil passing through the 3. Cavity
orifice is controlled so that it is less than during 4. Orifice
retraction. 5. Orifice
In this way, the amount of oil returning to cham- 6. Check ball
ber (1) is restricted to provide a shock absorb-
ing effect.
HM300-1 10-101
(9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD OSCILLATION HITCH
OSCILLATION HITCH
1. Steering cylinder 7. Disc

2. Front frame 8. Coupling
3. Center drive shaft 9. Shaft
4. Rear frame 10. Coupling
5. Pin 11. Pin
6. Hitch frame
10-102 HM300-1
10-104 HM300-1
Unit: mm
12 Standard shim thickness 2

1
13 Standard shim thickness Standard Tolerance Standard Clearance
size Shaft Hole clearance limit
Clearance between bushing -0.036 +0.054 0.036 –

14 110 –
and front frame -0.090 0 0.144
Clearance between shaft and -0.030 +0.046 0.030 –

15 80 0.5
bushing -0.049 0 0.095
Clearance between shaft and -0.030 0 0.015 –
16 80 0.5
bearing -0.049 -0.015 0.049
Clearance between shaft and -0.030 +0.046 0.030 –
17 80 0.5
bushing -0.049 0 0.095
Clearance between front frame -0.030 +0.046 0.030 –
18 80 –
and shaft -0.049 0 0.095
Clearance between bushing -0.030 +0.046 0.030 –
20 80 0.5
and pin -0.049 0 0.095
Clearance between pin and -0.030 0 0.015 – Replace
21 80 0.5
bearing -0.049 -0.015 0.049
Clearance between front frame +0.089 +0.054 -0.089 –
22 95 –
and bushing +0.054 0 0
Clearance between hitch frame 0 0 -0.035 –
23 120 –
and bearing -0.015 -0.035 0.015
Clearance between hitch frame 0 0 -0.035 –
24 300 –
and bearing -0.052 -0.035 0.052
Clearance between rear frame 0 -0.017 -0.080 –
25 420 –
and bearing -0.045 -0.080 0.028
Clearance between rear frame -0.018 +0.057 0.018 –
26 400 –
and retainer -0.075 0 0.122
Clearance between rear frame 0 -0.016 -0.073 –
27 380 –
and bearing -0.040 -0.073 0.024
Clearance between bearing -0.056 0 0.031 –
28 280 –
and hitch frame -0.108 -0.035 0.108
Clearance between hitch frame 0 -0.012 -0.006 –

29 150 –
and bearing -0.018 -0.052 0.013
Outline
• The front frame and the rear frame are connect- • In addition, the output from the transmission is
ed by the oscillation hitch. transmitted from center drive shaft (3) to cou-
• Front frame (2) is connected with bearings and pling (10). It is then transmitted from coupling
pins (5) and (11); rear frame (4) is connected (8) through the rear drive shaft to the rear axle.
with a spacer, retainer, and bearing. This makes
it possible for the front and rear frames to articu-
late and oscillate.
HM300-1 10-105
(9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING, HOIST OIL PRESSURE
STEERING, HOIST OIL PRESSURE PIPING DIAGRAM
1. Steering, hoist control pump

(SAR(3)63+63+(1)6)
2. Steering cylinder
3. Hydraulic tank
4. Flow amp valve
5. Steering valve
6. Hoist valve
7. Hoist cylinder
10-106 HM300-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DUMP BODY CONTROL
DUMP BODY CONTROL
1. Dump control lever Function

2. Hoist valve • This control is carried out by the body position
3. EPC valve sensors. The body position sensor senses the
4. Steering, hoist control pump position of the dump body and the retarder con-
(SAR(3)63+63+(1)6) troller (brake controller: E-SPEC) controls it.
5. Hoist cylinder • The signal from the dump control lever is con-
6. Body positioner sensor trolled by the retarder controller (Brake control-
7. Pilot check valve ler: E-SPEC), and actuates the EPC valve. The
pilot pressure generated by the EPC valve
moves the spool of the hoist valve and controls
the hoist cylinder.
HM300-1 10-107
4
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC TANK AND FILTER
HYDRAULIC TANK AND FILTER
1. Hydraulic oil filter

2. Breather
3. Oil level gauge
4. Drain plug
5. Bypass valve
6. Element
7. Strainer
10-108 HM300-1
4
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FLOW AMP VALVE
FLOW AMP VALVE
1. Valve CL. To steering cylinder Outline

2. Relief Valve L. To steering valve • The flow amp valve consists of the directional
3. Orifice P. To steering valve valve, amplifying stage, priority valve, relief
4. Spring PP. From steering valve valve, pressure control valve, and suction valve.
5. Pin HP. From hydraulic pump • It amplifies the oil flow sent from ports L and R of
6. Valve LS. From steering valve the steering unit by the specified ratio. The am-
7. Valve HT. From hoist valve plified oil then goes from ports CL and CR of the
8. Plug T. To steering valve flow amp valve and flows to the steering cylin-
9. Valve EF. To hoist valve der.
10. Spool R. From steering valve The amplified oil flow is proportional to the
11. Valve body CR. To steering cylinder amount the steering wheel is turned.
12. Stopper
HM300-1 10-109
Operation
Operation
1. At neutral
• Port P of steering unit (7) is closed and the flow • For priority valve (2) also, the oil is drained from
amp valve is closed at chamber M of pressure relief valve (1).
control valve (3). Before starting, priority valve (2) is pushed
• Ports L, R, and T of steering unit (7) are connect- strongly to the left by the spring, so in reality,
ed to each other, so the oil passes through port port EF of the flow amp valve is almost closed.
T of the flow amp valve and is drained to the hy- • At the same time as the engine starts, oil flows
draulic tank. to port HP of the flow amp valve and then flows
By connecting in this way, directional valve (6) to port P of steering unit (7). At the same time,
is always held at the neutral position by the the pilot pressure that is connected to port PP
springs on both sides. For this reason, at the suddenly rises. As a result of balancing with
neutral position, the reaction or impact from the the spring and moving to the right, port EF opens
steering cylinder is not transmitted to steering and the oil flows to the hoist piping.
unit (7).
10-110 HM300-1
2. When turning
• When steering unit (7) is actuated, the oil sent • The oil at the steering cylinder head end goes
from port P of priority valve (2) passes through out from suction valve (5). It then goes from port
ports P and L of steering unit (7) and enters port CR of directional valve (6) through check valve
L of directional valve (6). (4) and is drained to the hydraulic tank from port
At the same time, oil from priority valve (2) also HT of the flow amp valve.
enters chamber M of pressure control valve (3). • If there are rocks on the road or the the road sur-
• When the oil entering directional valve (6) rises face is uneven, and any abnormal external force
to a pressure greater than the force of the is applied to the tires and steering cylinder, relief
spring, it pushes the spool to the right, and en- valves (8) and (9) of suction valve (5) open at a
ters chamber C of pressure control valve (3). pressure of 29.1 MPa {285.5 kg/cm2}, so the oil
When it rises to a pressure greater than the passes through directional valve (6) and is
force of the spring in chamber C also, it pushes drained to the hydraulic tank.
the spool to the left.
• The oil that is already in chamber M of pressure
control valve (3) enters chamber N when the
spool is pushed to the left by the action of steer-
ing unit (7). It then flows from port P, goes out
from port CL of directional valve (6), and flows
from suction valve (5) to the bottom end of the
steering cylinder.
HM300-1 10-111
(9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING VALVE
STEERING VALVE
1. Cover L. To flow amp valve

2. Drive shaft LS. To flow amp valve
3. Valve body P. From flow amp valve
4. Center pin R. To flow amp valve
5. Bearing T. To flow amp valve
6. Spool
7. Centering spring
8. Sleeve
9. Stator
10. Rotor
11. Lower cover
10-112 HM300-1
(9)
Outline Structure
• The orbit-roll valve is connected directly to the • Spool (9) is connected to the drive shaft of the
steering wheel shaft. If the steering wheel is op- steering wheel, and is connected to sleeve (8)
erated, the orbit-roll valve operates the steering by center pin (7) (this is not touching the spool
valve by using the oil from the PPC pump as the when the steering wheel is at the neutral posi-
pilot pressure. Then, the oil from the steering tion) and centering spring (2).
pump is sent to the right or left steering cylinder • Drive shaft (3) is meshed at the top with center
through the steering valve to change the travel pin (7) and forms one unit with sleeve (8). The
direction of the machine. bottom is meshed with the spline of rotor (5) of
• The orbit-roll valve, broadly speaking, consists the Gerotor set.
of the following components: rotary type spool • Valve body (4) has five ports. These are con-
(9) and sleeve (8), which have the function of se- nected to the pump circuit, tank circuit, steering
lecting the direction, and the Girotor set (a com- cylinder head end, bottom end, and flow amp
bination of rotor (5) and stator (10)), which acts valve pilot end. In addition, the port at the pump
as hydraulic motor during normal steering oper- end and the port at the tank end are connected
ations, and as a hand pump (in fact, the operat- by the check valve inside the body. If there is
ing force of the steering wheel is too high, so it any failure in the pump or engine, this check
cannot be operated) when the steering pump or valve acts to suck in oil directly from the tank.
engine have failed and the supply of oil is
stopped.
HM300-1 10-113
(9)
CONNECTION BETWEEN HAND PUMP AND SLEEVE
• The diagrams above show the connections with

the sleeve ports used to connect the suction and Suctiion /
discharge port
discharged ports of the Girotor.
• If the steering wheel has been turned to the
right, ports a, c, e, g, i, and k are connected by
the vertical grooves in the spool to the pump
side. At the same time, ports b, d, f, h, j, and l are
connected to the head end of the left steering
cylinder in the same way.
In the condition in diagram above left, ports 1, 2,
and 3 are the discharge ports of the Girotor set.
They are connected to ports l, b, and d, so the SBW00727
oil is sent to the cylinder.
Ports 5, 6, and 7 are connected and the oil
flows in from the pump. • In this way, the ports of the Girotor acting as
If the steering wheel is turned 90°, the condition delivery ports are connected to ports which are
changes to the condition shown in diagram connected to the end of the steering cylinder.
above right. In this case, ports 1, 2, and 3 are The ports acting as suction ports are connected
the suction ports, and are connected to ports i, to the pump circuit.
k, and c. Ports 5, 6, and 7 are discharge ports, • Adjusting delivery in accordance with angle of
and are connected to ports d, f, and h. steering wheel:
For every 1/7 turn of the steering wheel, the
inner teeth of the Girotor gear advance one
position so the oil flow from the pump is
adjusted by this movement. In this way, the oil
delivered from the pump is directly proportional
to the amount the steering wheel is turned.
10-114 HM300-1
(9)
FUNCTION OF CENTER SPRING

• Centering spring (2) consists of four layers of
leaf springs crossed to form an X shape.
The springs are assembled in spool (9) and
sleeve (8) as shown in the diagram on the right.
When the steering wheel is turned, the spring is
compressed and a difference in rotation (angle
variation a) arises between the spool and the
sleeve.
Because of this, the ports in the spool and
sleeve are connected and oil is sent to the cylin-
der. When the turning of the steering wheel is
stopped, the Girotor also stops turning, so no
more oil is sent to the cylinder and the oil pres-
sure rises.
To prevent this, when the turning of the steering
wheel is stopped, the action of the centering
spring only allows it to turn by an amount equal
to the difference in angle of rotation (angle vari-
ation a) of the sleeve and spool, so the steering
wheel returns to the NEUTRAL position.
HM300-1 10-115
4
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING CYLINDER
STEERING CYLINDER
Unit: mm

Clearance between piston rod size Shaft Hole clearance limit
1
and bushing
-0.030 +0.271 0.105 –
70 0.675
-0.104 +0.075 0.375
Clearance between piston rod +0.174
2 65 – – 1.0
support shaft and bushing +0.100
Replace
Clearance between cylinder
+0.174
3 bottom support shaft and 65 – – 1.0
+0.100
bushing
4 Cylinder bore +0.15
110 –
+0.05
10-116 HM300-1
4
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HOIST VALVE
HOIST VALVE
10-118 HM300-1
T: To tank
P: From flow amp
A1: To hoist cylinder bottom
B1: To hoist cylinder head
PA: From EPC valve (Pressurized side for lowering and floating operation)
PB: From EPC valve (Pressurized side for raising operation)
T2: To tank (Via pilot check valve)
1. Body
2. Spool
3. Retainer
4. Spring (RAISE)
5. Relief valve
6. Spring (FLOAT)
7. Spring (LOWER)
8. Retainer
9. Retainer
10. Retainer
11. Check valve
Unit: mm

Free length Installed Installed Free Installed
12 Relief valve poppet spring x O.D. length load length load
259 N 233 N
49.4 x 12.8 4.2 –
(26.4 kg) {23.8 kg}
44 N 40 N Replace spring
13 Check valve spring 32.7 x 10.9 24.5 –
{4.5 kg} {4.1 kg} if damaged or
deformed
156 N 140 N
14 Spool return spring 51.3 x 34.5 50 –
{15.9 kg} {14.3 kg}
124 N 112 N
{12.7 kg} {11.4 kg}
1005 N 905 N
{102.6 kg} {92.3 kg}
HM300-1 10-119
OPERATION
1. Hoist valve at HOLD position
• The oil from the flow amp enters port C. The pas- • The ports to the hoist cylinder are blocked at
sage to the hoist cylinder is blocked by hoist both the bottom end and head end, so the hoist
spool (2), so the oil is drained from tank D to the cylinder is held in position.
tank.
10-120 HM300-1
4
2. Hoist valve at RAISE position
• When the hoist lever inside the cab is operated • At the same time, the return oil from the head
to the RAISE position, hoist spool (2) is moved end flows from port B to port D, and flows to the
to the left by the solenoid valve. tank circuit.
• As a result, the oil flows from chamber C, opens
check valve (11), and enters chamber A.
• From chamber A, the oil enters the bottom end
of the hoist cylinder, extends the hoist cylinder,
and raises the dump body.
HM300-1 10-121
4
(9)
3. Hoist valve at FLOAT position
• When the hoist lever inside the cab is operated • The bottom end and head end of the hoist cylin-
to the FLOAT position, hoist spool (2) is moved der are connected inside the hoist valve, so the
to the right by the solenoid valve. As a result, hoist cylinder is placed in the free condition.
chamber C and chamber D, and chamber B and
chamber H and chamber D are connected.
• The oil from the flow amp passes from chamber
C through chamber B and flows to the hoist cyl-
inder. Oil also flows from chamber C to chamber
D, and then flows to the brake oil cooler circuit.
10-122 HM300-1
4
4. Hoist valve at LOWER position
• When the hoist lever inside the cab is operated • At the same time, the return oil from the head
from the FLOAT position to the LOWER position, end of the hoist cylinder flows from chamber A to
hoist spool (2) is moved further to the right from chamber H.
the FLOAT position by the solenoid valve. As a • When the dump body is lowered, the output
result, the oil flows from chamber C, pushes pressure of the solenoid valve rises and be-
open check valve (11), and enters chamber B. comes greater than the cracking pressure of the
• The oil from chamber B enters the head end of pilot check valve. As a result, the return oil from
the hoist cylinder, retracts the cylinder, and low- chamber H returns to the tank through two lines:
ers the dump body. one from chamber D to the tank, and the other
from chamber E to the tank.
HM300-1 10-123
4
(9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD EPC VALVE
EPC VALVE
1. Manual operation button Function

2. Solenoid assembly • With the EPC valve, the oil from the hydraulic
3. Relief valve pump is controlled by the retarder controller
4. Solenoid assembly (EPC) (Brake controller: E-SPEC). It is then sent to the
spool of the hoist valve, and switches the pilot
A. To hoist valve pressure to control the hoist valve.
B. From hoist valve
P1. From hydraulic pump
T1. To hydraulic tank
T2. To hydraulic tank
10-124 HM300-1
(4
9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PILOT CHECK VALVE
PILOT CHECK VALVE
1. Body A. From hoist valve

2. Check valve B. To hydraulic tank
3. Retainer P.P.From EPC valve
4. Spring
5. Cover
Unit: mm

Free length Installed Installed Installed Replace spring if
6 spring length load Free length damaged or
x O.D. load
deformed
619.8 N 558 N
126.3 x 48 62 {63.2 kg} – {56.9 kg}
HM300-1 10-124-1
4
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HOIST CYLINDER
HOIST CYLINDER
Unit: mm

Clearance between cylinder size Shaft Hole clearance limit
1 and bushing
-0.036 +0.277 0.098 –
120 0.700
-0.123 +0.062 0.400
Clearance between piston rod -0.030 +0.271 0.091 – Replace
2 80 0.675
and bushing -0.104 +0.061 0.375
Clearance between piston rod +0.004
3 60 – – 1.0
support pin and bushing -0.019
Clearance between cylinder +0.004
4 60 – – 1.0
support pin and bushing -0.019
HM300-1 10-125
(9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
STEERING, HOIST AND PILOT PUMP
SAR(3) 63+63+(1)6
Unit: mm
Model Standard clearance Clearance limit
SAR(3)-63
1 Side clearance 0.10 – 0.15 0.19
SAR(3)-63
SAR(1)-6 0.10 – 0.15 0.19
Clearance between inside SAR(3)-63
0.060 – 0.149 0.20
2 diameter of plain bearing and SAR(3)-63
Replace
outside diameter of gear shaft SAR(1)-6 0.06 – 0.144 0.20
Model Standard size Tolerance Repair limit
SAR(3)-63 0
14
3 Depth for knocking in pin SAR(3)-63 -0.5
–
0
SAR(1)-6 10
-0.5
4 Rotating torque of spline shaft 8.7 – 20.7 Nm {0.9 – 2.1 kgm}
Delivery Standard
Rotating Delivery
pressure delivery
Model speed amount limit
{MPa amount
Discharge amount (rpm) (l/min) –
– Oil: EO10-CD (kg/cm2)} (l/min)
Oil temperature: 45–55°C SAR(3)-63
20.6 145.1 134.0
SAR(3)-63 2,500
{210}
SAR(1)-6 13.2 12.6
10-126 HM300-1
(9)
TORQUE CONVERTER, TRANSMISSION AND FRONT BRAKE COOLING PUMP

SAR(3) 90
Unit: mm
1 Side clearance
SAR(3)90 0.13 – 0.18 0.21
Clearance between inside
2 diameter of plain bearing and SAR(3)90 0.06 – 0.149 0.20
Replace
outside diameter of gear shaft
3 Depth for knocking in pin 0
14 –
-0.5
Delivery Standard
Rotating Delivery
pressure delivery
Discharge amount Model speed amount limit
{MPa amount –
– Oil: EO10-CD (rpm) (l/min)
(kg/cm2)} (l/min)
Oil temperature: 45–55°C
2.9
SAR(3)90 2,500 208.6 192.7
{30}
HM300-1 10-127
(9)
BRAKE COOLING AND BRAKE PUMP

SAR(3)80+(1)18
Unit: mm

1 Side clearance SAR(3)80
0.10 – 0.15 0.19
SAR(1)18
Clearance between inside SAR(3)80 0.06 – 0.149
2 diameter of plain bearing and 0.20 Replace
outside diameter of gear shaft SAR(1)18 0.06 – 0.144

3
Depth for knocking in pin 14 0
–
4 10 -0.5

Delivery Standard
Rotating Delivery
pressure delivery
Model speed amount limit
{MPa amount
(rpm) (l/min)
Discharge amount (kg/cm2)} (l/min) –
– Oil: EO10-CD
2.9
Oil temperature: 45–55°C SAR(3)80 200 –
{30}
2,500
20.6
SAR(1)18 40.4 36.3
{210}
10-128 HM300-1
(9)
EMERGENCY STEERING PUMP

SBL(1)26
Unit: mm
Standard clearance Clearance limit

1 Side clearance
0.10 – 0.15 0.19
Clearance between inside
2 diameter of plain bearing and 0.060 – 0.119 0.20
Replace
outside diameter of gear shaft
3 Depth for knocking in pin 0
10 –
-0.5
Delivery Standard
Rotating Delivery
pressure delivery
Discharge amount speed amount limit
{MPa amount –
– Oil: EO10-CD (rpm) (l/min)
(kg/cm2)} (l/min)
Oil temperature: 45–55°C
20.6
3,500 67.6 62.4
{210}
HM300-1 10-129
(9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CAB TILT
CAB TILT
1. Tilt stopper bar

2. Tilt cylinder (if equipped)
3. Breather
4. Adapter
5. Pin
10-130 HM300-1
4
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR CONDITIONER
AIR CONDITIONER
1. Air conditioner unit FUNCTION

2. Filter • The air conditioner makes a pleasant operating
3. Control panel environment for the operator and acts to reduce
4. Compressor fatigue.
5. Receiver dryer
6. Condenser
HM300-1 10-131
AIR CONDITIONER UNIT
1. FRESH/RECIRC selector damper

2. Evaporator
3. Heater core
4. Blower motor
A. Hot water inlet port

B. Hot water outlet port
C. Refrigerant gas inlet port
D. Refrigerant gas outlet port
E. Dehumidified water drain port
10-132 HM300-1
RECEIVER DRYER
1. Body
2. Sight glass
3. Dryer
4. Dryer
HM300-1 10-133
CONDENSER
1. Fin
2. Tube
A. Refrigerant gas inlet port

B. Refrigerant gas outlet port
10-134 HM300-1
COMPRESSOR
1. Case
2. Clutch
A. Suction service valve

B. Discharge service valve
HM300-1 10-135
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HEARTER
HEARTER
10-135-1 HM300-1
(11)
HM300-1 10-135-2
(11)
1. Engine oil pan heater Ourline

2. Transmission oil pan heater • This device is a starting aid to heat the oil with
3. Engine coolant heater an external power supply so that the engine will
4. Junction box start easily.
5. Connector for external power supply • If an external power supply is connected to
external power supply connector (5) of junction
Specification box (4), the engine coolant and the oil in the
• Engine oil pan heater: 0.6 kW (1 place) transmission oil pan and engine oil pan are
• Engine coolant heater: 1.5 kW (1 place) heated.
• Transmission oil pan heater: 0.6 kW (2 places) • The source voltage is 230 V and the power con-
sumption is 3.3 kW.
10-135-3 HM300-1
(11)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE MONITOR SYSTEM
MACHINE MONITOR SYSTEM
Network data
1. From machine monitor to each controller
• Switch input data
• Option setting data
2. From each controller to machine monitor
• Display data related to each controller
• Service mode data
• Troubleshooting data
3. From transmission controller to machine monitor
• Model selection data
10-136 HM300-1
4
Outline 4. Reduced cylinder mode

• With the machine monitor system, the control- This function is used to stop the supply of
lers on the network use the data from the sen- fuel sprayed from the fuel injector. This
sors installed to all parts of the machine to makes it possible to determine the cylinder
observe and control the condition of the machine where there is defective combustion.
and transmit that data as network data to the 5. ECMV compensation
machine monitor. This is used for the initial adjustment of the
The machine monitor is a system to display transmission.
these data and inform the operator of the condi- 6. Changing replacement time for filter, oil
tion of the machine. This changes the original setting for the
• There are two types of display on the machine replacement interval.
monitor: the normal mode and the service mode. 7. Controller initialize
• The items that are always displayed for the op- This function is used to set the machine
erator are the normal mode items. Their main monitor when the machine is shipped from
content is as follows. the factory.
1. Normal display items
• Meters (speedometer, tachometer) The service mode has the following functions.
• Gauges (engine coolant temperature, 1. Setting service meter
torque converter oil temperature, retard- • This can set service meter values re-
er oil temperature, fuel level) corded in machine monitor memory
• Pilot display • However, values can only be increased
• Service meter, odometer (character dis- from present value (they cannot be de-
play) creased).
2. Items displayed when there is abnormality
Caution, action code display (if an action 2. Setting total travel distance
code is being displayed, press machine • This can set travel distance values re-
monitor mode selector switch (2) (>), then corded in machine monitor memory
release it. A failure code (6-digit) is then dis- • However, values can only be increased
played.) from present value (they cannot be de-
3. When the filter, oil replacement interval is creased).
reached, the item needing replacement is
displayed in the character display. 3. Setting distance traveled in reverse
4. Other functions using the character display • This can set values for distance traveled
and the machine monitor mode selector in reverse recorded in machine monitor
switch to operate include the following: Total memory.
reverse distance traveled display, filter, oil • However, values can only be increased
replacement interval reset, telephone from present value (they cannot be de-
number input, and language selection. creased).
• To make it easier to carry out troubleshooting of • The machine monitor system consists of the
the controllers (including the monitor panel it- monitor panel, buzzer, and switches, network,
self), a service mode function is provided. Its controllers on the network, and the sensors in-
main content is as follows. putting data to the monitor panel.
1. Displaying trouble data for electrical compo-
nents, deleting from memory
• Displays electrical components failure
data from each controller that is saved
in machine monitor
• Deletes data from memory
2. Trouble data for machine
• Displays machine failure data from each
controller that is saved in machine mon-
itor
3. Real-time monitor
• Takes input and output signal values
recognized by each controller on net-
work and displays in real time
HM300-1 10-137
(9)
MACHINE MONITOR
1. Speedometer 23. Machine monitor, option system caution lamp

2. Engine tachometer 24. Engine system caution lamp
3. Retarder oil temperature gauge 25. Transmission system caution lamp
4. Torque converter oil temperature gauge 26. Retarder system caution lamp
5. Engine coolant temperature gauge (Brake system caution lamp: E-SPEC)
6. Fuel gauge 27. Tilt caution lamp
7. Character display 28. Seat belt caution lamp
8. Turn signal pilot lamp (R.H.) 29. Parking brake pilot lamp
9. Turn signal pilot lamp (L.H.) 30. Retarder pilot lamp
10. Front lamp high beam pilot lamp (Overrun protection brake pilot lamp: E-SPEC)
11. Gearshift lever position pilot lamp 31. Exhaust brake pilot lamp (option)
12. Shift indicator 32. Inter-axle differential lock pilot lamp
13. Lock-up pilot lamp 33. Left and right differential lock pilot lamp
14. Shift hold pilot lamp (if equipped)
15. Power mode pilot lamp (high power mode) 34. Dump body pilot lamp
16. Power mode pilot lamp (economy mode) 35. Emergency steering pilot lamp
17. Central warning lamp 36. Preheating pilot lamp
18. Maintenance caution lamp 37. Retarder oil temperature caution lamp
19. Battery charge circuit caution lamp 38. Torque converter oil temperature caution lamp
20. Steering oil temperature caution lamp 39. Engine coolant temperature caution lamp
21. Engine oil pressure caution lamp 40. Fuel level caution lamp
22. Brake oil pressure caution lamp
10-138 HM300-1
(9)(5)
41. Travel speed compensation switch [SW1]

42. Rotary switch [SW2]
43. Rotary switch [SW3]
44. Switch for setting left and right differential lock [SW5-4]
45. Dipswitch [SW5-3]
46. Switch for setting exhaust brake [SW5-2]
HM300-1 10-139
OPTION SETTING CONNECTOR DIAGRAM
52. Option setting connector [OP1]

58. Setting connector [OP7]
ADJUSTING MACHINE MONITOR

1. For details of the setting of the rotary switches, dipsswitch, and options setting connectors at the rear
face of the machine monitor, see TESTING AND ADJUSTING, Adjusting machine monitor.
2. Precautions
1) When setting, follow the instructions in TESTING AND ADJUSTING, Adjusting machine monitor, and
do not change them.
2) When moving the switches, use a precision screwdriver and turn slowly.
3) Be careful not to touch anything except the switches inside the grommet.
4) Be careful not to let any dirt or dust get in.
5) After completing the setting, return the grommet securely to its original position.
10-140 HM300-1
(9)
MACHINE MONITOR NORMAL DISPLAY FUNCTIONS
c: Lights up U: Sounds intermittently

✩1: c means that lamps light up while machine monitor check switch is ON
✩2: c shows that all lamps light up for approx. 2 seconds after starting → all off for 1 second
Related actuation ✩1 When ✩2

machine Immediately
Display Display Display range/ Method of Central monitor after
No. Device Color Alarm Remarks
item category conditions display warning check starting
buzzer switch is switch is
lamp
operated turned ON
Note: When machine monitor
Scale: 0 - 80 km/h or 0 - 50
check switch is operated, display
White mph Analog
Meter Movement Background    starts from present position,
(mph display is only display (Note)
Travel completes one cycle, and
1 color: Black when non-SI is used)
speed returns to the starting position
Lights up
When side lamps light
Backlight LED Amber when   c c
up
actuated
Scale:
0 - 3400 rpm (red check switch is operated, display

Movement White, red zone: More than 2500
Analog
Meter c U  starts from present position,
Background display (Note)
Engine rpm) completes one cycle, and
2 color: Black
speed returns to the starting position
Lights up
up
actuated
Scale:
50 - 150°C check switch is operated, display
White, red (red zone: Analog
Gauge Movement More than    starts from present position,
Background display (Note)
120°C) completes one cycle, and
color: Black
returns to the starting position
3 Brake
cooling oil When temperature is
Lights up
37 temperature Caution LED Red when c U c c
more than 120°C
abnormal
Lights up
up
actuated
Scale:
Gauge Movement Background More than    starts from present position,
display (Note)
color: Black
Torque returns to the starting position
4 converter
oil Lights up
38 When temperature is
temperature Caution LED Red when c U c c
more than 120°C
abnormal
Lights up
up
actuated
Scale:
Gauge Movement Background More than    starts from present position,
display (Note)
color: Black
5 Engine
coolant Lights up
39 temperature When temperature is
Caution LED Red when c U c c
more than 102°C
abnormal
Lights up
up
actuated
Scale:
check switch is operated, display
White Analog
Gauge Movement Background EMPTY-FULL    starts from present position,
display (Note)
completes one cycle, and
color: Black
6 Fuel level When below specified
Lights up
40 gauge level (amount of fuel
Caution LED Red when   c c
less than 75 l)
remaining in tank is
actuated
Lights up
up
actuated
Actuated
Service when
0 - 65535.0h
meter engine is
Service * Displayed on top When time exceeds 65535.0h,
(normal Display running  
meter letters: line of character stops at 65535.0h
display Ratio of
Black display
7 items) LCD movement
Background to time 1:1
color:
Odometer Green 0 - 999999.9km
Actuated When distance exceeds
(normal * Displayed on bottom
Odometer when   999999.9km, stops at
display line of character
traveling 999999.9km
items) display
HM300-1 10-141
4
(9)
Related actuation When Immediately

machine after
Display Display range/ Central monitor
No Display item Device Color Method of display Alarm starting Remarks
category conditions warning check switch is
buzzer switch is
lamp turned ON
operated
When abnormality
When abnormality or or Note 1: Top line displays
failure occurs on
failure occurs on "HM300-1"
machine, top line
machine Note 2: Top line displays
Action code Action code shows action   Note 1 Note 2
* Displayed on top and code; "KOMATSU", bottom
bottom lines of bottom line displays "SYSTEM
displays remedy or
character display CHECK"
nature of failure
Top line displays
failure code (6
When there is digit) and
abnormality or failure, controller that See Operation &
Failure press mode switch ">". detected problem;   Maintenance Manual for
Failure code
code * Displayed on top bottom line
details of failure display
and bottom lines of displays system
character display that is abnormal or
nature of
7 abnormality
Reverse
travel
distance
meter, filter, Operate machine
oil Press machine monitor monitor mode See Operation &
Other displays replacement mode selector switch selector switch ">" Maintenance Manual for
time reset, "<>" or "<" to switch details of failure display
telephone screen
No. setting,
language
selection
Brightness
When side lamps light reduced one level
Night lighting Backlight LED Green   c c
up when side lamps
light up
When operated:
Lights up
Right turn
8 LED Green When operated When not   c c
signal
operated: Goes
out
When operated:
Lights up
9 Left turn signal LED Green When operated When not   c c
operated: Goes
out
When operated:
Lights up
10 High beam LED Blue When operated When not   c c
operated: Goes
out
11 Gearshift lever When gearshift lever is * Flashes when neutral
LED Green Lights up (*)   c c
(R2) position R2 at R2 safety is actuated
(R1) position R1 at R1 safety is actuated
11 Gearshift lever
Orange When gearshift
lever is
LED Lights up   c c
(N) position N at N
(D) position D Pilot at D safety is actuated
(5) position 5 at 5 safety is actuated
(4) position 4 a4 safety is actuated
F1,F2,F3,F4,F5,F6,N,R
1,R2,R3
* According to shift
range signal received
Back- When shift range
from transmission
ground signal is received c c
Shift indicator LED controller  
12 color: * When alarm is
from transmission All light up All light up
Gray controller
actuated when making
emergency escape, "E-"
and "N" are displayed in
turn
Night lighting LED Amber
10-142 HM300-1
(9)

machine after
Display Display Display range/ Method of Central monitor
No Device Color Alarm starting Remarks
item category conditions display warning check switch is
buzzer switch is
lamp turned ON
operated
When
When torque
operated:
converter lock-up is
Lights up
13 Lock-up LED Green actuated and   c c
When not
transmission is set to
operated:
direct drive
Goes out
When
operated:
When shift hold Lights up
14 Shift hold LED Green   c c
switch is operated When not
operated:
Goes out
Pilot
High power
Output mode:
mode Lights up
15 (high power LED Green High power mode When not   c c
mode) actuated:
Goes out
Economy
Output mode:
mode Lights up
16 LED Green Economy mode   c c
(economy When not
mode) actuated:
Goes out
Central Lights up
17 warning LED Red When there is when c U c c
abnormality in system abnormal
lamp
When warning is Note 1: Lamp lights up and at

same time action code E01 and
issued for
location for warning is displayed
18 Maintenance LED Red
maintenance system, Lights up or
  c c on character display
caution or when filter, oil flashes
Note 2: See Operation and
replacement interval
Maintenance Manual for details
has passed of applicable item
Battery
When there is Lights up
charge
19 LED Red abnormality in charge when c U c c
circuit circuit abnormal
caution
Steering oil Lights up
When steering oil
20 temperature LED Red when c U c c
temperature rises
caution abnormal
Engine oil Lights up
21 pressure LED Red When engine oil when c U c c
pressure drops
caution abnormal
Brake oil Lights up
When brake oil Note: Actuated only when
22 pressure LED Red when c(Note) U(Note) c c
caution pressure drops abnormal alternator R terminal = ON
Machine When there is

monitor or abnormality in Lights up
Actually only used when failure
23 option Caution LED Red machine monitor or when U U c c
occurs in machine monitor
system option controller abnormal
caution system
Engine When there is Lights up
24 system LED Red abnormality in engine when U U c c
caution control system abnormal
Transmission When there is

Lights up
abnormality in
25 system LED Red when U U c c
caution transmission control
abnormal
system
Retarder When there is
system abnormality in
caution retarder control Lights up
26 (Brake LED Red system (When there when U U c c
system is abnormality in abnormal
caution: E- brake control system:
SPEC) E-SPEC)
When dump body is
Lights up
27 Tilt caution LED Red raised and there is when c U c c
excessive tilt to left or
abnormal
right
When
actuated:
Seat belt When seat belt is not Lights up
28 LED Red   c c
caution fastened When not
actuated:
Goes out
HM300-1 10-143
(9)

machine after
Display Display Display range/ Method of Central monitor
No Device Color Alarm starting Remarks
item category conditions display warning check switch is
buzzer switch is
lamp turned ON
operated
Parking Lights up Note: Actuated when parking
When parking brake
29 brake pilot Red when c(Note) U(Note) c c brake is applied and gearshift
is applied
lamp applied lever is at position other than N
Retarder
pilot lamp When retarder brake
(Overrun is applied (When Lights up
30 protection Orange overrun protection when   c c
brake pilot brake is applied: E- applied
lamp: E- SPEC)
SPEC)
Exhaust
brake Lights up
When exhaust brake
31 actuation LED Orange when   c c
is actuated
lamp actuated
(option)
When
Inter-axle operated:
Lights up when inter-
differential Lights up
32 LED Orange axle differential lock is   c c
lock pilot When not
operated
lamp operated:
Goes out
Left and When
right Pilot Lights up when left
actuated:
33 differential LED Orange and right differential
Lights up
  c c
lock lamp When not
(if lock is actuated actuated:
equipped) Goes out
When
For details, see operated:
Body pilot Operation and Lights up c(Note) U(Note) Note: Actuated when gearshift
34 lamp LED Red Maintenance Manual When not c c lever is at position other than N
operated:
Goes out
When
operated:
Emergency Lights up when
Lights up
35 steering LED Red emergency steering is When not   c c
ready lamp actuated
operated:
Goes out
When
operated:
Lights up when Lights up
36 Preheating
electric heater for   c c
LED Red When not
pilot lamp engine preheating is operated:
actuated Goes out
Self-diagnostic function when operating starting switch

1. When the starting switch is turned to the ON position before starting the engine, the system check is carried
out for 3 seconds.
2. If the starting switch is turned to the START position before 3 seconds have passed with the starting switch
at the ON position, everything will go to the normal operating condition. However, even if everything goes
to the normal operating condition, the indicator gauges and meters will not work until 3 seconds have
passed after the starting switch was turned to the ON position.
Check function of central warning lamp, alarm buzzer, monitor lamps, and meters
To check the normal display functions of the machine monitor, press the machine monitor check switch to check
the actuation. For details of the actuation, see “When operating machine monitor normal display functions with
machine monitor check switch”.
10-144 HM300-1
(4
9)
OUTLINE OF SERVICE MODE

1. Outline
1) Trouble data for electrical system
The system is used to check the trouble data for the electrical system of each controller saved in the
machine monitor. For details of the failure codes displayed for the trouble data of the electrical system,
see the troubleshooting section. After repairing the failure, check that the system works properly, then
delete the trouble data.
The trouble data display for the electrical system is displayed on the character display as shown below.
*** : Displays order of trouble data items

###### : Displays failure code
$$$ : Displays number of times that applicable failure code has occurred
%%%%% : Displays time that has elapsed since failure first occurred (Present service meter read-
ing – Service meter reading when problem first occurred = Time elapsed)
@@@@@ : Displays time that has elapsed since failure last occurred (Present service meter read-
ing – Service meter reading when problem last occurred = Time elapsed)
The failure code flashes for failures that are still occurring at present.
The number of times that the failure code for the machine system has occurred is saved in memory.
2) Trouble data for machine system
The system is used to check the trouble data for the machine system of each controller saved in the
machine monitor. For details of the failure codes displayed for the trouble data of the machine sys-
tem, see the troubleshooting section. After repairing the failure, check that the system works properly,
then delete the trouble data.
The trouble data display for the machine system is displayed on the character display as shown below.
*** : Displays order of trouble data items

###### : Displays failure code
$$$ : Displays number of times that applicable failure code has occurred
%%%%% : Displays time that has elapsed since failure first occurred
@@@@@ : Displays time that has elapsed since failure last occurred
The failure code flashes for failures that are still occurring at present. The number of times that the fail-
ure code for the machine system has occurred is saved in memory.
HM300-1 10-145
(9)
3) Real-time monitor
This function is used when checking the input and output signals recognized by the controllers on the
network.
The real-time monitor display on the character display is as shown below.
*** : Displays name of item

##### : Displays ID No. given to each item
%%% : Displays data. If units are used, the unit is displayed on the right side of the data by specifying
the ID No. given to each item, it is possible to display the desired 2 items at the same thing.
By specifying the ID No. given to each item, any 2 items can be displayed simultaneously on the char-
acter display as shown below.
*** : Displays specified ID No.

%%% : Displays data. If units are used, the unit is displayed on the right side of the data
10-146 HM300-1
(9)
4) Reduced cylinder mode

For details of this function, see TESTING AND ADJUSTING, Engine reduced cylinder mode operation.
5) ECMV compensation
For details of this function, see TESTING AND ADJUSTING, Adjusting transmission, 2. ECMV com-
pensation.
6) Changing filter, oil replacement time
For details of this function, see the Operation and Maintenance Manual, OPERATION, Character dis-
play portion, Filter, oil replacement time display. This is used when changing the replacement interval.
7) Controller initialize
This function is used only at the factory, so do not touch it.
HM300-1 10-147
(7)
2. Method of operation
For details of the method of operating each service mode function, see TROUBLESHOOTING.
REMARK : When the starting switch is turned OFF, it returns to the normal mode.
10-148 HM300-1
(7)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AUTOMATIC SHIFT CONTROL SYSTEM
AUTOMATIC SHIFT CONTROL SYSTEM

(Transmission control system with all-range electronic modulation)
HM300-1 10-149
4
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AUTOMATIC SHIFT CONTROL SYSTEM
OUTLINE
• The transmission controller receives the shift po-
sition signal for the gearshift lever, the accelera-
tor signal for the accelerator pedal, the speed
signal for the transmission, and the other signals
from the switches and sensors. It then automat-
ically controls the transmission and shifts it to
the optimum speed range.
• In addition to the shift control, the transmission
controller also controls the torque converter
lock-up solenoid and operates the brake to pre-
vent overrun.
Each clutch pack of the each transmission
clutch and torque converter lock-up clutch is
equipped with an electronically controlled mod-
ulation valve, and each clutch pack is independ-
ently controlled.
In this way, the initial pressure, build-up ratio,
and torque-off time for each clutch is controlled
according to the condition of the machine. This
reduces the gearshifting shock and prevents
shift hunting, and in this way contributes to
improving the durability of the clutches.
• The transmission shift controller uses the sig-
nals from the switches and sensors to operate
the machine monitor displays and caution and
pilot lamps, and transmits these data to the net-
work.
10-150 HM300-1
(9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION CONTROLLER
TRANSMISSION CONTROLLER
1. Self-diagnostic display window 6. Speed sensors are installed at three places

2. Connector (transmission input shaft, intermediate
3. Case shaft, and output shaft). This makes it pos-
4. Motherboard sible to detect slippage of the transmission
5. Model selector switch (rotary switch 1) clutches and to protect the transmission
6. Model selector switch (rotary switch 2) when there is any abnormality in the hydrau-
lic system.
Outline 7. It connects to the network and shares vari-
• The transmission controller controls the trans- ous data with other controllers.
mission system. 8. It receives input of the model selection data
It has the following features and functions. (what model it is mounted on), and uses the
1. It has a high power mode and economy network to contact other controllers. (For
mode, and the gearshifting pattern can be details of the method of setting, see TEST-
selected. ING AND ADJUSTING.)
2. The braking mode is the mode when the 9. It has a self-diagnostic function which di-
brake is used. By raising the gearshifting vides the input and output systems further
point and increasing the speed of the brake into small parts.
cooling pump it is possible to raise the cool- 10. The self-diagnostic function is displayed in
ing effect of the retarder and make effective two digits.
use of the engine brake. 11. When an abnormality is detected, it trans-
3. It controls the torque converter lock-up sole- mits the details to the network and displays
noid valve, overrun prevention solenoid it on the other displays.
valve, and exhaust brake solenoid valve. 12. It uses the machine monitor to display if the
4. It controls the inter-axle differential lock so- failure is still existing.
lenoid valve according to the output com- 13. It provides an escape function for use when
mand from the retarder controller (Brake there is a failure in the electrical system.
controller: E-SPEC). 14. It is separate from the gearshift lever.
5. To reduce the shock when shifting gear, it
outputs the throttle correction command to
the engine controller when shifting gear and
limits the engine speed.
HM300-1 10-151
4
(9)
ATC1 ATC3A ATC4 ATC5A

1  1 Connector check 1  1 Connector check
2  Transmission input shaft speed 2  Hydraulic tank level signal input (if
2 2
input equipped)
Power source output (24V) for 3 
3 torque converter oil pressure Transmission output shaft speed 3 Radiator coolant level signal input
sensor 3 4 
input
4 
Power source input (24V) for 4 Engline load condition signal input 5 
4 overrun prevention solenoid output 5 
command Throttle correction command 6 Network signal output
5
output Transmission oil filter condition
Power source input (24V) for 7  6
signal input
5 exhaust brake solenoid output Potentiometer power source
command 6 8 
output (5V) Speed range N action command 1
7
6  signal input
Torque converter oil pressure 9 
7
signal input Speed range N action command 2
7 Battery
direct power source input 10 Network signal GND 8
(24V) signal input
8 Inter-axel
differential lock
command input 11  Hydraulic filter condition signal
8 GND 9
9  12 Network signal output input (if equipped)
9 Power source input (24V)
10 Emergency escape switch input 10 Fill switch input Low
10 
Steering oil temperature signal 11 Fill switch input lock-up
11  11
input
12 Fill switch input High
12  Transmission intermediate shaft
12 13 Fill switch input 1st
speed input
13 Overrun
prevention solenoid
output command 13 Engine speed input 14 Fill switch input 2nd
Exhaust brake solenoid output 14 GND (for speed input) 15 Fill switch input 3rd
14 command (if equipped)
15  16 Fill switch input Rev
15 Transmission cut relay
16 GND (for sensor) Fill switch input inter-axel
17
16 GND differential lock
GND input for torque converter oil
17 Power source input (24V) 17 18 Start signal input
pressure
GND input for inter-axel differential 19 

18
lock command input
20 
Air cleaner filter condition signal
19
input
20 —
ATC5B
ATC2 ATC3B 1
Emergency steering actuation
signal 2 input
Proportional solenoid power 1 Alternator terminal R input
1
source input 24V Gearshift lever position R1 signal
2  2
input
2 ECMV output 1st (+)
Brake cooling oil temperature
3 Gearshift lever position R2 signal
3 ECMV output 3rd (+) (front wheel ) signal input 3
input
4 ECMV output High (+) 4 Fuel level signal input
Gearshift lever position N signal
4
5 ECMV output Rev (+) 5  input
6  6  Gearshift lever position D signal

5
input
7 ECMV output Low (+) Torque converter oil temperature
7 Gearshift lever position 1 signal
signal input 6
input
8 ECMV
output inter-axle differential
lock (+) Brake cooling oil temperature
8 Gearshift lever position 2 signal
(center wheel) signal input 7
9 ECMV output 2nd (+) input
Transmission oil temperature
10 ECMV output lock-up (+) 9 Gearshift lever position 3 signal
signal input 8
input
11  10 
Gearshift lever position 4 signal
Proportional solenoid power 9
12 11 Accelerator signal input input
source input 24V
12  Gearshift lever position 5 signal
13 ECMV output 1st, 3rd (-) 10
input
13 
14 Sensor power source output (12V) 11 Shift hold signal input
14 
15 ECMV output High, Rev (-) 12 
15 
16  13 
17 ECMV output Low (-) 16 Machine inclination angle signal
input 14 Model selection 1 input
ECMV output inter-axel differential 15 Model selection 2 input
18
lock (-)
16 Model selection 3 input
19 ECMV output 2nd (-)
20 ECMV output Lock-up (-)
21 GND
10-152 HM300-1
(4
9)
GEARSHIFT LEVER POSITION AND AUTOMATIC GEARSHIFTING RANGE

• The relationship between each gearshift position and the automatic gearshifting range is as shown in the
table below.
Gearshifting characteristics High power mode:

• Shifting the transmission up and down is carried The high power mode uses the power of the ma-
out according to the shift map saved in the con- chine to the maximum to provide the maximum pay-
troller memory. load. However, when the machine is unloaded or
There are three types of shift map, depending has only a light load (high acceleration), an acceler-
on the condition of the input signals. ation sensitive type variable shifting point is used.
The settings for each mode are as shown in the This detects the acceleration of the machine and
table below. shifts the transmission up sooner to provide better
acceleration and to improve the fuel consumption,
Mode Set conditions noise, and transmission shock.
When either of the following conditions is fulfilled
Braking mode
1. Brake signal ON Economy mode:
(footbrake, retarder brake operated)
2. Accelerator pedal released When the machine is being used under light load,
such as when traveling unloaded or on flat ground,
When the following three conditions are fulfilled
1. Brake signal OFF the shift-up point and shift-down point are both low-
High power
mode
(footbrake, retarder brake not operated) ered, the engine speed is maintained at a lower lev-
2. Accelerator pedal depressed
3. Power mode selector switch is at high power el, and the fuel consumption, noise, and transmis-
sion shock are improved. In this mode, the engine
When the following three conditions are fulfilled
1. Brake signal OFF output is limited to 90% of the maximum engine out-
Economy
mode
(footbrake, retarder brake not operated) put.
2. Accelerator pedal depressed
3. Power mode selector switch is at economy
Braking mode:
The shift-down point and the shift-up point are both
raised, the engine speed is maintained at a higher
level, and the amount of cooling oil for the retarder is
ensured to provide greater effect when the engine is
used as a brake.
HM300-1 10-153
(9)
AUTOMATIC GEARSHIFTING GRAPH

• The shift-up/shift-down points, the torque converter lock-up ON/OFF points, and the automatic braking (for
overrun prevention) ON/OFF points of each mode are as shown in the figure below.
Note: • If the travel speed lowers below 4 km/h or the

1. High power mode foot brake is not applied or the lock-up is kept
• For the shift-up point, the optimum point be- turned on for a long period, the lock-up is turned
tween 1,850 and 2,150 min-1 is selected accord- off and a gear speed proper for the travel speed
ing to the amount the accelerator pedal is is selected.
depressed, the acceleration of the machine, and Accordingly, if the machine travels downhill with
the speed range. the foot brake applied and the engine speed
• For the shift-down point also, the optimum point kept low by the lock-up, the brake cooling oil flow
between 1,120 and 1,350 min-1 is selected ac- becomes insufficient and the engine overheats
cording to the amount the accelerator pedal is easily.
depressed and the speed range.
4. Lock-up
2. Economy mode • For the lock-up ON point, the optimum point be-
• For the shift-up point, the optimum point between 1,050 and 1,350 min-1 is selected accord-
tween 1,680 and 1,800 min-1 is selected according to the torque converter input speed (engine
ing to the amount the accelerator pedal is speed) and output speed (transmission input
depressed, the acceleration of the machine, and shaft speed).
the speed range. • The lock-up OFF point when the foot brake or re-
• For the shift-down point also, the optimum point tarder brake are operated is 950 min-1.
between 1,060 and 1,100 min-1 is selected ac- • When the foot brake or retarder brake are not
cording to the amount the accelerator pedal is operated, it is 850 min-1.
depressed and the speed range. • When the machine moves off downhill with the
3. Keeping gear speed in braking mode (foot accelerator pedal released, the lock-up is not
brake) engaged until the accelerator pedal is de-
• If the travel speed lowers below 10 km/h while pressed or the foot brake is applied.
the foot brake is applied, the gear speed at that 5. The auto brake ON point when traveling in F6 is
time (F3, F4, F5) is held. 2,400 min- 1.
10-154 HM300-1
(9)
Gearshift lever positions and method of shifting The safety functions related to travel in reverse
1) Gearshift lever position D are the directional inhibitor and reverse safety.
When shifting up (in high power mode) If the operation is not correct, gearshifting is
I) When the gearshift lever is set at position D, the restricted.
transmission is set to F2 torque converter 4) Gearshift lever position N
range. At the neutral position, none of the transmission
II) When the accelerator pedal is depressed, the clutches are actuated.
engine speed rises and accelerates. When the
transmission input shaft speed reaches 1050 - Shift hold function
1,350 min-1, the lock-up clutch is engaged, so • If the hold switch on the gearshift lever is pushed
the torque converter is directly engaged and the once, the current gear speed is held. If the hold
transmission is set to direct travel. switch is pressed once again or the gearshift le-
III) As the engine speed rises further and reaches ver is operated, the gear speed can be changed.
1,850 - 2,150 min-1, the transmission shifts up to If the travel speed lowers excessively while the
F3. gear speed is held, the gear is shifted down.
While the transmission is shifting up, the engine When the travel speed rises again, however,
speed is also lowered (a command is output to the original gear speed is held.
the engine controller) in order to reduce the
shock when shifting gear. Time when gear cannot be shifted
IV) Immediately after shifting up, the engine speed • In the automatic shift range, to prevent mistaken
momentarily goes down, but as the machine operation caused by excessive variation in the
accelerates, it rises again and the transmission speed when shifting gear, a time delay is used to
shifts up in turn to F4 to F6 in the same way as prevent the gears from being shifted within the
in III) above. set time.
The gearshifting time delay is controlled pre-
When shifting down (in high power mode) cisely by each gearshifting pattern through the
I) When the load increases and the engine speed use of the all-range electronic modulation sys-
drops to 1,060 - 1,100 min-1, the transmission tem.
shifts down one speed. The approximate values for the gearshifting pat-
(For example, when traveling in F6, the trans- tern and gearshifting time delay are shown in
mission shifts down to F5.) the diagram below.
While the transmission is shifting up, the engine
speed is also raised (a command is output to
the engine controller) in order to reduce the
shock when shifting gear.
II) As the engine speed goes down further and the
transmission shifts down in turn to F2, the
torque converter lock-up clutch is disengaged
and the transmission enters the torque con-
verter drive.
★ In the above explanation, the set speed or actu-

ation may differ according to the travel condi-
tions. For details, see the automatic
gearshifting graph.
2) Gearshift lever positions 5, 4, 3, 2, 1

The method of shifting automatically from F1 to
F5 (F4, F3, F2) is the same as for gearshift
lever position D above.
3) Gearshift lever positions R1, R2
These are the gearshift lever positions for
traveling in reverse. The transmission shifts to
the range (R1 or R2) specified by the gearshift
lever position. (Manual shift)
HM300-1 10-155
(9)
Safety functions 4) Power train overrun prevention rear brake func-

1) Down-shift inhibitor function tion
If gearshift lever is operated D → 5 - 1, 5 → 4 - If the engine speed rises to more than 2400
1, 4 → 3 - 1, 3 → 2 - 1, 2 → 1 min-1 (more than 2350 min-1 in F6), the central
For example, when traveling in D (F6), even if warning lamp flashes and the alarm buzzer
the gearshift lever is operated to 4, the trans- sounds.
mission does not shift directly F6 → F4. It shifts If the engine speed rises to more than 2450
down F6 → F5 → F4 in turn according to the min-1 (more than 2400 min -1 in F6), the rear
engine speed. brake is automatically actuated.
(Even if the operator makes a mistake in opera- (To prevent overrun of engine, torque converter,
tion of the gearshift lever, the transmission does and transmission, to improve durability and reli-
not skip a gear speed. This is to prevent over- ability)
running of the engine.) 5) REVERSE safety
2) Neutral safety function The machine will not travel in reverse if the
This circuit prevents the engine from starting if dump control lever is not at FLOAT and the
the gearshift lever is not at the N position, even dump body is not completely lowered.
if the starting switch is turned to the START (Turnover prevention function)
position. However, if the gearshift lever is at the R1 posi-
(This is a safety circuit to prevent the machine tion and the shift hold switch is pressed, it is
from moving unexpectedly when the engine is possible to travel in reverse while the switch is
started.) being pressed, even if the dump body is not
3) Directional inhibit function fully lowered.
When traveling in reverse at a speed of more 6) Speed range limit function when dump body is
than 3.8 km/h, even if the gearshift lever is raised
operated to D or positions 5 to 1, the transmis- After dumping the load, if the body is not com-
sion will not be shifted immediately to travel for- pletely lowered, shifting up is limited.
ward. The engine speed is lowered to reduce If the gearshift lever is at D, the machine starts
the travel speed, and when the travel speed in F2. If the former is at positions 5 to 1, the lat-
goes below 3.8 km/h, the transmission is shifted ter starts in F1. The gear is not shifted up until
to FORWARD. the body is completely lowered.
When traveling forward at a speed of more than
1.9 km/h, even if the gearshift lever is operated Self-diagnostic function
to positions R1 or R2, the transmission will not The controller carries out self-diagnosis of the sys-
be shifted immediately to travel in reverse. The tem and displays any abnormalities.
speed range is shifted to N and the engine The details of the self-diagnosis are displayed as a
speed is lowered to reduce the travel speed. 2-digit code with LEDs.
When the travel speed goes below 1.9 km/h, If any abnormality is detected by the self-diagnosis
the transmission is shifted to REVERSE. function, the abnormality data is transmitted to the
When traveling in reverse at a speed of more network and is displayed as an action code on the
than 7.2 km/h with the gearshift lever at position machine monitor. The transmission system caution,
R2, even if the gearshift lever is operated from warning lamp, or alarm buzzer may also be actuat-
R2 to R1, the transmission does not shift to R1. ed.
When the travel speed goes below 1.9 km/h,
the transmission is shifted to R1.
When starting the engine, if the machine is
already traveling forward or in reverse at a
speed of more than 3.8 km/h, even if the gear-
shift lever is operated to a position other than N,
the machine will not move and the transmission
will be held at N.
When the travel speed goes below 1.9 km/h, it
is permitted to move the machine off.
(To prevent overload on power train, to improve
durability and reliability)
10-156 HM300-1
(9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AUTO EMERGENCY STEERING SYSTEM
AUTO EMERGENCY STEERING SYSTEM
1. Hydraulic tank Outline

2. Flow amp valve • If the engine stops or an abnormality occurs in
3. Steering oil pressure sensor the hydraulic pump when the machine is
4. Emergency steering pump traveling, and the oil in the steering circuit goes
5. Emergency steering motor below the specified oil pressure, the auto emer-
gency steering system automatically actuates
the emergency steering pump to ensure the
steering oil pressure and to make it possible to
operate the steering. It is also possible to oper-
ate it manually.
HM300-1 10-157
4
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SENSORS, SWITCHES
SENSORS, SWITCHES
ENGINE SPEED SENSOR
1. Magnet
2. Locknut
3. Wiring harness
4. Connector
Function
• The engine speed sensor is installed to the ring
gear of the flywheel housing. It uses the rotation
of the gear teeth to generate a pulse voltage and
transmits a signal to the transmission controller.
10-158 HM300-1
ACCELERATOR SENSOR
1. Connector
2. Connector
3. Pedal
OUTLINE
Accelerator signal
• This is installed under the operator’s cab. The
accelerator pedal and accelerator sensor are
connected by a link. When the accelerator pedal
is depressed, the movement is passed through
the link and rotates the shaft of the potentiome-
ter inside the accelerator sensor.
As a result, the resistance changes. A fixed
voltage is impressed between the No. 1 – 3 pins
of the potentiometer. A voltage signal corre-
sponding to the angle of the accelerator pedal is
sent from the No. 2 pin to the transmission con-
troller.
Idle validation signal

• This is installed under the operator’s cab.
When the accelerator pedal is released, signal
2 (No. 5 pin) is connected to the ground; when
the accelerator pedal is depressed, signal 3
(No. 6 pin) is connected to the ground.
The engine controller then detects the condi-
tion.
HM300-1 10-159
(9)
ENGINE COOLANT TEMPERATURE SENSOR

BRAKE COOLING OIL TEMPERATURE SENSOR
1. Thermistor
2. Plug
3. Wiring harness
4. Connector
Function
• The sensors are installed to the brake cooling
piping. They take the change in resistance of
the thermistor as the change in the temperature
and transmit a signal to the transmission control-
ler. The signal is sent from the transmission
controller through the network to the machine
monitor panel to display the temperature level.
When the display on the monitor panel reaches
the specified position, the lamp flashes and the
buzzer sounds to warn of an abnormality.
STEERING OIL TEMPERATURE SENSOR
1. Sensor
2. Terminal
3. Connector
Function
• The steering oil temperature sensor is installed
to the steering and hoist piping. The sensor por-
tion detects the temperature, and when the oil
temperature goes above the specified level, the
warning lamps lights up and a message is dis-
played on the character display of the monitor
panel.
10-160 HM300-1
(4
9)
FUEL LEVEL SENSOR
1. Connector Function
2. Wire resistor • The fuel sensor is installed to the side face of the
3. Arm fuel tank. The float moves up and down accord-
4. Float ing to the fuel level. This movement of the float
is transmitted by the arm and actuates a variable
resistance. This sends a signal to the monitor
panel to indicate the remaining fuel level. When
the display of the monitor panel reaches a cer-
tain level, a warning lamp flashes.
HM300-1 10-161
(9)
TILT SENSOR
1. Magnetic resistance particle

2. Leaf spring
3. Damper oil
Function
• The tilt sensor is installed to the rear of the chas-
sis. A magnet supported by a leaf spring is in-
stalled to a case charged with damper oil. It uses
the position in relation to the magnetic resist-
ance element to detect the tilt angle of the chas-
sis.
The magnet is supported by the leaf spring, so
it does not detect the front-to-rear tilt of the
chassis.
10-162 HM300-1
AIR CLEANER CLOGGING SENSOR
1. Indicator
2. Spring
3. Adapter
Function
• The air cleaner clogging sensor is installed to
the outward port of the air cleaner. If the air
cleaner becomes clogged and reaches the set
pressure (negative pressure), the maintenance
warning lamp lights up to warn of the abnormal-
ity.
HM300-1 10-163
HYDRAULIC OIL LEVEL SENSOR
1. Connector
2. Float
3. Switch
Function
• The hydraulic oil level sensor is installed to the
side face of the hydraulic tank. When the oil
goes below the specified level, the float goes
down, the switch is turned OFF, and the mainte-
nance caution lamp lights up to warn of the ab-
normality.
10-164 HM300-1
4
BODY POSITIONER SENSOR
1. Bearing
2. Rotor
3. Connector
Function
• The body position sensor is installed to the rear
of the chassis. When the angle of the dump body
changes, the shaft receives sliding resistance
through the link installed to the dump body, and
the dump body angle is detected.
HM300-1 10-165
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD RETARDER CONTROL SYSTEM
RETARDER CONTROL SYSTEM
10-166 HM300-1
4
RETARDER CONTROLLER
1. Self-diagnostic display window

2. Rotary switch
3. Motherboard
4. Case
5. Connector
Outline
The retarder controller has the following functions.
1. Retarder control
The electromagnetic proportional valve for the front and rear wheels is controlled according to the
operating angle of the retarder control lever and actuates the retarder brake.
2. Overrun prevention, retarder control when there is transmission abuse

The electromagnetic proportional valve for the front and rear wheels is controlled based on the command
(ON/OFF command) from the transmission controller and actuates the retarder brake by a fixed amount.
3. Hoist control
This controls the hoist EPC valve (electromagnetic proportional valve) and hoist selector valve (ON/OFF
valve) according to the position of the dump control lever and actuates the dump body.
4. Differential lock control

Inter-axle differential lock control
The differential lock command is output to the transmission controller according to the condition of the
machine (differential lock switch, travel speed, etc.).
Based on the command from the retarder controller, the transmission controller drives the ECMV and
actuates the inter-axle differential lock.
HM300-1 10-167
(12)
4
5. Exhaust brake control (If equipped)

Based on the command from the transmission controller, the exhaust brake solenoid is driven and the
exhaust brake is actuated.
6. Transmission of network data

1) Retarder actuation, float caution, parking brake actuation, exhaust brake actuation, inter-axle differen-
tial lock actuation, accumulator oil pressure drop warning, and other data are transmitted to the moni-
tor panel.
2) The exhaust brake command, overrun prevention, retarder command when there is abuse, and other
data sent from the transmission controller are received.
3) The inter-axle differential lock actuation command, reverse inhibit, and other data are transmitted to
the transmission controller.
10-168 HM300-1
4
BRC1 BRC3A BRC4 BRC5A

Power source for +24V output 1 Connector check 1 1 RS422 TX(+) 1 Connector check 2
1
sensor
2  2 RS422 RX(+) 2 Exhaust brake switch (if equipped)
Rear wheel differential lock
2
solenoid (if equipped) 3  3 RS232 TXD 3 Service brake switch
3 Exhaust brake solenoid 4  4 RS232C TXD 4 Retarder switch
4 Brake cut relay (+24V IN) 5  5 RS485 (+)

5 Parking
brake emergency brake
switch
5 
6 Sensor
power source +5V (hoist 6 S-NET (+)
lever potentiometer, body position) 6 Lever validation switch 1
6 Neutral signal 1 7 RS422 TX(-)
7  7 Lever validation switch 2
7 Battery direct power source input 8 FLASH SW. (ON/OFF)
8 
8 Brake
system filter switch
8 GND 9 RS422 RX(-) (if equipped)
9 
9 Power source +24V 10 GND. (SERIAL) 9 Brake cooling filter switch
10 
Front wheel differential lock 11 RS485(-) 10 
10 solenoid (if equipped)
11 
12 S-NET (+) Differential actuation switch (front)
11 (if equipped)
11 Kick-out solenoid 12 Transmission rear axel speed
12 Hoist selector valve

12 Differential
13 Transmission ouput shaft speed actuation switch (rear)
(if equipped)
13 Brake cut relay 14 GND (pulse)
13 
14  15 
14 
15 Neutral signal 2 16 GND (analog)
15 
16 GND 17 
16 
17 Power source +24V 18 
17 
19 
18 Starting switch terminal C (engine
20  start signal)
19 
20 
BRC2 BRC3B
Proportional solenoid power 1 
1
source +24V BRC5B
2 
1 
2 
3 
2 Brake wear switch FL (if equipped)
3 
4 
3 Brake wear switch FR (if equipped)
4 
5 Accumulator oil pressure (FRONT)
Exhaust brake command (FRONT
5  4
6 Accumulator oil pressure (REAR)) TRANSMISSION)
Inter-axel differential lock
6 Accumulator gas pressure Overrun command (FRONT
command 7 5
(FRONT) TRANSMISSION)
7 
8 Accumulator gas pressure (REAR) 6 Brake wear switch RL (if equipped)
Front wheel retarder
8 electromagnetic proportional 9  7
Brake wear switch RR
reducing valve (+) (if equipped)
10 
Rear wheel retarder Brake wear switch ML
8
9 electromagnetic proportional 11  (if equipped)
reducing valve (+)
12 Hoist lever potentiometer 2 Brake wear switch MR
10 Hoist EPC valve (+) 9
(if equipped)
13 Body position sensor
11  10 
14 Hoist lever potentiometer 1
12
source +24V 15 Steering angle potentiometer
12 
13  16 Manual retarder lever
potentiometer 13 
14 Sensor power source +12V (pulse)
14 
15 
15 
16 Sensor
power source +5V
(retarder lever potentiometer) 16 
17 
Front wheel retarder

18 electromagnetic proportional
reducing valve (–)
Rear wheel retarder

19 electromagnetic proportional
reducing valve (–)
20 Hoist EPC valve (–)
21 GND
HM300-1 10-169
4
(9)
RETARDER CONTROL FUNCTION

RETARDER CONTROL SYSTEM DIAGRAM
Retarder lever control

The operating angle of the retarder lever is detected by the potentiometer and a current corresponding to this
is output to the electromagnetic proportional valve for the front and rear wheels to actuate the retarder.
Overrun prevention, retarder control when there is transmission abuse

The electromagnetic proportional valve for the front and rear wheels is controlled based on the command (ON/
OFF command) from the transmission controller and actuates the retarder by a fixed amount.
10-170 HM300-1
4
Relationship between retarder lever potentiometer and output to electromagnetic proportional valve
1 To improve the initial response of the electromagnetic proportional reducing valve, the output (trigger out-
put) is set to a high value.
2 To make the actuation of the hydraulic pressure smooth in the low pressure range, the output is set to a
high value.
3 In the range where the retarder is normally used, the output is proportional to the angle of the lever.
4 To make the opening of the hydraulic pressure smooth in the low pressure range, the output is set to a low
value.
HM300-1 10-171
HOIST CONTROL FUNCTION
HOIST CONTROL SYSTEM DIAGRAM
1. Hoist control function

When the engine is running, the EPC valve (electromagnetic proportional valve) and selector valve are
controlled according to the operation of the dump control lever and operate the dump body.
2. Lever positioner function

The dump control lever has four positions: RAISE, HOLD, FLOAT, and LOWER.
If the dump control lever is operated to the RAISE position, the dump body is raised, and when the top of
the dump body reaches the set position of the body position sensor, the lever is returned to the HOLD posi-
tion.
If the lever is kept at the RAISE position, the RAISE output continues to be given.
3. Body seating speed control

When the dump body is lowered and reaches the position just before it is seated, the area of opening of
the EPC valve is throttled to control the lowering speed of the dump body and reduce the shock when the
dump body comes into contact with the chassis.
10-172 HM300-1
(9)
4. Control when starting switch is turned to ON, OFF, or START

Starting switch at ON:
The output is set to HOLD, regardless of the position of the lever.
If the engine is not started, even if the hoist lever is operated, the condition remains at HOLD.
Starting switch at OFF:
The dump body is held in position regardless of the position of the lever.
Engine started:
Immediately after the engine is started, the output is set to HOLD, regardless of the position of the lever.
After the lever is moved to the HOLD position, it becomes possible to carry out normal operations.
5. Float caution function

If the output is not FLOAT or the dump body is not fully lowered, the float caution lamp on the monitor panel
lights up.
"FLOAT OUTPUT" and "SEATED" → Float caution OFF
"NO FLOAT OUTPUT" or "NOT SEATED" → Float caution ON
6. Reverse inhibit function

The retarder controller judges if it is permissible to travel in reverse or not, and transmits the result of the
judgment through the network to the transmission controller.
"FLOAT OUTPUT" and "SEATED" → Reverse travel permitted
"NO FLOAT OUTPUT" or "NOT SEATED" → Reverse travel not permitted
7. Calibration function
To absorb any inherent error in the dump body potentiometer, calibration is carried out to recognize the
dump body seating and the body cylinder stopper condition.
After adjusting the installation of the body potentiometer or after replacing the retarder controller, carry out
calibration in the following order.
Order of dump control calibration (hydraulic oil temperature: 80 - 90°C)
(1) Lower the dump body completely and run the engine. Change the lever from HOLD to FLOAT and
check that the float caution lamp goes off.
(2) Operate the lever to the RAISE position and raise the dump body until it contacts the stopper. Keep
the lever at the RAISE position with the cylinder at the stopper position for at least 5 seconds.
(3) Lower the dump body completely and keep the lever at HOLD for at least 5 seconds.
(4) Run the engine at low idle and operate RAISE → FLOAT with the dump body raised to the maximum
height, then lower the dump body completely. Repeat this operation 10 times.
(5) Run the engine at high idle and operate RAISE → FLOAT with the dump body raised to the maximum
HM300-1 10-173
4
(9)
DIFFERENTIAL LOCK CONTROL FUNCTION
DIFFERENTIAL LOCK CONTROL SYSTEM DIAGRAM
(Note: HM300-1 is not equipped with the right and left differential locks.)

The inter-axle differential lock is actuated automatically, or manually by turning the inter-axle differential
lock switch ON/OFF.
• Manual differential lock:
In low speed ranges (F1, F2, F3, R1, R2) or N, the inter-axle differential lock command is output when
the differential lock switch is ON.
• Emergency braking control (automatic):
The inter-axle differential lock command is output when the travel speed is more than 35 km/h and the
brake is ON.
• Brake ON control (automatic):
The inter-axle differential lock command is output according to the difference in speed between the
front and rear axles when the brake is ON.
• Control (automatic) when there is variation in transmission output shaft speed:
The inter-axle differential lock command is output when the variation in the transmission output shaft
speed exceeds the set value.
The inter-axle differential lock command is an analog signal and is transmitted to the transmission con-
troller. To cancel the inter-axle differential lock the transmission controller outputs electric current to the
electromagnetic proportional valve.
10-174 HM300-1
(9)
Inter-axle differential lock output

The inter-axle differential lock command is an analog signal and is transmitted from the retarder controller to the
transmission controller. The transmission controller outputs electric current to the electromagnetic proportional
valve.
The differential lock clutch is engaged by a pressure proportional to the current.
Output specification from retarder controller to transmission controller
The retarder controller output is constant value A when starting to control the differential lock. After A is output,
when the fill signal (signal reporting the completion of filling the electromagnetic proportional valve with oil)
comes ON, it provides an output and angle θ1 to line B and angle θ2 to target output line C.
Retarder control lever

The manual retarder potentiometer and lever validation switches 1 and 2 are built into the lever.
The manual retarder potentiometer output is a voltage signal matching the position of the lever and is sent to
the retarder controller.
The lever validation switches output the ON/OFF data for the lever position to the retarder controller.
Dump control lever

The dump control lever potentiometer and lever kick-out solenoid are built into the dump control lever.
The dump control lever potentiometer output is a voltage signal matching the position of the lever and is sent to
the retarder controller.
The lever kick-out solenoid fixes the lever at the RAISE position when it receives the ON signal from the retarder
controller and returns the lever to the HOLD position when it receives the OFF signal.
HM300-1 10-175
(9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE CONTROL SYSTEM (E-SPEC)
BRAKE CONTROL SYSTEM (E-SPEC)
q1: Since the retarder function is not used in E-SPEC, the retarder control lever potentiometer is used to bleed
air from the brake oil circuit.
10-175-1 HM300-1
(4
9)
BRAKE CONTROLLER (E-SPEC)
1. Self-diagnostic display window

2. Rotary switch
3. Motherboard
4. Case
5. Connector
Outline
The brake controller has the following functions.
1. Overrun prevention, brake control when there is transmission abuse

The electromagnetic proportional valve for the front and rear wheels is controlled based on the command
(ON/OFF command) from the transmission controller and actuates the brake by a fixed amount.
2. Hoist control
This controls the hoist EPC valve (electromagnetic proportional valve) and hoist selector valve (ON/OFF
valve) according to the position of the dump control lever and actuates the dump body.
3. Differential lock control

The differential lock command is output to the transmission controller according to the condition of the
machine (differential lock switch, travel speed, etc.).
Based on the command from the brake controller, the transmission controller drives the ECMV and actu-
ates the inter-axle differential lock.
HM300-1 10-175-2
(12)
4
4. Exhaust brake control (If equipped)

Based on the command from the transmission controller, the exhaust brake solenoid is driven and the
exhaust brake is actuated.
5. Transmission of network data

1) Brake actuation, float caution, parking brake actuation, exhaust brake actuation, inter-axle differential
lock actuation, accumulator oil pressure drop warning, and other data are transmitted to the monitor
panel.
2) The exhaust brake command, overrun prevention, brake command when there is abuse, and other
data sent from the transmission controller are received.
3) The inter-axle differential lock actuation command, reverse inhibit, and other data are transmitted to
10-175-3 HM300-1
(4
9)
BRC1 BRC3A BRC4 BRC5A

Power source for +24V output 1 Connector check 1 1 RS422 TX(+) 1 Connector check 2
1
sensor
2  2 RS422 RX(+) 2 Exhaust brake switch (if equipped)
Rear wheel differential lock
2
solenoid (if equipped) 3  3 RS232 TXD 3 Brake switch
3 Exhaust brake solenoid 4  4 RS232C TXD 4 Overrun protection brake switch
4 Brake cut relay (+24V IN) 5  5 RS485 (+)

5 Parking
brake emergency brake
switch
5 
6 Sensor
power source +5V (hoist 6 S-NET (+)
lever potentiometer, body position) 6 Lever validation switch 1
6 Neutral signal 1 7 RS422 TX(-)
7  7 Lever validation switch 2
7 Battery direct power source input 8 FLASH SW. (ON/OFF)
8  8 Brake system filter switch
8 GND 9 RS422 RX(-) (if equipped)
9 
9 Power source +24V 10 GND. (SERIAL) 9 Brake cooling filter switch
10 
Front wheel differential lock 11 RS485(-) 10 
10 solenoid (if equipped)
11 
11 Differential
12 S-NET (+) actuation switch (front)
11 Kick-out solenoid 12 Transmission rear axel speed (if equipped)
12 Hoist selector valve 13 Transmission ouput shaft speed 12 Differential

actuation switch (rear)
(if equipped)
13 Brake cut relay 14 GND (pulse)
13 
14  15 
14 
15 Neutral signal 2 16 GND (analog)
15 
16 GND 17 
16 
17 Power source +24V 18 
17 
19 
18 Starting
switch terminal C (engine
20  start signal)
19 
20 
BRC2 BRC3B
1
source +24V BRC5B
2 
1 
2 
3 
2 Brake wear switch FL (if equipped)
3 
4 
3 Brake wear switch FR (if equipped)
4 
5 Accumulator oil pressure (FRONT)
Exhaust brake command (FRONT
5  4
6 Accumulator oil pressure (REAR)) TRANSMISSION)
Inter-axel differential lock
6 Accumulator gas pressure Overrun command (FRONT
command 7 5
(FRONT) TRANSMISSION)
7 
8 Accumulator gas pressure (REAR) 6 Brake wear switch RL (if equipped)
8 Front
wheel brake electromagnetic
proportional reducing valve (+) 9  Brake wear switch RR
7
(if equipped)
10 
9 Rear
proportional reducing valve (+) Brake wear switch ML
8
11  (if equipped)
10 Hoist EPC valve (+)
12 Hoist lever potentiometer 2 Brake wear switch MR
9
11  (if equipped)
13 Body position sensor
12 14 Hoist lever potentiometer 1
source +24V
11 
13  15 Steering angle potentiometer
12 
16 (Manual
14 Sensor power source +12V (pulse) retarder lever
potentiometer) 13 
15 
14 
16 Sensor power source +5V 15 
(retarder lever potentiometer)
17  16 
18 Front
proportional reducing valve (–)
19 Rear wheel brake electromagnetic

proportional reducing valve (–)
20 Hoist EPC valve (–)
21 GND
HM300-1 10-175-4
(9)
4
BRAKE CONTROL FUNCTION

BRAKE CONTROL SYSTEM DIAGRAM
Overrun prevention, brake control when there is transmission abuse

The electromagnetic proportional valve for the front and rear wheels is controlled based on the command (ON/
OFF command) from the transmission controller and actuates the brake by a fixed amount.
10-175-5 HM300-1
(4
9)
HOIST CONTROL FUNCTION
HOIST CONTROL SYSTEM DIAGRAM
1. Hoist control function

When the engine is running, the EPC valve (electromagnetic proportional valve) and selector valve are
controlled according to the operation of the dump control lever and operate the dump body.
2. Lever positioner function

The dump control lever has four positions: RAISE, HOLD, FLOAT, and LOWER.
If the dump control lever is operated to the RAISE position, the dump body is raised, and when the top of
the dump body reaches the set position of the body position sensor, the lever is returned to the HOLD posi-
tion.
If the lever is kept at the RAISE position, the RAISE output continues to be given.
3. Body seating speed control

When the dump body is lowered and reaches the position just before it is seated, the area of opening of
the EPC valve is throttled to control the lowering speed of the dump body and reduce the shock when the
dump body comes into contact with the chassis.
HM300-1 10-175-6
(9)
4
4. Control when starting switch is turned to ON, OFF, or START

Starting switch at ON:
The output is set to HOLD, regardless of the position of the lever.
If the engine is not started, even if the hoist lever is operated, the condition remains at HOLD.
Starting switch at OFF:
The dump body is held in position regardless of the position of the lever.
Engine started:
Immediately after the engine is started, the output is set to HOLD, regardless of the position of the lever.
After the lever is moved to the HOLD position, it becomes possible to carry out normal operations.
5. Float caution function

If the output is not FLOAT or the dump body is not fully lowered, the float caution lamp on the monitor panel
lights up.
"FLOAT OUTPUT" and "SEATED" → Float caution OFF
"NO FLOAT OUTPUT" or "NOT SEATED" → Float caution ON
6. Reverse inhibit function

The brake controller judges if it is permissible to travel in reverse or not, and transmits the result of the
judgment through the network to the transmission controller.
"FLOAT OUTPUT" and "SEATED" → Reverse travel permitted
"NO FLOAT OUTPUT" or "NOT SEATED" → Reverse travel not permitted
7. Calibration function
To absorb any inherent error in the dump body potentiometer, calibration is carried out to recognize the
dump body seating and the body cylinder stopper condition.
After adjusting the installation of the body potentiometer or after replacing the brake controller, carry out
calibration in the following order.
Order of dump control calibration (hydraulic oil temperature: 80 - 90°C)
(1) Lower the dump body completely and run the engine. Change the lever from HOLD to FLOAT and
check that the float caution lamp goes off.
(2) Operate the lever to the RAISE position and raise the dump body until it contacts the stopper. Keep
the lever at the RAISE position with the cylinder at the stopper position for at least 5 seconds.
(3) Lower the dump body completely and keep the lever at HOLD for at least 5 seconds.
(4) Run the engine at low idle and operate RAISE → FLOAT with the dump body raised to the maximum
(5) Run the engine at high idle and operate RAISE → FLOAT with the dump body raised to the maximum
10-175-7 HM300-1
(4
9)
DIFFERENTIAL LOCK CONTROL FUNCTION
DIFFERENTIAL LOCK CONTROL SYSTEM DIAGRAM

The inter-axle differential lock is actuated automatically, or manually by turning the inter-axle differential
lock switch ON/OFF.
• Manual differential lock:
In low speed ranges (F1, F2, F3, R1, R2) or N, the inter-axle differential lock command is output when
the differential lock switch is ON.
• Emergency braking control (automatic):
The inter-axle differential lock command is output when the travel speed is more than 35 km/h and the
brake is ON.
• Brake ON control (automatic):
The inter-axle differential lock command is output according to the difference in speed between the
front and rear axles when the brake is ON.
• Control (automatic) when there is variation in transmission output shaft speed:
The inter-axle differential lock command is output when the variation in the transmission output shaft
speed exceeds the set value.
The inter-axle differential lock command is an analog signal and is transmitted to the transmission con-
troller. To cancel the inter-axle differential lock the transmission controller outputs electric current to the
electromagnetic proportional valve.
HM300-1 10-175-8
(9)
4
Inter-axle differential lock output

The inter-axle differential lock command is an analog signal and is transmitted from the brake controller to the
transmission controller. The transmission controller outputs electric current to the electromagnetic proportional
valve.
The differential lock clutch is engaged by a pressure proportional to the current.
Output specification from brake controller to transmission controller
The brake controller output is constant value A when starting to control the differential lock. After A is output,
when the fill signal (signal reporting the completion of filling the electromagnetic proportional valve with oil)
comes ON, it provides an output and angle θ1 to line B and angle θ2 to target output line C.
Dump control lever

The dump control lever potentiometer and lever kick-out solenoid are built into the dump control lever.
The dump control lever potentiometer output is a voltage signal matching the position of the lever and is sent to
the brake controller.
The lever kick-out solenoid fixes the lever at the RAISE position when it receives the ON signal from the brake
controller and returns the lever to the HOLD position when it receives the OFF signal.
10-175-9 HM300-1
(4
9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DUMP CONTROL LEVER
DUMP CONTROL LEVER
10-176 HM300-1
1. Lever
2. Rod
3. Spring
4. Spring
5. Retainer
6. Body
7. Body
8. Bushing
9. Solenoid
10. Nut
11. Rod
12. Detent spring
13. Retainer
14. Ball
15. Seat
16. Potentiometer
17. Lever
18. Rod
19. Rod
20. Detent spring
HM300-1 10-177
Function
• When lever (1) is operated, rod (18) moves up or
down according to the amount the lever is oper-
ated, and rotates potentiometer (16).
• The amount the control lever is operated (trav-
els) is detected by the potentiometer, and this is
sent as a signal voltage to the controller.
• One potentiometer is installed and outputs two
related signal voltages as shown in the "Output
voltage characteristics" graph.
Operation
1. Dump control lever operated to FLOAT
• When LOWER rod (2) is pushed by lever (1) and
moves down, ball (14) contacts protrusion a of
rod (11) during the stroke. (Before start of actu-
ation of mechanical detent)
• When rods (2) and (11) are pushed in further,
ball (14) is being held by detent spring (12).
While pushing retainer (13) up, it escapes to the
outside, and rod (11) passes over protrusion a.
• When this happens, rod (18) on the opposite
side is pushed up by spring (4). Ball (14) is
moved to the small diameter side of protrusion b
of rod (19) by retainer (13) that is being held by
detent spring (20).
• Even if the lever is released, rod (18) is held in
position by the pushing force of the ball and pro-
trusion b of rod (19), so the lever is held at the
FLOAT position.
10-178 HM300-1
2. Dump control lever FLOAT canceled 4. Dump control lever operated to RAISE
• When lever (1) is returned from the FLOAT posi- • When RAISE rod (18) is pushed by lever (1) and
tion, it is pushed down by a force greater than moves down, ball (14) contacts protrusion a of
the holding force of rod (19), detent spring (20), rod (19) during the stroke. (Before start of actu-
retainer (13), and ball (14). ation of mechanical detent)
• When rods (18) and (19) are pushed in further,
3. Dump control lever operated to LOWER ball (14) pushes up retainer (13) which is held by
• When lever (1) is operated further from the detent spring (20) and it escapes to the outside,
FLOAT position, it moves to the LOWER posi- and rod (19) passes over protrusion a.
tion. • When this happens, rod (2) on the opposite side
• Rod (18) is pushed up by the spring (4) in ac- is pushed up by spring (4).
cordance with the amount lever (1) is operated. • When an electric current is flowing to solenoid
• Lever (17) and rod (19), which are installed to (9), if rod (2) is pushed up, nut (10) is held in con-
the rotating shaft of potentiometer (16), are inter- tact with bushing (8).
connected, so a voltage matching the up or • As a result, rod (2) is held at the pushed up po-
down movement of the rod is output from poten- sition, so even if the lever is released, it is held
tiometer (16). at the RAISE position.
HM300-1 10-179
(9)
5. Dump control lever RAISE canceled

• When lever (1) is returned from the RAISE posi-
tion, it is pushed down by a force greater than
the attraction force of the solenoid.
Or, when the solenoid power source is turned
OFF, the RAISE position is canceled and the
lever returns to the N position.
10-180 HM300-1
20 TESTING AND ADJUSTING
STANDARD VALUE TABLES

Standard value table for engine ......................................................................................................... 20- 2
Standard value table for chassis ........................................................................................................ 20- 3
Standard value table for electrical parts ............................................................................................ 20- 7
TESTING AND ADJUSTING ................................................................................................................... 20-101
TROUBLESHOOTING ............................................................................................................................ 20-201
★ Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the ma-
chine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the re-
sults of various tests. It is used for reference together with the state of repair and the history of operation to
judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
HM300-1 20-1
1c
1
(5) c
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE

Machine model HM300-1
Engine SAA6D125E-3
Standard value for Service limit
Item Measurement conditions Unit
new machine value
Power mode 2,200 ± 50 2,200 ± 50
High idle
Economy mode 2,000 ± 50 2,000 ± 50
Power mode 945 ± 25 945 ± 25
Engine speed Low idle rpm
Economy mode 700 ± 25 700 ± 25
Power mode 2,000 2,000
Rated speed
Economy mode 1,600 1,600
Air supply kPa Min. 106.7 79.8
At rated output
(boost pressure) {mmHg} {Min. 800} {600}
At sudden acceleration Bosch Max. 4.5 6.5
Exhaust gas color
At high idle index Max. 1.0
Exhaust temperature
Whole speed range
(Turbocharger inlet °C Max. 650 700
(Ambient temperature 20°C)
temperature)
Valve clearance Intake valve 0.33 —

mm
(normal temperature) Exhaust valve 0.71 —
Compression MPa Min. 2.9

Oil temperature: 40 – 60°C
pressure {kg/cm2} {Min. 30} —
(SAE oil) (Engine speed) (rpm) (150 – 200)
Blow-by pressure (Coolant temperature: Operating range) kPa Max. 0.98 1.96
(SAE oil) At rated output {mmH2O} {Max. 100} {200}
(Coolant temperature: Operating range)

392 – 588 206
At high idle (SAE30)
{4.0 – 6.0} {2.1}
343 – 539 176
At high idle (SAE10W) kPa
Oil pressure {3.5 – 5.5} {1.8}
{kg/cm2}
Min. 147 69
At low idle (SAE30)
{Min. 1.5} {0.7}
Min. 98 69
At low idle (SAE10W)
{Min. 1.0} {0.7}
Oil temperature Whole speed range (Inside oil pan) °C 90 – 120 Min. 120
Deflection when
pressed with a Alternator – crankshaft pulley 10 —
Belt tension finger force of mm
approx. 58.8N Air conditioner compressor –
10 10
{approx. 6kg}. fan belt
20-2 HM300-1
c 11c
(9)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS
Cate- Standard value for Service limit

gory new machine value
• Point 150mm from ped- Starting to 17.7 ± 4.9 17.7 ± 4.9
Accelerator pedal
al fulcrum depress {1.8 ± 0.5} {1.8 ± 0.5}

N
Operating effort
Fully {kg} 42.2 +– 2.0
4.9 42.2 +– 2.0
4.9
depressed {4.3 +– 0.2 {4.3 +– 0.2
0.5 } 0.5 }
Travel • Point 150mm from pedal fulcrum mm 45 ± 5 45 ± 5
Torque converter lock- • Engine coolant

1,400 ± 50 1,400 ± 50
up actuation speed temperature:
Within operating range Brake
• Torque converter oil 950 ± 50 950 ± 50
Torque converter lock- ON
temperature:
up cancel speed Brake
Within operating range rpm 850 ± 50 850 ± 50
OFF
• Hydraulic oil
temperature: Power
1,910 ± 100 1,910 ± 100
Torque converter stall 45 – 55°C mode
Engine
speed Economy
1,730 ± 100 1,730 ± 100
mode
Engine speed
Transmission • Engine coolant

2,150 ± 50 2,150 ± 50
shift-up speed temperature: Normal
Within operating range mode
Transmission
• Torque converter oil 1,250 ± 50 1,250 ± 50
shift-down speed
temperature:
Transmission Within operating range
rpm 2,200 ± 50 2,200 ± 50
shift-up speed • Hydraulic oil Brake
temperature: mode
Transmission
45 – 55°C 1,550 ± 50 1,550 ± 50
shift-down speed
• Brake mode:
Transmission down- Accelerator OFF or 1,550 ± 50 1,550 ± 50
shift inhibit speed brake ON
Overrun prevention
2,600 ± 50 2,600 ± 50
actuation speed
rpm
Overrun prevention
2,350 ± 50 2,350 ± 50
cancel speed
• Center of lever grip N 21.6 ± 3.9 Max. 19.6
Gearshift
Operating effort
• Between each position {kg} {2.2 ± 0.45} {Max. 2.0}
lever
Travel mm 24.5 ± 1 24.5 ± 2
• Torque converter oil 2.55 ± 0.2 2.55 ± 0.2

Low idle
temperature: {26 ± 2.0} {26 ± 2.0}
Power train
Power train main relief MPa

pressure Within operating range {kg/cm2} 2.55 ± 0.2 2.55 ± 0.2
• Gearshift lever: N High idle
{26 ± 2.0} {26 ± 2.0}
Oil pressure
Torque converter • Torque converter oil temperature: 0.91 ± 0.10 0.91 ± 0.10
inlet port pressure Within operating range {9.3 ± 1.0} {9.3 ± 1.0}
Torque converter • Engine speed: High idle MPa 0.59 ± 0.10 0.59 ± 0.10
outlet port pressure {kg/cm2} {6.0 ± 1.0} {6.0 ± 1.0}
Torque converter lock- 1.81 ± 0.15 1.81 ± 0.15
up clutch pressure {18.5 ± 1.0} {18.5 ± 1.0}
HM300-1 20-3
1c
1
(9) c

Transmission Lo • Torque converter oil temperature: 2.45 ± 0.15 2.45 ± 0.15
clutch pressure Within operating range MPa {25.0 ± 1.5} {25.0 ± 1.5}
Transmission Hi • Engine speed: High idle {kg/cm2} 2.45 ± 0.15 2.45 ± 0.15
clutch pressure {25.0 ± 1.5} {25.0 ± 1.5}
Transmission 1st 2.45 ± 0.15 2.45 ± 0.15
clutch pressure {25.0 ± 1.5} {25.0 ± 1.5}
Transmission 2nd 2.35 ± 0.15 2.35 ± 0.15
Oil pressure
clutch pressure {24.0 ± 1.5} {24.0 ± 1.5}

Transmission 3rd 2.45 ± 0.15 2.45 ± 0.15
clutch pressure {25.0 ± 1.5} {25.0 ± 1.5}
MPa
Transmission R {kg/cm2} 2.45 ± 0.15 2.45 ± 0.15
clutch pressure {25.0 ± 1.5} {25.0 ± 1.5}
Inter-axle differential 2.35 ± 0.15 2.35 ± 0.15
lock clutch pressure {24.0 ± 1.5} {24.0 ± 1.5}
Transmission 0.147 ± 0.029 0.147 ± 0.029
lubricating pressure
(reference) {1.5 ± 0.3} {1.5 ± 0.3}
Power train
• Flat ground
F1 6.2 ± 5% 6.2 ± 5%
• Engine coolant temperature:
Within operating range
F2 • Torque converter oil temperature: 9.8 ± 5% 9.8 ± 5%
F3 • Dump body: Unloaded 15.2 ± 5% 15.2 ± 5%
• Travel resistance: 3.3%
Travel speed
F4 23.9 ± 5% 23.9 ± 5%
km/h
F5 37.5 ± 5% 37.5 ± 5%
F6 59.0 ± 5% 59.0 ± 5%
R1 7.2 ± 5% 7.2 ± 5%
R2 17.5 ± 5% 17.5 ± 5%
• Standard tire: 23.5 – R25 0.343 0.343

Front
Tire inflation • Dump body: Unloaded MPa {3.50} {3.50}
pressure Center, {kg/cm2} 0.402 0.402
rear {4.1} {4.1}
• Tip of pedal N Max. 299 Max. 299
Operating effort
Brake
pedal
{kg} {Max. 30.5} {Max. 30.5}
Travel mm 66 ± 5 66 ± 5
Brakes
• Point 10mm from tip of lever N 5.9 – 9.8 3.0 – 14.7

lever(q1)
Retarder
Operating effort
{kg} {0.6 – 1.0} {0.3 – 1.5}
°
Travel 78 – 02 78 – 40
(degree)
q1. Not installed in E-SPEC
20-4 HM300-1
c (4
1c
9)

• Gas temperature 4.4 ± 0.15 4.4 ± 0.15
Accumulator
For front service brake

pressure
Charge
(atmosphere temperature): MPa {45 ± 1.5} {45 ± 1.5}

20 ± 5 °C {kg/cm2} 4.4 ± 0.15 4.4 ± 0.15
For rear service brake
{45 ± 1.5} {45 ± 1.5}
• Wheel brake actuation pressure: 11.77 + 0.29 11.77 + 0.29
Charge valve cut-in 0 0
Actuation pressure when brake is
pressure {120 + 3.0 {120 + 3.0
operated for first time after en- 0 } 0 }
gine is stopped
Charge valve cut-out 20.59 +– 0.98
0.5 20.59 +– 0.98
0.5
• Drop in wheel brake actuation
pressure {210 +– 10 {210 +– 10
pressure: 5 } 5 }
Oil pressure
Drop in pressure 5 minutes after

Wheel brake MPa 4.9 ± 0.49 4.9 ± 0.49
specified oil pressure (4.9MPa
actuation pressure 2 {kg/cm2
} {50 ± 5} {50 ± 5}
{50kg/cm }) is applied
Drop in wheel brake • Parking, exhaust brake actuation Max. 0.49 Max. 0.49
actuation pressure pressure: {Max. 5} {Max. 5}
Parking brake Engine at high idle 3.92 ± 0.4 3.92 ± 0.4
actuation pressure Parking brake switch: ON {40 ± 4.0} {40 ± 4.0}
Exhaust brake Exhaust brake switch: ON 2.60 ± 0.4 2.60 ± 0.4
actuation pressure {26.5 ± 4.0} {26.5 ± 4.0}
Brakes
Foot brake • Engine speed: High idle

1,440 1,440
braking performance • Gearshift lever: D
Wheel brake
• Torque converter stall speed rpm

Retarder brake
1,440 1,440
braking performance
• Flat, dry road surface
Foot brake braking
• When load is 27.3t m Max. 22.3 Max. 22.3
distance
• Travel speed: 32km/h
• Engine at high idle
Braking performance • Gearshift lever: D rpm 1,490 1,490
Parking
brake
• Engine stall speed

• When load is 27.3t
Braking slope angle % Min. 25 Min. 25
• Slope angle (sin θ)
• 9 ± 1% downhill slope
Emergency brake braking
• When load is 27.3t m Max. 102 Max. 102
distance
• Travel speed: 50 ± 3km/h
• Engine speed: Low idle N Max. 29.4 Max. 35.3
Operating effort • Gearshift lever: N (stopped) {kg} {Max. 3.0} {Max. 3.6}
• Measure at circumference of steer-
Steering wheel
Play ing wheel mm Max. 150 Max. 150

• Operating effort:
When turning at 10rpm
Steering
No. of turns • Play: Turns 4.3 ± 0.4 4.3 ± 0.6

Until point where tires start to move
Turning time • No. of turns: Lock - lock Sec. Max. 6 Min. 6
• Turning time: Lock - lock
• Hydraulic oil temperature: 20.59 + 0.98 20.59 + 0.98
MPa 0 0
Steering relief pressure 45 – 55 °C
{kg/cm2} {210 + 10 {210 + 10
• Engine speed: High idle 0 } 0 }
HM300-1 20-5
1 Å
(10) Å

• Horizontal
Installed length (a) mm 163 ± 10 163 ± 10
Suspension cylinder
road surface
Front
• Dump body: MPa 5.88 ± 0.49 5.88 ± 0.49

Pressure Unloaded {kg/cm2} {60 ± 5.0} {60 ± 5.0}
Installed length (a) mm 106 ± 5 106 ± 5

Rear
MPa 0.98 ± 0.15 0.98 ± 0.15

Pressure
{kg/cm2} {10 ± 1.5} {10 ± 1.5}
• Engine stopped HOLD → Max. 29.4 Max. 35.3
• Center of grip RAISE {Max. 3.0} {Max. 3.6}
RAISE → Must return smoothly when engine is
HOLD at high idle
HOLD → Max. 29.4 Max. 35.3
FLOAT N {Max. 3.0} {Max. 3.6}
Dump lever operating effort
FLOAT → {kg} Max. 29.4 Max. 35.3
HOLD {Max. 3.0} {Max. 3.6}
FLOAT → Max. 29.4 Max. 35.3
LOWER {Max. 3.0} {Max. 3.6}
LOWER → Must return smoothly when engine is
FLOAT at 2,000rpm
• Hydraulic oil temperature:
Lifting time 70 – 90 °C 12 ± 1.5 12 ± 1.5
• Engine speed: High idle Sec.
Lowering time • Lowering time when operating Max. 12.5 Max. 12.5
Dump
FLOAT
Dump body

70 – 90 °C
• Hold at point where No. 2 cylinder
Hydraulic drift is extended 100mm mm Max. 85 170
• Engine stopped
• Downward movement at tip of
dump body over 5 minutes
• Hydraulic oil temperature: 20.59 + 0.98 20.59 + 0.98
0 0
Dump main relief pressure 45 – 55 °C
• Engine speed: High idle {210 + 10
0 } {210 + 10
0 }
3.4 ± 0.49 3.4 ± 0.49
45 – 55 °C MPa
{35 ± 5} {35 ± 5}
• Engine speed: High idle {kg/cm2}
Dump pilot relief pressure • Hydraulic oil temperature:
45 – 55 °C 2.6 ± 0.49 2.6 ± 0.49
• Engine speed: Low idle {27 ± 5} {27 ± 5}
(Reference value)
20-6 HM300-1
41 Å
Å (10)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Connector Inspection Measurement
System Name of component Judgement table
No. method conditions
If the condition is as shown in the table below, it is 1)Insert T-adapter to
normal AS1.
Potentiometer 2)Turn starting
Between (3) and (1) 4.6 – 5.4V switch ON.
Between (2) and (3) 0.3 – 4.5V
Acceleration pedal Measure Switch
AS1
(throttle sensor) voltage
Potentiometer
Pin Voltage
voltage
Between (5) Max. 0.446V Max. 1V
and (4) Min. 0.446V 15 – 30V
Between (6) Max. 0.446V 20 – 30V
and (4) Min. 0.446V Max. 1V
If the condition is as shown in the table below, it is 1)Turn starting

normal switch OFF.
Engine Ne rotation NE Measure
sensor (male) resistance Between (1) and (2) 85Ω – 210Ω 2)Disconnect NE.
Between (1) (2) and ground Min. 1MΩ
normal switch OFF.
Engine G rotation G Measure
sensor (male) resistance Between (1) and (2) 1.4kΩ – 3.5kΩ 2)Disconnect G.
normal switch OFF.
Resistance 2)Disconnect PSL.
Position Engine
Engine controller system
Engine oil PSL Measure value

low-pressure switch (terminal) resistance Engine
Between Max. 1Ω
stopped
switch terminal
and ground At 600rpm
Min. 1MΩ
and above

normal switch OFF.
Resistance 2)Disconnect PSH.
Engine oil PSH Measure Position Engine
value
high-pressure switch (terminal) resistance Engine
Between Max. 1Ω
stopped
switch terminal
and ground At 1,300rpm
Min. 1MΩ
and above

Engine coolant normal switch OFF.
TWL Measure
low-temperature 2)Disconnect TWL.
(male) resistance Between (1) and (2) 9kΩ – 0.3kΩ
sensor Between (1) (2) and ground Min. 1MΩ
Engine coolant normal switch OFF.
TWH Measure
high-temperature 2)Disconnect TWH.
(male) resistance Between (1) and (2) 90kΩ – 3.5kΩ
sensor Between (1) (2) and ground Min. 1MΩ
normal switch OFF.
Fuel temperature THL Measure
sensor (male) resistance Between (1) and (2) 9kΩ – 0.3kΩ 2)Disconnect THL.
normal switch OFF.
Engine oil filter OF Measure Resistance 2)Disconnect OF.
Position Oil filter
value
clogging switch (terminal) resistance
Between When normal Max. 1Ω
switch terminal
and ground When clogged Min. 1MΩ
HM300-1 20-7
1c
1
(9) c

normal switch OFF.
OL Measure Resistance 2)Disconnect OL.
Engine oil level switch Pin Oil level
value
(male) resistance
Between (1) When normal Max. 1Ω
and ground When low Min. 1MΩ
normal PIM.
PIM Measure
Boost pressure sensor 2)Turn starting
(male) voltage Between (1) and (3) 4.6 – 5.4V
normal PFUEL.
Common rail fuel PFUEL Measure
pressure sensor (male) voltage Between (1) and (3) 4.6 – 5.4V 2)Turn starting
normal switch OFF.
Fuel supply pump PCV1 Measure
PCV1 (male) resistance Between (1) and (2) 2.3 – 5.3Ω 2)Disconnect PCV1.
normal switch OFF.
Fuel supply pump PCV2 Measure

PCV2 (male) resistance Between (1) and (2) 2.3 – 5.3Ω 2)Disconnect PCV2.
normal switch OFF.
CN1 Measure
No. 1 injector solenoid 2)Disconnect CN1.
(male) resistance Between (1) and (2) 0.4 – 1.1Ω
normal switch OFF.
CN2 Measure
normal switch OFF.
CN3 Measure
normal switch OFF.
CN4 Measure

normal switch OFF.
CN5 Measure
normal switch OFF.
CN6 Measure
20-8 HM300-1
c 11 c

normal SF1.
Gearshift lever position 2)Turn starting
Pin
and voltage switch ON.
Between (1)
20 – 30V
and (2)
Between (3) Other than R2:
R2: 20 – 30V
and (2) Max. 1V
Between (4) Other than R1:
R1: 20 – 30V
and (2) Max. 1V
Between (5) Other than N:
N: 20 – 30V
and (2) Max. 1V
Measure Between (6) Other than D:
Gearshift lever SF1 D: 20 – 30V
voltage and (2) Max. 1V
Between (7) Other than 5:
5: 20 – 30V
and (2) Max. 1V
4: 20 – 30V
and (2) Max. 1V
3: 20 – 30V
and (2) Max. 1V
2: 20 – 30V
and (2) Max. 1V
1: 20 – 30V
and (2) Max. 1V
Between (12) Canceled:
HOLD: 20 – 30V
and (2) Max. 1V
Transmission controller system

normal AS2.
Acceleration pedal Measure
AS2 2)Turn starting
(throttle sensor) voltage Between (1) and (3) 4.6 – 5.4V
normal switch OFF.
EREV Measure
Engine speed sensor 2)Disconnect EREV.
(male) resistance Between (1) and (2) 500 – 1,000Ω
normal switch OFF.
Air cleaner clogging T11 Measure Resistance 2)Disconnect T11.
Pin Air cleaner
sensor (male) resistance value
and (2) When clogged Min. 1MΩ
normal switch OFF.
Radiator coolant level T01 Measure Radiator Resistance 2)Disconnect T01.
Pin
switch (male) resistance coolant level value
and (2) When low Min. 1MΩ
If the condition is as shown in the table below, it is 1)Disconnect termi-
normal nal R.
Position Engine Voltage 2)Start engine.
R, E Measure
Alternator Between R Mid-range
terminal voltage 27.6 – 29.5V
and E speed or above
★ If the battery is old, or after starting in cold areas,
the voltage may not rise for some time.
normal switch OFF.
T08 Measure Resistance 2)Disconnect T08.
Fuel level sensor Pin Fuel level
value
(male) resistance
Between (1) Full Max. 12Ω
and (2) Empty 74 – 100Ω
HM300-1 20-9
1c
1
(9) c

normal switch OFF.
Transmission input N1 Measure
shaft speed sensor (male) resistance Between (1) and (2) 500 – 1,000Ω 2)Disconnect N1.
Between (2) and (3) Min. 1MΩ
Transmission normal switch OFF.
N2 Measure
intermediate shaft 2)Disconnect N2.
(male) resistance Between (1) and (2) 500 – 1,000Ω
speed sensor Between (1) (2) and ground Min. 1MΩ
normal switch OFF.
Transmission output N3 Measure
shaft R speed sensor (male) resistance Between (1) and (2) 500 – 1,000Ω 2)Disconnect N3.
normal switch OFF.
Lock-up clutch L/U-SW Measure Resistance 2)Disconnect
Pin Clutch
ECMV fill switch (male) resistance value L/U-SW.
Between (1) When disengaged Min. 1MΩ
and ground When engaged Max. 1Ω
normal switch OFF.
R clutch R-SW Measure Resistance 2)Disconnect R-SW.
Pin Clutch
value
ECMV fill switch (male) resistance

normal switch OFF.
Hi clutch H-SW Measure Resistance 2)Disconnect H-SW.
Pin Clutch
ECMV fill switch (male) resistance value
normal switch OFF.
Lo clutch L-SW Measure Resistance 2)Disconnect L-SW.
Pin Clutch
normal switch OFF.
1st clutch 1-SW Measure Resistance 2)Disconnect 1-SW.
Pin Clutch
normal switch OFF.
2nd clutch 2-SW Measure Resistance 2)Disconnect 2-SW.
Pin Clutch
normal switch OFF.
3rd clutch 3-SW Measure Resistance 2)Disconnect 3-SW.
Pin Clutch
20-10 HM300-1
c 1c

normal switch OFF.
Differential lock clutch D/L-SW Measure Resistance 2)Disconnect
Pin Clutch
ECMV fill switch (male) resistance value D/L-SW.
normal switch OFF.
Torque converter oil TC-SE Measure Torque converter Resistance 2)Disconnect
Pin
temperature sensor (male) resistance oil temperature value TC-SE.
Between (1) 25°C 37kΩ – 50kΩ
and (2) 100°C 3.5kΩ – 4.0kΩ
normal TC-INT.
Torque converter oil TC-INT Measure
pressure sensor (male) voltage Between (2) and (1) 20 – 30V 2)Turn starting
normal switch OFF.
Transmission oil filter T03 Measure Transmission Resistance 2)Disconnect T03.
Pin
clogging switch (male) resistance oil filter value

normal switch OFF.
Transmission valve oil LUB-T Measure Transmission Resistance 2)Disconnect LUB-T.
Pin
temperature sensor (male) resistance oil temperature value
and (2) 100°C 3.5kΩ – 4.0kΩ
normal switch OFF.
Hydraulic tank oil T06 Measure Hydraulic Resistance 2)Disconnect T06.
Pin
level switch (male) resistance oil level value
and (2) When low Min. 1MΩ
normal switch OFF.
Hydraulic oil filter T05 Measure Hydraulic Resistance 2)Disconnect T05.
Pin
clogging switch (male) resistance oil filter value
normal switch OFF.
Steering oil T04 Measure Steering oil Resistance 2)Disconnect T04.
Pin
temperature switch (male) resistance temperature value
Between (1) 25°C Max. 1Ω
and ground 123°C Min. 1MΩ
normal switch OFF.
Front brake oil T15 Measure Brake oil Resistance 2)Disconnect T15.
Pin
temperature sensor (male) resistance temperature value
and (2) 100°C 3.5kΩ – 4.0kΩ
HM300-1 20-11
1! !

normal switch OFF.
Center brake oil T14 Measure Brake oil Resistance 2)Disconnect T14.
Pin
temperature sensor (male) resistance temperature value
and (2) 100°C 3.5kΩ – 4.0kΩ
normal T10.
T10 Measure Between (1) and (3) 11 – 13V 2)Turn starting
Inclination sensor
(male) voltage 1.4 – 4.6V switch ON.
Between (2) and (3) (when horizontal:
2.9 – 3.1V)
normal switch OFF.
Lock-up clutch L/U-PS Measure
ECMV solenoid (male) resistance Between (1) and (2) 5 – 15Ω 2)Disconnect
Between (1) (2) and ground Min. 1MΩ L/U-PS.
normal switch OFF.
R clutch R-PS Measure
ECMV solenoid (male) resistance Between (1) and (2) 5 – 15Ω 2)Disconnect R-PS.

normal switch OFF.
Hi clutch H-PS Measure
ECMV solenoid (male) resistance Between (1) and (2) 5 – 15Ω 2)Disconnect H-PS.
normal switch OFF.
Lo clutch L-PS Measure
ECMV solenoid (male) resistance Between (1) and (2) 5 – 15Ω 2)Disconnect L-PS.

normal switch OFF.
1st clutch 1-PS Measure
ECMV solenoid (male) resistance Between (1) and (2) 5 – 15Ω 2)Disconnect 1-PS.

normal switch OFF.
2nd clutch 2-PS Measure
normal switch OFF.
3rd clutch 3-PS Measure

normal switch OFF.
Differential lock clutch D/L-PS Measure
ECMV solenoid (male) resistance Between (1) and (2) 5 – 15Ω 2)Disconnect
Between (1) (2) and ground Min. 1MΩ D/L-PS.
20-12 HM300-1
! 1!

normal switch OFF.
Transmission output FE1 Measure
shaft F speed sensor (male) resistance Between (1) and (2) 500 – 1,000Ω 2)Disconnect FE1.

normal B25.
Front accumulator oil B25 Measure
normal B24.
Rear accumulator oil B24 Measure
If the condition is as shown in the table below, it is Measuring voltage
normal 1)Insert T-adapter to
Potentiometer RTL.
Between (1) and (3) 4.1 – 4.8V 2)Turn starting
Switch Measuring resistance
Measure
1)Turn starting
Retarder controller(q1) system
voltage, Pin (male) Lever position

Resistance
Retarder lever RTL value switch OFF.
measure
Released 2)Disconnect RTL.
resistance Max. 1Ω
Between (4) position
and (6) Applied
Min. 1MΩ
position
Released
Min. 1MΩ
Between (5) position
and (6) Applied
Max. 1Ω
position
normal switch OFF.
Brake cooling filter B03 Measure Resistance 2)Disconnect B03.
Pin Retarder filter
clogging sensor (male) resistance value
If the condition is as shown in the table below, it is 1)Disconnect B15.
normal 2)Start engine.
Brake oil Resistance
Foot brake oil B15 Measure Pin
pressure value
pressure switch (male) resistance Max. 0.39MPa
Min. 1MΩ
Between (1) {Max. 4kg/cm2}
and (2) Min. 0.59MPa
Max. 1Ω
{Min. 6kg/cm2}
Brake oil Resistance
Retarder oil B16 Measure Pin
pressure value
Min. 1MΩ
and (2) Min. 0.59MPa
Max. 1Ω
{Min. 6kg/cm2}
q1. Used as the brake controller in E-SPEC.
HM300-1 20-13
4c
1 c

Parking brake oil B17 Measure Resistance
Pin Parking brake
pressure switch (male) resistance value
Between (1) When released Min. 1MΩ
and (2) When applied Max. 1Ω
Exhaust brake oil B30 Measure Resistance
Pin Exhaust brake
pressure switch (male) resistance value
Between (1) When released Min. 1MΩ
and (2) When applied Max. 1Ω
normal switch OFF.
Front brake (L.H.) B01 Measure Resistance 2)Disconnect B01.
Pin Brake
wear switch (male) resistance value
and (2) When worn Min. 1MΩ
normal switch OFF.
Front brake (R.H.) B28 Measure Resistance 2)Disconnect B28.
Pin Brake

normal switch OFF.
Center brake (L.H.) B02 Measure Resistance 2)Disconnect B02.
Pin Brake
normal switch OFF.
Center brake (R.H.) B26 Measure Resistance 2)Disconnect B26.
Pin Brake
normal HSL.
Dump lever Measure 2)Turn starting
HSL Between (4) and (1) 4.6 – 5.4V
(potentiometer) voltage switch ON.
Between (3) and (1) 0.3 – 4.7V
Between (2) and (1) 0.3 – 4.7V

normal B34.
Body positioner B34 Measure
sensor (male) voltage Between (3) and (1) 4.6 – 5.4V 2)Turn starting
normal switch OFF.
Front brake pressure B19 Measure
reducing valve (male) resistance Between (1) and (2) 10 – 30Ω 2)Disconnect B19.

normal switch OFF.
Rear brake pressure B18 Measure
reducing valve (male) resistance Between (1) and (2) 10 – 30Ω 2)Disconnect B18.
20-14 HM300-1
c 4
1c

normal switch OFF.
Exhaust brake B29 Measure
solenoid (male) resistance Between (1) and (2) 20 – 60Ω 2)Disconnect B29.

normal switch OFF.
Dump lever LKO Measure
(kick-out solenoid) (male) resistance Between (1) and (2) 39Ω ± 5% 2)Disconnect LKO.

normal switch OFF.
Dump pilot valve B31 Measure
(selector solenoid) (male) resistance Between (1) and (2) 15 – 35Ω 2)Disconnect B31.

normal switch OFF.
Dump pilot valve B32 Measure
(EPC solenoid) (male) resistance Between (1) and (2) 15 – 20Ω 2)Disconnect B32.

normal switch OFF.
Machine monitor CK1 Measure Resistance 2)Disconnect CK1.
Pin Switch
check switch (male) resistance value
Between (3) Released Max. 1Ω
and (6) Pressed Min. 1MΩ
normal switch OFF.
Resistance 2)Disconnect CH1.
Pin Switch
Machine mode CH1 Measure value
selector switch 1 (male) resistance Between (2) [] Pressed Max. 1Ω
and (3) Neutral Min. 1MΩ
Between (1) Neutral Min. 1MΩ
Machine monitor system
and (3) [] Pressed Max. 1Ω

normal switch OFF.
Resistance 2)Disconnect CH2.
Pin Switch
Machine mode CH2 Measure value
selector switch 2 (male) resistance Between (2) [ >] Pressed Max. 1Ω
and (3) [ < ] Pressed Max. 1Ω
normal switch OFF.
Power mode PWM Measure Resistance 2)Disconnect PWM.
Pin Switch
selector switch (male) resistance value
Between (1) Up Min. 1MΩ
and (3) Down Max. 1Ω
normal switch OFF.
AISS Measure Resistance 2)Disconnect AISS.
AISS LOW switch Pin Switch
value
(male) resistance
HM300-1 20-15
4c
1 c

normal switch OFF.
Inter-axle differential DEF Measure Resistance 2)Disconnect DEF.
Pin Switch
lock switch (male) resistance value

normal switch OFF.
Resistance 2)Disconnect EXH.
Pin Switch
EXH Measure value
Exhaust brake switch Up Max. 1Ω
(male) resistance Between (1)
normal switch OFF.
SBS Measure Resistance 2)Disconnect SBS.
Seat belt switch Pin Belt
value
(male) resistance
Between (1) Removed Min. 1MΩ
and (2) Fitted Max. 1Ω
normal switch OFF.
Working lamp (front) WRF Measure Resistance 2)Disconnect WRF.
Pin Switch
switch (male) resistance value
normal switch OFF.
Working lamp (rear) WRR Measure Resistance 2)Disconnect WRR.
Pin Switch
Others (other than controllers)

normal switch OFF.
HAZ Measure Resistance 2)Disconnect HAZ.
Hazard lamp switch Pin Switch
value
(male) resistance
normal LS.
Night lighting dimmer Measure
LS 2)Turn starting
switch voltage Between (1) and (3) 20 – 30V
Between (2) and (3) 6 – 27V switch ON.
normal switch OFF.
FOG Measure Resistance 2)Disconnect FOG.
Fog lamp switch Pin Switch
value
(male) resistance
normal switch OFF.
Yellow rotating lamp BLS Measure Resistance 2)Disconnect BLS.
Pin Switch
20-16 HM300-1
c 1c

normal switch OFF.
SDE Measure Resistance 2)Disconnect SDE.
Side lamp switch Pin Switch
value
(male) resistance
normal switch OFF.
Emergency steering ST Measure Resistance 2)Disconnect ST1
Position Switch
switch (terminal) resistance value and ST2.
Between ST1 OFF Min. 1MΩ
and ST2 ON Max. 1Ω
normal switch OFF.
R33 Measure Resistance 2)Disconnect R33.
Parking brake switch Pin Switch
value
(male) resistance
normal switch OFF.

Differential lock Resistance 2)Disconnect B21.
Front accumulator oil B21 Measure Pin
oil pressure value
Min. 1MΩ
and (2) Min. 5.9MPa
Max. 1Ω
{Min. 60kg/cm2}
normal switch OFF.
Differential lock Resistance 2)Disconnect B20.
Rear accumulator oil B20 Measure Pin
oil pressure value
Min. 1MΩ
and (2) Min. 5.9MPa
Max. 1Ω
{Min. 60kg/cm2}
normal switch OFF.
Parking brake B14 Measure
solenoid (male) resistance Between (1) and (2) 30 – 50Ω 2)Disconnect B14.

normal switch OFF.
— Measure 2)Disconnect relay
Relay (5-pin type) Between (1) and (2) 100 – 500Ω
(male) resistance Between (3) and (5) Min. 1MΩ connector.
Between (3) and (6) Max. 1Ω

normal switch OFF.
— Measure 2)Disconnect relay
Relay (6-pin type) Between (5) and (6) 100 – 500Ω
(male) resistance connector.
Between (1) and (2) Min. 1MΩ
HM300-1 20-17
1! !

normal switch OFF.
Switch (1) (2) 2)Disconnect CM.
(3)
CM Measure
Lamp switch OFF ★ Between
(male) resistance connected pins:
Small ! !
Max. 1Ω
Head ! ! ! Between
Combination switch
If the condition is as shown in the table below, it is

other pins:
normal Min. 1MΩ
CM Measure Switch (4) (5)
Dimmer switch
(male) resistance OFF
PASS ! !

normal
Switch (6) (7) (8)

CM Measure
Turn signal switch L (left) ! !
(male) resistance
N !
R (right) ! !

normal switch OFF.
Switch (1) (2) (3) (4) (5) (6) 2)Disconnect WPS.
OFF ! ! ★ Between
connected pins:
WPS Measure ! !
Front wiper switch INT Max. 1Ω
(male) resistance ! ! Between
LOW ! ! other pins:
Min. 1MΩ
Wiper switch
HIGH ! !
WASH ! !

normal
Switch (7) (8) (9) (10)
WASH ! !
WPS Measure
Rear wiper switch OFF ! !
(male) resistance
ON ! !
! !
WASH
! !
20-18 HM300-1
! 1!
TESTING AND ADJUSTING 20 TESTING AND ADJUSTING
Tools for testing, adjusting, and troubleshooting ..................................................................................... 20-102

Measuring engine speed ......................................................................................................................... 20-104
Measuring air supply pressure (boost pressure) ..................................................................................... 20-105
Measuring exhaust temperature .............................................................................................................. 20-106
Measuring exhaust color ......................................................................................................................... 20-108
Measuring compression pressure ........................................................................................................... 20-109
Adjusting valve clearance ........................................................................................................................ 20- 110
Measuring blow-by pressure ................................................................................................................... 20- 111
Measuring engine oil pressure ................................................................................................................ 20- 112
Handling equipment in fuel circuit ............................................................................................................ 20- 113
Releasing remaining pressure in fuel system .......................................................................................... 20- 113
Measuring fuel pressure .......................................................................................................................... 20- 114
Bleeding air from fuel circuit .................................................................................................................... 20- 115
Reduced cylinder mode operation for engine .......................................................................................... 20- 117
Checking for leakage in fuel circuit .......................................................................................................... 20- 118
Adjusting engine speed sensor ............................................................................................................... 20- 119
Testing and adjusting alternator belt tension ........................................................................................... 20-120
Testing and adjusting air conditioner compressor belt tension ................................................................ 20-120
Adjusting the body mount .......................................................................................................................20-120-1
Testing torque converter stall speed ........................................................................................................ 20-121
Measuring power train oil pressure ......................................................................................................... 20-122
Adjusting transmission speed sensor ...................................................................................................... 20-129
Testing and adjusting brake oil pressure ................................................................................................. 20-130
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas .....20-133-1
Testing brake performance ...................................................................................................................... 20-134
Bleeding air from brake circuit ................................................................................................................. 20-135
Testing wear of wheel brake disc ............................................................................................................. 20-136
Testing wear of parking brake pad ........................................................................................................... 20-137
Method for emergency release of parking brake ..................................................................................... 20-138
Testing and adjusting steering circuit pressure ........................................................................................ 20-139
Testing and adjusting suspension cylinder .............................................................................................. 20-141
Method of tilting cab up ........................................................................................................................... 20-145
Testing and adjusting dump circuit pressure ........................................................................................... 20-146
Adjusting body positioner sensor ............................................................................................................. 20-147
Procedure for adjusting length of spring in body heating spherical joint .................................................. 20-148
Handling engine controller high-voltage circuit ........................................................................................ 20-148
Adjusting transmission controller ............................................................................................................. 20-149
Method for emergency escape when there is failure in electrical system ............................................... 20-150
Adjusting machine monitor ...................................................................................................................... 20-154
Special functions of machine monitor ...................................................................................................... 20-158
Pm-clinic inspection sheet ........................................................................................................................ 20-192
HM300-1 20-101
(15)
1 Å Å
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
Measurement Item Symbol Part Number Part Name Remarks

–101 – –199.9kPa
Air supply pressure A 799-201-2202 Boost gauge kit
{–760 – 1,500mmHg}
Exhaust, coolant, and
B 799-101-1502 Digital temperature gauge –99.9 – 1,299°C
oil temperatures
1 799-201-9001 Handy smoke checker

Exhaust color C Bosch index : 0 – 9
Commercially
2 Smoke meter
available
Commercially
Valve clearance D Feeler gauge Intake: 0.35mm; exhaust: 0.57mm
available
Blow-by pressure E 799-201-1504 Blow-by checker 0 – 4.9MPa {0 – 500mmH2O}
2.5, 5.9, 39.2, 58.8MPa
799-101-5002 Hydraulic tester
{25, 60, 400, 600kg/cm2}
790-261-1204 Digital hydraulic tester 58.8MPa {600kg/cm2}
799-401-2320 Hydraulic gauge 0.98MPa {10kg/cm2}
799-101-5220 Nipple
Oil pressure F M10 × P1.25
07002-11023 O-ring
799-101-5260 Nipple
M12 × P1.5
799-101-5270 Seal washer
799-101-5230 Nipple
M14 × P1.5
07002-11423 Seal washer
Brake oil pressure G 793-520-1805 Brake test kit
P1 762-610-1700 Gas charge tool
792-610-1310 Nipple (For Russia) GOST
792-610-1320 Nipple (For USA) CGA No. 351
Accumulator 792-610-1330 Nipple (For USA) ASA B-571-1965

P2
DIN 477-1963
792-610-1350 Nipple (For Germany) NEN 3268-1966
SIS-SMS 2235/2238
792-610-1360 Nipple (For UK) BS 341 Part1-1962
1 792-610-1000 Suspension tool H2 – H6: Pump assembly
Kit Part No.: 792-610-1100
2 792-610-1130 • Pump
3 792-610-1110 • Hose H7 – H13: Charging tool assembly
4 792-610-1120 • Joint Kit Part No.: 792-610-1200
5 07020-21732 • Fitting
6 792-610-1140 • Joint
Suspension cylinder H 7 792-610-1250 • Valve
8 792-610-1260 • Nipple
9 792-610-1480 • Stem
10 792-610-1640 • Joint
11 792-610-1400 • Regulator
12 792-610-1430 • Gauge 24.5MPa {250kg/cm2}
13 792-610-1440 • Gauge 9.8MPa {100kg/cm2}
20-102 HM300-1
Å (10)
1 Å
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
Measurement Item Symbol Part Number Part Name Remarks

79A-264-0021 Push-pull scale 0 – 294N {0 – 30kg}
Operating effort I
79A-264-0091 Push-pull scale 0 – 490N {0 – 50kg}
Method of tilting cab up R 792-454-1100 Pump assembly For tilt cylinder
Commercially
Stroke, hydraulic drift J Scale
available
Commercially
Work equipment speed K Stop watch
available
Voltage, resistance L 79A-264-0211 Tester
1 795-502-1590 Compression garge Kit Part No.: 795-502-1205
Compression pressure N
2 795-471-1410 Adapter 0 – 6.9MPa {0 – 70kg/cm2}
a For the model names and part Nos. of the T-adapters and boxes used for troubleshooting for the machine
monitor, controllers, sensors, actuators, and wiring harnesses, see TROUBLESHOOTING, T-adapters list.
HM300-1 20-103
(10)
1 Å Å
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED

¤ Put blocks under the tires.
¤ Before starting measurement, check that there is
no one in the surrounding area.
★ Measure the engine speed under the following

conditions.
• Coolant temperature:
• Hydraulic temperature:
45 – 55°C
• Torque converter oil temperature:
60 – 80°C
1. Measuring engine speed (low idle and high

idle)
1) Switch to the monitoring function of Service
Mode 1 and display the engine speed. For
details, see SPECIAL FUNCTIONS OF MA-
CHINE MONITOR in the TROUBLESHOOT-
ING section.
★ Monitoring item: ENG SPEED
2) Start the engine, set to the measurement

conditions, and measure the engine speed.
2. Measuring torque converter stall speed.

★ See TESTING OF TORQUE CONVERTER
STALL SPEED.
20-104 HM300-1
c 1 c
(9)
TESTING AND ADJUSTING MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)
MEASURING AIR SUPPLY 5. Turn the parking brake switch ON, depress the
brake pedal, then set the gearshift lever to the D
PRESSURE position.
¤ If the gearshift lever is operated to any posi-
(BOOST PRESSURE) tion other than the D position, the machine
may move off even if the brake is being de-
¤ Be careful not to touch any hot parts when re- pressed, so always measure at the D posi-
moving or installing the measuring tools. tion.
1. Open the engine hood. 6. Depress the accelerator pedal gradually, run the
engine at high idle and stall the torque converter,
2. Remove air supply pressure measurement plug then measure the air supply pressure.
(1). ¤ There is danger of damage to the internal
parts of the transmission, so never operate
the gearshift lever to any position other than
the D position during the stall operation.
★ After completing the measurement, run the
engine at low idle, then return the gearshift
lever to the N position.
3. Fit nipple and hose [1], then connect to boost

gauge A.
7. After completing the measurement, remove the

measuring equipment and set to the original con-
dition.
4. Run the engine at a mid-range speed or above

to bleed the oil from inside the hose.
★ Insert the connection of the hose and pres-
sure gauge about half way, repeat the action
to open the self-seal portion at the hose end,
and bleed the oil.
★ If Pm kit (A) is available, the air bleed cou-
pling (790-261-1130) inside the kit can be
used.
★ If there is oil inside the hose, the gauge will
not work, so always bleed the oil.
HM300-1 20-105
1 c
(9) c
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST 1) Start the engine and raise the temperature of

the coolant to the operating range.
TEMPERATURE 2) Turn the parking brake switch ON, depress
the brake pedal, then set the gearshift lever
to the D position.
¤ Wait for the temperature of the exhaust pipe to
go down before removing or installing the mea- ¤ If the gearshift lever is operated to any
suring equipment. position other than the D position, the
machine may move off even if the brake
is being depressed, so always measure
1. Open the engine hood and remove the adiabatic
at the D position.
cover of the turbocharger.
3) Depress the accelerator pedal gradually, run
the engine at high idle and stall the torque
2. Remove exhaust temperature measurement
converter. At the same time, operate the
plug (1).
dump lever to the LOWER position and re-
lieve the oil pressure (full stall).
★ Continue until the exhaust temperature
reaches the standard value of 650°C.
¤ There is danger of damage to the inter-
nal parts of the transmission, so never
operate the gearshift lever to any posi-
tion other than the D position during the
stall operation.
4) When the temperature stabilizes at near the
target temperature, return the dump lever to
NEUTRAL and measure the temperature
with only the torque converter stalled.
★ The exhaust temperature will start to go
3. Install sensor, then connect to digital tempera- down from the full stall condition, so
ture gauge B. measure the temperature when it stabi-
★ Clamp the wiring harness of the temperature lizes.
gauge at a suitable place to prevent it from ★ If the exhaust temperature does not go
touching any hot part. down but rises, make the set tempera-
ture at full stall higher.
★ After completing the measurement, low-
er the engine speed to low idle, then re-
turn the gearshift lever to the N position.
4. When measuring the exhaust temperature at

torque converter stall, do as follows.
★ To prevent the torque converter from over-
heating, use the full stall (torque converter
stall + hydraulic relief) to stabilize the ex-
haust temperature, then stall only the torque
converter and measure the temperature.
20-106 HM300-1
c 1 c
(9)
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
5. When measuring the maximum value for the ex-

haust temperature during actual operation, do as
follows.
Carry out actual work and record the maximum
exhaust temperature during operation.
★ Set the temperature gauge to the PEAK
mode. The maximum temperature is auto-
matically recorded.

dition.
HM300-1 20-107
1 c c
TESTING AND ADJUSTING MEASURING EXHAUST COLOR
MEASURING EXHAUST
COLOR
¤ Be careful not to touch any hot parts when re-
moving or installing the measuring tools.
★ When measuring in the field where there is no air

or electric power supply, use Handy Smoke
Checker C1; when recording formal data, use
Smoke Meter C2.
1. Measuring with Handy Smoke Checker C1

2) Connect the air hose and the socket of the
1) Install filter paper to Handy Smoke Checker
probe hose and accelerator switch to Smoke
C1.
Meter C2.
2) Insert the exhaust gas suction port into the
★ Keep the pressure of the air supply be-
exhaust pipe.
low 1.5MPa {15kg/cm2}.
3) Start the engine and raise the temperature of
3) Connect the power cord to the AC100V
socket.
4) Accelerate the engine suddenly, and operate
★ Before connecting the cord, check that
the handle of Handy Smoke Checker C1
the power switch of the Smoke Meter is
while running at high idle to collect the ex-
OFF.
haust gas on the filter paper.
4) Loosen the cap nut of the suction pump, and
fit the filter paper.
★ Fit the filter paper securely so that the
exhaust gas does not leak.
5) Turn the power switch of Smoke Meter C2
ON.
5) Remove the filter paper and compare it with

the scale supplied to judge the condition.
2. Measuring with Smoke Meter C2

1) Insert probe [1] of Smoke Meter C2 into the
outlet port of the exhaust pipe, then tighten
the clip to secure it to the exhaust pipe.
7) Accelerate the engine suddenly, and de-
press the accelerator pedal of Smoke Meter
C2 while running at high idle to collect the
exhaust gas on the filter.
8) Place the filter paper used to catch the ex-
haust gas color on top of at least 10 sheets
of unused filter paper inside the filter paper
holder, and read the value shown.
9) After completing the measurement, remove
the measuring equipment and set to the orig-
inal condition.
20-108 HM300-1
c 1 c
(9)
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION 5. Fit adapter N2 and connect to compression

gauge N1.
PRESSURE ★ Coat the connection of the adapter and
gauge with a small amount of engine oil to
make leakage more difficult.
¤ When measuring the compression pressure, be
★ Secure the adapter with the injector holder.
3 Mounting bolt:
careful not to touch the exhaust manifold or muf-
fler and burn yourself, or to get caught in any ro-
tating parts. 58.8 – 73.5Nm {6.0 – 7.5kgm}
★ Measure the compression pressure with the en-

gine warmed up (engine oil temperature: 40 –
60°C).
1. Open up the engine hood.
2. Disconnect 6 fuel high-pressure tubes (1).

• Remove the tube clamps also.
3. Remove cylinder head cover (2).

3 Head cover mounting bolt:
9.8 ± 1Nm {1.0 ± 0.1kgm}
6. Disconnect 2 engine centralized connectors (4)
(CN EG4 and EG5).
¤ If the connectors are not disconnected, there
is a danger that the engine may start during
the measurement, so disconnect them with-
out fail.
¤ Cover the connector at the controller end
with vinyl to prevent short circuits and leak-
ages of electricity.
4. Disconnect the injector wiring harness to remove

fuel injector (3).
7. Crank the engine with the starting motor and

measure the compression pressure.
★ Measure the compression pressure at the
point where the compression gauge indica-
tor remains steady.

measuring equipment and return to the original
condition.
★ For details of the assembly of the fuel injec-
tor and fuel high-pressure tub, see DISAS-
SEMBLY AND ASSEMBLY.
HM300-1 20-109
1 ! !
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE 5. To adjust the valve clearance, insert feeler gauge

F into clearance b between rocker arm (4) and
CLEARANCE cross head (5), and adjust the valve clearance
with adjustment screw (6).
★ Insert the feeler gauge and turn the adjust-
1. Open left and right engine side covers.
ment screw until the clearance is a sliding fit.
2. Disconnect 6 fuel high-pressure tubes (1).
• Remove the tube clamps also.
3. Remove cylinder head cover (2).

9.8 ± 1Nm {1.0 ± 0.1kgm}
6. Hold adjustment screw (6) in position and tighten

locknut (7).
3 Locknut:
53.0 – 64.7Nm {5.4 – 6.6kgm}
★ After tightening the locknut, check the clear-
ance again.
4. Rotate the crankshaft in the normal direction,
and align 1.6 line a on the damper with pointer
(3) to set the No. 1 cylinder to compression top
dead center.
★ At compression top dead center, the rocker
arm can be moved by hand by the amount of
the valve clearance. If the rocker arm does
not move, the crankshaft is not at compres-
sion top dead center, so rotate it one more
turn.
7. Rotate the crankshaft 120° each time in the nor-

mal direction and repeat the procedure in Steps
4 to 6 to adjust the clearance of the intake and
exhaust valves of each cylinder according to the
firing order.
★ Firing order: 1 – 5 – 3 – 6 – 2 – 4
8. After completing the measurement, return to the

original condition.
★ For details of the assembly of the fuel high-
pressure tube, see DISASSEMBLY AND AS-
SEMBLY.
20-110 HM300-1
! 1 !
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY
PRESSURE
2. Install nozzle and hose [1] to blow-by hose (1),

then connect to blow-by checker E.

dition.
3. Start the engine and raise the temperature of the

coolant to the operating range.
4. Turn the parking brake switch ON, depress the

parking brake pedal, then set the gearshift lever
to the D position.
¤ If the gearshift lever is operated to any posi-
tion other than the D position, the machine
pressed, so always measure at the D posi-
tion.
5. Depress the accelerator pedal gradually, run the

engine at high idle and stall the torque converter,
and measure the blow-by pressure.
¤ There is danger of damage to the internal
parts of the transmission, so never operate
the gearshift lever to any position other than
★ After completing the measurement, run the
engine at low idle, then return the gearshift
lever to the N position.
HM300-1 20-111
1 c
(9) c
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL

PRESSURE
1. Open the engine hood.
2. Remove oil pressure measurement plug (1).

dition.
3. Fit nipple and hose [1], then connect oil pressure

gauge F.
★ Use a 0.98MPa {10kg/cm2} oil pressure gauge.
4. Start the engine and raise the temperature of the

coolant to the operating range.
5. Measure the oil pressure with the engine at both

low idle and high idle.
20-112 HM300-1
c 1 c
(9)
HANDLING EQUIPMENT IN FUEL CIRCUIT
TESTING AND ADJUSTING RELEASING REMAINING
HANDLING EQUIPMENT
PRESSURE IN FUEL SYSTEM
CIRCUIT
HANDLING EQUIPMENT IN RELEASING REMAINING

FUEL CIRCUIT PRESSURE IN FUEL SYSTEM
★ Precautions when carrying out inspection and ★ When the engine is running, pressure is gener-
maintenance of fuel system ated in both the low-pressure circuit and high-
With the common rail type fuel injection system, pressure circuit of the fuel line.
more precise equipment is used than on the con- Low-pressure circuit:
ventional fuel injection pump and nozzle, so Feed pump – fuel filter – fuel supply pump
problems may occur if dirt or dust get in. High-pressure circuit:
When carrying out inspection or maintenance of Fuel supply pump – common rail – fuel injector
the fuel line, pay more attention than usual to ★ For both the low-pressure circuit and high-pres-
prevent dirt or dust from getting in. If there is any sure circuit, the pressure automatically goes
dirt stuck to any part, use clean fuel to wash it off down to a safe level 30 seconds after the engine
completely. is stopped.
★ Precautions when replacing fuel filter cartridge ★ The remaining pressure in the fuel circuit must
Always use a genuine Komatsu part for the fuel be completely released before carrying out in-
filter cartridge. spection of the fuel system or removal or instal-
With the common rail type fuel injection system, lation of the equipment. Always obey the
more precise equipment is used than on the con- following precautions when carrying out the op-
ventional fuel injection pump and nozzle. To pre- eration.
vent dirt or dust from getting in, so a special filter ¤ When inspecting the fuel line or removing or in-
with highly efficient filtering performance is used. stalling equipment, wait for at least 30 seconds
For this reason, do not use imitation filters. If after the engine is stopped to release the re-
they are used, there is danger of problems oc- maining pressure in the fuel system before start-
curring in the fuel line. ing the operation. (There is still pressure
remaining in the circuit, so do not start opera-
tions immediately after the engine is stopped).
HM300-1 20-113
1 c c
TESTING AND ADJUSTING MEASURING FUEL PRESSURE
MEASURING FUEL
PRESSURE
★ Measure the fuel pressure only for the low-pres-
sure circuit between the feed pump – fuel filter –
fuel supply pump.
¤ The high-pressure circuit between the fuel sup-

ply pump – common rail – fuel injector is under
extremely high pressure, so it cannot be mea-
sured.

1. Open the engine hood.
dition.
2. Remove fuel pressure measurement plug (1).
3. Fit nipple and hose [1], then connect pressure

gauge F.
★ Use a 0.98MPa {10kg/cm2} oil pressure gauge.
4. Start the engine and measure the fuel pressure

at high idle.
★ If the fuel pressure is in the following range,
it is normal.
0.15 – 0.3MPa {1.5 – 3kg/cm2}
20-114 HM300-1
c 1 c
(9)
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT
BLEEDING AIR FROM FUEL CIRCUIT
★ Bleeding the air as follows if the engine has run

out of fuel or the fuel circuit equipment has been
removed and installed.
1. Remove fuel filter (1), fill with fuel, then install

again.
★ When filling, use clean fuel and be careful
not to let dirt get in.
★ Add fuel through inlet port portion a (8 plac-
es) of the filter. Portion b is the outlet port
(clean side) after the fuel has been filtered,
so never add fuel from here.
★ If clean fuel is not available, do not remove
the filter. Operate the priming pump to fill the
filter with fuel.
HM300-1 20-115
1 c c
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT
2. Remove air bleed plug (2) of the fuel filter and Air bleeding steps
operate priming pump (4). i) Remove air bleeding plug (2) of fuel filter
★ Continue operating the priming pump until (1) and operate priming pump (4).
flow out from the plug hole. When fuel comes • Continue to operate the priming
3 Air bleed plug:

out, install the plug. pump until fuel is confirmed to flow
out of the air bleeding plug hole and
3 Air bleeding plug:

7.8 – 9.8Nm {0.8 – 1.0kgm} then tighten it.
3. There are the following two cases that the en- 7.8 – 9.8Nm {0.8 – 1.0kgm}
gine does not start up easily after bleeding air ii) Remove fuel pressure measuring plug
from CRI, (Common Rail Injection System), i.e. (3) for the fuel filter and operate priming
even after carrying out the Items 1 and 2 above. pump (4).
★ If air has not been removed completely, leav- • Continue to operate the priming
ing some in the system, cranking up the en- pump until fuel is confirmed to flow
gine with the engine starting motor cannot out of the air bleeding plug hole and
3 Fuel pressure measuring plug:

get rid of the remaining air in a short span of then tighten it.
time. Thus the engine start-up becomes dif-
ficult. 3.9 – 6.9Nm {0.4 – 0.7kgm}
1) In the cases that the fuel has run out, that the
iii) Loosen air bleeder (5) of the fuel supply
fuel filter has been replaced or that some fuel
pump (only after loosening the lock nut)
device has been removed and installed.
and operate priming pump (4) 90 to 100
• Most of the fuel is left in the fuel circuit,
times.
so the engine may be started after bleed-
• Continue to operate the priming
ing air with the air bleeding methods in-
pump until fuel is confirmed to flow
troduced in the Items 1 and 2 above.
out of air bleeder (5) and then tighten
2) In the case that a number of fuel devices
3 Air bleeder:
it.
have been removed and installed in course
of engine overhauling.
• Little fuel is left in the fuel circuit, so air 4.9 – 6.9Nm {0.5 – 0.7kgm}
cannot be got rid of completely with the • Still continue to operate the priming
air bleeding methods introduced in the pump until it becomes harder to op-
Items 1 and 2 above (i.e. ordinary meth- erate and a relief sound of overflow
od). In that case, bleed air in the follow- valve (6) in the fuel supply pump is
ing manner. heard. (A high pitch sound) It re-
quires approx. 50 times of operation
to reach that stage.
iv) Push in the knob of priming pump (4) to
tighten it.
v) Crank up the engine with the engine
starting motor for start-up.
★ Do not keep the engine starting mo-
tor running idly for more than 20 sec-
onds. Moreover try to start up the
engine only after 2 minute pause.
★ If the engine does not start up even
after repeating to crank for 20 sec-
onds 4 times, insufficient air bleeding
is suspected of. In that case, start the
air bleeding steps once again from
the beginning.
20-116 HM300-1
c 1 c
(9)
TESTING AND ADJUSTING REDUCED CYLINDER MODE OPERATION FOR ENGINE
4. Loosen air bleeder (5) of the fuel supply pump REDUCED CYLINDER MODE
and operate priming pump (4) 90 to 100 times.
★ Continue operating the priming pump until OPERATION FOR ENGINE
fuel flows out from the bleeder.
When fuel comes out, tighten the bleeder, ★ Reduced cylinder mode operation for the engine
then operate several times until the priming means setting the fuel injectors of a single cylin-
3 Air bleeder:
pump becomes stiff. der or multiple cylinders electronically to the NO
injection condition to run the engine on a re-
4.9 – 6.9Nm {0.5 – 0.7kgm} duced number of cylinders. The reduced cylin-
der mode operation is used when it is thought
5. Crank the engine with the starting motor and that one of the engine cylinders is not giving nor-
start the engine. mal output (combustion). It is a method to deter-
★ When the engine is cranked, the air in the mine which cylinder is not operating normally.
high-pressure circuit is automatically bled. ★ The reduced cylinder mode operation is carried
★ If the engine does not start, the air has prob- out by using the reduced cylinder mode opera-
ably been not properly bled from the low- tion setting function on the monitor panel.
pressure circuit, so repeat the procedure ★ For details of the method of operation, see the
from Step 2. SPECIAL FUNCTIONS OF MACHINE MONI-
TOR.
HM300-1 20-117
1 c
(9) c
TESTING AND ADJUSTING CHECKING FOR LEAKAGE IN FUEL CIRCUIT
CHECKING FOR LEAKAGE IN 7. Check the fuel piping and equipment for fuel
leakage.
FUEL CIRCUIT ★ Check the high-pressure circuit for fuel leak-
age, particularly at the places sprayed with
color checker.
¤ With the fuel system, the high-pressure circuit is
★ If there is fuel leakage, carry out repairs,
under extremely high pressure, so if fuel leaks
then repeat the check from Step 2.
when the engine is running, there is danger of
fire.
8. Start the engine, run it at high idle, then apply
Check for fuel leakage as follows when checking
load to the engine.
the fuel circuit or when equipment has been re-
★ Carry out dump relief.
moved and installed.
9. Check the fuel piping and equipment for fuel
★ To make it easier to check for fuel leakage, wipe leakage.
the engine itself and the surrounding area clean ★ Check the high-pressure circuit for fuel leak-
and remove all oil and grease before starting the age, particularly at the places sprayed with
inspection. color checker.
1. Spray the fuel supply pump, common rail, fuel in- then repeat the check from Step 2.
jector, and high-pressure piping connections ★ If no fuel leakage is found, the check is com-
with a color checker (developing solution). plete.
2. Start the engine, run it at under 1000rpm, and

when the speed stabilizes, stop the engine.

leakage.
★ Check the high-pressure circuit for fuel leak-
color checker.
4. Start the engine and run it at low idle.

leakage.
★ Check the high-pressure circuit for fuel leak-
color checker.
6. Start the engine and run it at high idle.
20-118 HM300-1
c 1 c
(9)
TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR
ADJUSTING ENGINE SPEED

SENSOR
★ The G speed sensor and Ne speed sensor for
the engine controller cannot be adjusted.
★ Adjust the engine speed sensor (1) (CN-EREV)
for the transmission controller as follows.
5. After completing the adjustment, check that the

engine speed is displayed normally by using the
monitoring function of the machine monitor.
★ For details of the method of operation, see
SPECIAL FUNCTIONS OF MACHINE
MONITOR.
1. Tilt the cab up.

★ For details, see METHOD OF TILTING CAB
UP.
2. Screw in until the tip of sensor (1) contacts the tip

of the tooth of flywheel ring gear (2).
★ Be careful not to let the tip of the sensor be
scratched or to let any iron particles stick to
the sensor tip.
2 Thread: Hydraulic Sealant
3. When sensor (1) contacts gear (2), turn it back 1/2

– 2/3 turn.
★ Adjust clearance a between the tip of the
sensor and the tip of the gear tooth to 0.75 –
1.00mm.
4. Tighten sensor (1) with nut (3).

2 Locknut: 69 – 74Nm {7.0 – 7.5kgm}
HM300-1 20-119
1 ! !
TESTING AND ADJUSTING ALTERNATOR BELT TENSION
TESTING AND ADJUSTING TESTING AND ADJUSTING
TESTING AIR CONDITIONER
AND ADJUSTING COMPRESSOR
ALTERNATOR BELTTENSION
BELT TENSION
TESTING AND ADJUSTING TESTING AND ADJUSTING AIR

ALTERNATOR BELT CONDITIONER COMPRESSOR
TENSION BELT TENSION
1. Testing 1. Testing
Measure the deflection when the belt is pressed Measure the deflection when the belt is pressed
with a finger at a point (marked by the arrow) with a finger at a point (marked by the arrow)
midway between the alternator pulley and fan midway between the compressor pulley and
pulley. crankshaft pulley.
★ Pushing force: Approx. 58.8Nm {approx. 6kg} ★ Pushing force: Approx. 58.8Nm {approx. 6kg}
★ Deflection: Approx. 10mm ★ Deflection: 10mm
2. Adjusting 2. Adjusting
★ If the deflection is not within the specified ★ If the deflection is not within the specified
range, adjust as follows. range, adjust as follows.
1) Loosen mounting bolt nut (5) for alternator 1) Loosen 3 mounting bolts of compressor as-
(1) and mounting bolt (6) for adjusting rod sembly (1) and adjustment rod (2).
(2). 2) Loosen locknut (3), move compressor as-
2) Loosen lock nut (3) and slide alternator (1) sembly (1) with adjustment nut (4), and ad-
with adjusting nut (4) to adjust the belt ten- just the tension of the belt.
sion. 3) Tighten locknut (3).
3) Tighten lock nut (3). 4) Tighten 3 mounting bolts of compressor as-
4) Tighten mounting bolt nut (5) for alternator sembly (1) and adjustment rod (3).
(1) and mounting bolt (6) for adjusting rod ★ After adjusting, check the belt tension again.
(2).
★ Check the belt tension again after all the ad-
justment work has been finished.
20-120 HM300-1
! 1 !
TESTING AND ADJUSTING ADJUSTING THE BODY MOUNT
ADJUSTING THE BODY 3. Insert shims to each part of bottom mount.

a Use mounting bolt (3) of appropriate length
MOUNT
3 Mounting bolt:
according to the thickness of the shims.
(If clearance is found by clearance check)
a Perform shim adjustment of dump body mount 235 – 285 Nm {23.5 – 29.5 kgm}
according to the following procedure if there is
clearance between dump body bottom mount 4. Raise the dump body and check that all of the 4
and the frame top. places of bottom mount are in contact with the
1. Measure the maximum clearance of (a) between top of frame (2) evenly.
dump body mount (1) and top of frame (2) by us-
ing steel tape measure [1] and steal scale [2].
Measure 4 places in total of (A), (B) on right and
left sides.
2. Prepare shims of which thickness is the same as

the measured maximum clearance (a).
a Shim thickness for adjustment should be
more than clearance (a) and a minimum in-
tegral number.
Example
Clearance (a) Shim thickness for adjustment
3.3 mm 4 mm
2.7 mm 3 mm
1.1 mm 2 mm
a Shim for adjustment

Part No. Part name Thickness
569-74-61531 SHIM 1 mm
HM300-1 20-120-1
(15) Å Å
Å
TESTING AND ADJUSTING TESTING TORQUE CONVERTER STALL SPEED
TESTING TORQUE 4. Depress the accelerator pedal gradually, run the

engine at high idle and stall the torque converter
CONVERTER STALL SPEED to raise the torque converter oil temperature.
¤ There is danger of damage to the internal
¤ Stop the machine on flat ground, turn the parking parts of the transmission, so never operate
brake switch ON, and block the tires. the gearshift lever to any position other than
1. Switch the machine monitor display to the moni-
5. When the torque converter oil temperature goes
toring function of service mode 1 and display the
above 90°C, run the engine immediately at low
following 2 items at the same time with the mon-
idle and return the gearshift lever to the N posi-
itoring function.
tion.
★ Monitoring items
(1) Code No. 01001: ¤ Never operate the gearshift lever with the ac-
Engine speed celerator pedal depressed. It will cause a big
(2) Code No. 30100: shock and will also lead to a reduction in the
Torque converter oil temperature service life of the machine.
SPECIAL FUNCTIONS OF MACHINE 6. Run the engine at a mid-range speed, and when
MONITOR. the torque converter oil temperature goes down
to approx. 80°C, run at low idle.
★ Keep the gearshift lever at the N position.
7. Repeat Steps 3 – 6 and equalize the oil temper-

ature in the torque converter and transmission.
8. At the same time as repeating Steps 3 and 4,

measure the stall speed when the torque con-
verter oil temperature is 80°C.
★ Measure the stall speed 2 or 3 times.
★ The stall speed may vary according to the follow-

ing conditions, so always measure the stall
speed at the time of delivery.
2. Start the engine and raise the temperature of the 1) Variations according to the engine serial
hydraulic oil and torque converter oil. number
★ Torque converter oil temperature: 60 – 80°C 2) Variations in engine output due to atmo-
Hydraulic oil oil temperature: 45 – 55°C spheric pressure and temperature
3) Variations due to consumption torque of ac-
3. Turn the parking brake switch ON, depress the cessories
brake pedal, then set the gearshift lever to the D 4) Variations due to features of the torque con-
position. verter
★ If the gearshift lever is operated to any posi- 5) Variations according to the method of mea-
tion other than the D position, the machine suring the stall
pressed, so always measure at the D posi-
tion.
HM300-1 20-121
1 c
(9) c
TESTING AND ADJUSTING MEASURING POWER TRAIN OIL PRESSURE
MEASURING POWER TRAIN OIL PRESSURE
★ Table of oil pressure measurement port posi-

tions and gauges to use
Gauge
No. Measurement location
(MPa {kg/cm2})
1 Power train main relief pressure 5.9 {60}
2 Torque converter inlet port pressure 5.9 {60}
3 Torque converter outlet port pressure 0.98 {10}
4 Torque converter lock-up clutch pressure 5.9 {60}
5 Transmission Lo clutch pressure 5.9 {60}
6 Transmission Hi clutch pressure 5.9 {60}
7 Transmission 1st clutch pressure 5.9 {60}
8 Transmission 2nd clutch pressure 5.9 {60}
9 Transmission 3rd clutch pressure 5.9 {60}
10 Transmission R clutch pressure 5.9 {60}
11 Inter-axle differential lock clutch pressure 5.9 {60}
★ The transmission lubrication temperature is rep-

resented by the torque converter outlet port
pressure, so there is no need to measure it.
20-122 HM300-1
c 1 c
(9)
¤ Stop the machine on flat ground, turn the parking Power train overall
brake switch ON, and block the tires. 1. Measuring power train main relief pressure
¤ Wait for the oil temperature to go down fully be- 1) Tilt the cab up.
fore removing or installing the measuring tools. 2) Remove oil pressure measurement plug (1),
¤ When measuring the oil pressure when travel- then install nipple and hose [1].
ing, make sure that there is a wide travel area ★ Pull the hose out to the rear of the trans-
and check the safety in the surrounding area. mission.
★ When tilting the cab up or down, see METHOD
OF TILTING CAB UP for details.
★ When taking measurement of ECMV-related hy-
draulic oil pressure, remove and install the nip-
ple, hoses and gauge for the measurement from
the rear underside of the cab.
3) Tilt the cab down and return it to its original

position.
4) Connect oil pressure gauge F.
the torque converter oil to the operating
range.
6) Keep the gearshift lever at the N position and
measure the oil pressure at low idle and high
idle.

inal condition.
HM300-1 20-123
1 c
(9) c
Torque converter related 3. Measuring torque converter outlet oil pres-

2. Measuring torque converter inlet oil pressure sure
1) Fit hose [1] to hydraulic oil pressure measur- 1) Tilt the cab up.
ing coupler (2). 2) Remove oil pressure measurement plug (3),
then install nipple and hose [1].
★ Pull the hose out to the rear of the trans-
mission.

range. 3) Tilt the cab down and return it to its original
4) Keep the gearshift lever at the N position and position.
measure the oil pressure at high idle. 4) Connect oil pressure gauge F.
range.
6) Keep the gearshift lever at the N position and
measure the oil pressure at high idle.
inal condition.

inal condition.
20-124 HM300-1
c 1 c
(9)
4. Measuring torque converter lock-up clutch Transmission related

pressure ★ Table of gearshift lever positions, speed
1) Remove hydraulic oil pressure measuring ranges, and clutches actuated
plug (4) and install the nipple and hoses for
Speed range
measurement. Gearshift lever Clutches
R3 R2 R1 N D 5 4 3 2 1 Lo Hi 1st 2nd 3rd R

! ! ! ! ! F1 " "
! ! ! ! ! F2 "
! ! ! ! F3 "
! ! ! F4
! ! F5 "
! F6
! N
! R1 "
! R2
! R3
2) Connect oil pressure gauge F. ★ The ! mark indicates the speed ranges that are
3) Start the engine and raise the temperature of actuated for each position of the gearshift lever.
the torque converter oil to the operating ★ The mark and " mark indicate the clutches
range. that are actuated for each travel speed.
4) Turn the parking brake switch OFF, depress ★ The " mark indicates the speed range when
the brake pedal, then set the gearshift lever measuring the oil pressure for each clutch.
to position 1.
5) Release the brake, travel at high idle, and 5. Measuring transmission Lo clutch pressure
measure the oil pressure when the lock-up 1) Remove hydraulic oil pressure measuring
pilot lamp lights up. plug (5) and install the nipple and hoses for
¤ In F1, a maximum travel speed of ap- the measurement.
prox. 6.2km/h is reached, so check care-
fully that the surrounding area is safe.

6) After completing the measurement, remove the torque converter oil to the operating
the measuring equipment and set to the orig- range.
inal condition. 4) Turn the parking brake switch OFF, depress
the brake pedal, then set the gearshift lever
to position 1.
5) Release the brake and measure the oil pres-
sure when traveling at high idle.
¤ In F1, a maximum travel speed of ap-
inal condition.
HM300-1 20-125
(9)
1 ! !
6. Measuring transmission Hi clutch pressure 7. Measuring transmission 1st clutch pressure

1) Remove hydraulic oil pressure measuring 1) Remove hydraulic oil pressure measuring
plug (6) and install the nipple and hoses for plug (7) and install the nipple and hoses for
the measurement. the measurement.
2) Connect oil pressure gauge F. 2) Connect oil pressure gauge F.

3) Start the engine and raise the temperature of 3) Start the engine and raise the temperature of
the torque converter oil to the operating the torque converter oil to the operating
range. range.
4) Turn the parking brake switch OFF, depress 4) Turn the parking brake switch OFF, depress
the brake pedal, then set the gearshift lever the brake pedal, then set the gearshift lever
to position 2. to position 1.
5) Release the brake, travel at high idle, and 5) Release the brake and measure the oil pres-
measure the oil pressure when the shift indi- sure when traveling at high idle.
cator shows “2”. ¤ In F1, a maximum travel speed of ap-
¤ In F2, a maximum travel speed of approx. 6.2km/h is reached, so check care-
prox. 9.8km/h is reached, so check carefully that the surrounding area is safe.
fully that the surrounding area is safe. 6) After completing the measurement, remove
inal condition.

inal condition.
20-126 HM300-1
c 1 c
(9)
8. Measuring transmission 2nd clutch pressure 9. Measuring transmission 3rd clutch pressure
1) Remove hydraulic oil pressure measuring 1) Remove hydraulic oil pressure measuring
plug (8) and install the nipple and hoses for plug (10) and install the nipple and hoses for
the measurement. the measurement.
2) Connect oil pressure gauge F. 2) Connect oil pressure gauge F.

3) Start the engine and raise the temperature of 3) Start the engine and raise the temperature of
the torque converter oil to the operating the torque converter oil to the operating
range. range.
4) Turn the parking brake switch OFF, depress 4) Turn the parking brake switch OFF, depress
the brake pedal, then set the gearshift lever the brake pedal, then set the gearshift lever
to position 3. to position 5.
5) Release the brake, travel at high idle, and 5) Release the brake, travel at high idle, and
measure the oil pressure when the shift indi- measure the oil pressure when the shift indi-
cator shows “3”. cator shows “5”.
¤ In F3, a maximum travel speed of ap- ¤ In F5, a maximum travel speed of ap-
prox. 15.2km/h is reached, so check prox. 37.5km/h is reached, so check
carefully that the surrounding area is carefully that the surrounding area is
safe. safe.
inal condition.

inal condition.
HM300-1 20-127
1 c
(9) c
10. Measuring transmission R clutch pressure 11. Measuring inter-axle differential lock clutch
1) Remove hydraulic oil pressure measuring pressure
plug (7) and install the nipple and hoses for 1) Remove hydraulic oil pressure measuring
the measurement. plug (11) and install the nipple and hoses for
the measurement.

3) Start the engine and raise the temperature of 2) Connect oil pressure gauge F.
the torque converter oil to the operating 3) Start the engine and raise the temperature of
range. the torque converter oil to the operating
4) Turn the parking brake switch OFF, depress range.
the brake pedal, then set the gearshift lever 4) Keep the gearshift lever at the N position and
to position R1. move the inter-axle differential lock switch to
5) Release the brake and measure the oil pres- the MANUAL position.
sure when traveling at high idle. 5) Measure the oil pressure when the engine is
¤ In R1, a maximum travel speed of ap- at high idle.
inal condition.

inal condition.
20-128 HM300-1
c 1 c
(9)
TESTING AND ADJUSTING ADJUSTING TRANSMISSION SPEED SENSOR
ADJUSTING TRANSMISSION SPEED SENSOR
★ There are 4 speed sensors installed to the trans- 4) Fixing sensor (1), tighten nut (3).
mission. Adjust each sensor as follows. 3 Nut: 49.0 – 68.6Nm {5 – 7kgm}
N1: Input shaft speed sensor
N2: Intermediate shaft speed sensor
N3: Output shaft R speed sensor
B09: Output shaft F speed sensor
★ For the input shaft speed sensor, tilt the cab up
before carrying out adjustment.
★ For the intermediate shaft speed sensor and out-
put F shaft speed sensor, remove the transmis-
sion and front differential assembly before
carrying out adjustment.
1. Adjusting input shaft speed sensor (N1)

1) Remove input shaft speed sensor (1) and
check that its tip is free from steel chips and
flaws, and then reinstall it temporarily.
2 Threads: Gasket sealant (LG-5)
2) Screw in sensor (1) until its tip touches the
tooth tip of input shaft gear (2).
3) Return sensor (1) by 1/2 - 1 turn.
★ At this time, clearance (a) between the
sensor tip and gear tooth tip is 0.75 - 1.5
mm.
HM300-1 20-129
(7)
1 ! !
TESTING AND ADJUSTING ADJUSTING TRANSMISSION SPEED SENSOR
2. Adjusting intermediate shaft speed sensor 4. Adjusting output shaft F speed sensor (B09)
(N2) 1) Remove output shaft F speed sensor (10)
1) Remove intermediate shaft speed sensor (4) and check that its tip is free from steel chips
and check that its tip is free from steel chips and flaws, and then reinstall it temporarily.
and flaws, and then reinstall it temporarily. 2 Threads: Gasket sealant (LG-5)
2 Threads: Gasket sealant (LG-5) 2) Screw in sensor (10) until its tip touches the
2) Screw in sensor (4) until its tip touches the tooth tip of front output shaft gear (11).
tooth tip of intermediate shaft gear (5). 3) Return sensor (10) by 1/2 - 1 turn.
3) Return sensor (4) by 1/2 - 1 turn. ★ At this time, clearance (d) between the
★ At this time, clearance (b) between the sensor tip and gear tooth tip is 0.75 - 1.5
sensor tip and gear tooth tip is 0.75 - 1.5 mm.
mm. 4) Fixing sensor (10), tighten nut (12).
4) Fixing sensor (4), tighten nut (6). 3 Nut: 49.0 – 68.6Nm {5 – 7kgm}
3 Nut: 49.0 – 68.6Nm {5 – 7kgm}
5. Checking sensor input signal

3. Adjusting output shaft R speed sensor (N3) After finishing the adjustment, check that the
1) Remove output shaft R speed sensor (7) and monitoring function of the machine monitor indi-
check that its tip is free from steel chips and cates each transmission shaft speed normally.
flaws, and then reinstall it temporarily. ★ For details of the monitoring function, see
2 Threads: Gasket sealant (LG-5) Special function of machine monitor.
2) Screw in sensor (7) until its tip touches the
tooth tip of rear output shaft gear (8).
3) Return sensor (7) by 1/2 - 1 turn.
★ At this time, clearance (c) between the
sensor tip and gear tooth tip is 0.75 - 1.5
mm.
4) Fixing sensor (7), tighten nut (9).
3 Nut: 49.0 – 68.6Nm {5 – 7kgm}
20-129-1 HM300-1
! (7) !
TESTING AND ADJUSTING TESTING AND ADJUSTING BRAKE OIL PRESSURE
TESTING AND ADJUSTING 2) Start the engine.

3) Measure the cut-in pressure at high idle.
BRAKE OIL PRESSURE i) Repeatedly depress and release the
brake pedal to gradually lower the pres-
sure inside the accumulator.
¤ Stop the machine on flat ground, turn the parking
ii) Measure the pressure at the point where
brake switch ON, and block the tires.
the indicator of oil pressure gauge F
stops going down and starts to go up
TESTING again.
1. Measuring charge valve cut-in pressure and 4) Measure the cut-out pressure at high idle.
cut-out pressure Measure the oil pressure when the pressure
★ Measure the charge valve oil pressure at re- goes up after the cut in and the indicator of
mote pressure detection port (1). pressure gauge F stops.
1) Install hose [1] and connect oil pressure 5) After completing the measurement, remove
gauge F. the measuring equipment and set to the orig-
★ Use a 39.2MPa {400kg/cm2} oil pressure inal condition.
gauge.
20-130 HM300-1
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(9)
2. Measuring wheel brake actuation pressure 4) Measure the actuation pressure of the re-
and drop in pressure tarder brake under the following conditions.
★ Use the same procedure to measure the i) Run the engine for several minutes at
front brake circuit, center brake circuit. low idle to charge the accumulator, then
1) Remove air bleeder (2) of the slack adjuster. stop the engine.
ii) Turn the starting switch ON.
iii) Pull the retarder lever fully and measure
the oil pressure.
5) Measure the drop in the pressure of the foot
brake under the following conditions.
★ Check that the foot brake actuation pres-
sure and the retarder actuation pressure
are correct before starting.
i) Run the engine for several minutes at
low idle to charge the accumulator, then
stop the engine.
ii) Depress the brake pedal fully and mea-
sure the oil pressure.
★ Keep the brake pedal depressed.
2) Install brake test kit G and bleed the air from iii) Measure the oil pressure after 5 minutes
the brake circuit. and calculate the drop in pressure.
★ For details, see BLEEDING AIR FROM 6) After completing the measurement, remove
BRAKE CIRCUIT. the measuring equipment and set to the orig-
inal condition.
★ Bleed the air from the brake circuit.
For details, see BLEEDING AIR FROM
BRAKE CIRCUIT.
3) Measure the actuation pressure of the foot

brake under the following conditions.
i) Run the engine for several minutes at
low idle to charge the accumulator, then
stop the engine.
ii) Depress the brake pedal fully and mea-
sure the oil pressure.
HM300-1 20-131
1 c
(9) c
3. Measuring actuation pressure of parking

brake
1) Disconnect hose (3) of parking brake cylin-
der.
¤ Check that the parking brake switch is
ON before carrying out the operation.

inal condition.
4. Measuring actuation pressure of exhaust

2) Install adapter [1] and nipple and hose [2],
brake solenoid (machine equipped with ex-
and connect oil pressure gauge F.
haust brake)
★ Use a 5.9MPa {60kg/cm2} oil pressure
1) Open the engine hood.
gauge.
2) Disconnect hose (4) of the exhaust brake
cylinder.
3) Start the engine and operate the parking

brake switch several times at high idle to
bleed the air from the circuit. 3) Install adapter [1] and nipple and hose [2],
4) Stop the engine and turn the starting switch and connect oil pressure gauge F.
ON. ★ Use a 5.9MPa {60kg/cm2} oil pressure
gauge.
5) Measure oil pressure when parking brake
switch is turned OFF.
20-132 HM300-1
c 1 c
(9)
4) Start the engine and turn the exhaust brake 1. Remove mudguard sheet inside left front tire
switch ON. (In the condition shown in Fig. 1 housing.
(a))
5) Turn the parking brake OFF.
6) Drive the machine forward and measure the
oil pressure when the exhaust brake pilot
lamp lights up.
2. Loosen locknut (6).
3. Turn adjustment screw (7) and adjust oil pres-

sure.
Fig. 1 ★ Adjust with the adjustment screw as follows.
• To INCREASE pressure, turn clockwise
¤ During the measuring operation, check • To DECREASE pressure, turn counter-
that the surrounding area is safe and clockwise
drive carefully.
★ If the accelerator pedal is released while 4. Hold adjustment screw (7) in position and tighten
the machine is traveling with exhaust locknut (8).
brake switch at position (a) and the Locknut: 10.2Nm {1kgm}
torque converter in the lock-up condition,
the exhaust brake is actuated. ★ After completing the adjustment, repeat the pro-
7) After completing the measurement, remove cedure for measurement to check the oil pres-
the measuring equipment and set to the orig- sure again.
inal condition.
ADJUSTING
Adjusting charge valve cut-in pressure and cut-
out pressure
★ If the cut-in pressure and cut-out pressure of the
charge valve are not correct, adjust the R1 relief
valve of charge valve (5) as follows.
★ If the R1 relief valve is adjusted, the cut-in pres-
sure and cut-up pressure will both change.
HM300-1 20-133
1 c
4 c
TESTING OF ACCUMULATOR NITROGEN GAS
PRESSURE AND PROCEDURE FOR CHARGING
TESTING AND ADJUSTING ACCUMULATOR WITH NITROGEN GAS
TESTING OF ACCUMULATOR
NITROGEN GAS PRESSURE
AND PROCEDURE FOR
CHARGING ACCUMULATOR
WITH NITROGEN GAS
a Testing instrument
Symbol Part No. Part name Remarks
P1 792-610-1700 Gas charge tool —
Nipple
792-610-1310 GOST
(For Russia)
Nipple 3. Connect gas charge tool P1 to valve (4) of
792-610-1320 (For USA) CGA No. 351
accumulator (1) according to the following pro-
P2 792-610-1330 Nipple ASA B-571-1965 cedure.
(For USA)
1) Turn handle (a) of gas charge tool P1 to
DIN 477-1963 the left until it stops.
Nipple
792-610-1350 NEN 3268-1966
(For Germany) q Nitrogen gas cylinder (c) must be con-
SIS-SMS 2235/2238
792-610-1360 Nipple (For UK) BS 341 Part 1-1962 nected even when you measure only
the gas pressure.
k Put on proper protection gear (goggles, q Close the valve of nitrogen gas cylin-
leather gloves and protective clothes) so der (c) and handle (b).
that the leaking nitrogen gas will not touch q For connection of nitrogen gas cylin-
your skin or clothes and work on the wind- der (c) and gas charge tool P1, see
ward side as long as possible. "Procedure for charging accumulator
k When handling nitrogen gas in a room or with nitrogen gas".
another place which is not ventilated well, 2) Connect gas charge tool P1 to valve (4) of
ventilate the work place forcibly and observe accumulator (1).
the Oxygen Deficiency Prevention Rules of
the Labor Safety and Sanitation Law.
k Since the accumulator is charged with high-
pressure nitrogen gas, wrong handling of it
can cause an explosion and injury or death.
When handling the accumulator, observe
the following strictly.
q Do not bring fire near the accumulator or
put the accumulator in fire.
q Do not drill, weld or gas-cut the accumulator.
q Do not give impacts to the accumulator by
hitting or rolling.
q When discarding accumulator, discharge it
of the nitrogen gas.
Testing of accumulator nitrogen gas pressure

a The nitrogen gas pressure in the accumulator
disconnected from the machine can be mea-
sured according to the following procedure, too.
1. Stop the engine and press the brake pedal
repeatedly to lower the oil pressure in the brake
circuit to zero.
a Generally, if the brake pedal is pressed 30
times, the reaction force to the brake pedal
is lost and the oil pressure is lowered to
zero.
2. Remove valve guard (2) and cap (3) from accu-
mulator (1).
20-133-1 HM300-1
(10)
4. Turn handle (a) of gas charge tool P1 to the left 3. Connect gas charge tool P1 and nitrogen gas
and read the gauge. cylinder (c) to valve (4) of accumulator (1)
a Since the indicated value varies with the according to the following procedure.
ambient temperature, correct it by the fol- 1) Turn handle (a) of gas charge tool P1 to
lowing formula. (The unit of each value in the left until it stops.
the formula is °C.) 2) Turn handle (b) to the left to open.
Indicated gas pressure = 3) Connect gas charge tool P1 to valve (4) of
Standard gas pressure x ((273 + t)/ accumulator (1).
(273 + 20))
4) Connect gas charge tool P1 and nitrogen
Standard gas pressure =
gas cylinder (c).
Indicated gas pressure/((273 + t)/
q There are 2 types of threads of nitro-
(273 + 20))
gen gas cylinders, W22-14 thread
t = Gas temperature at time of charge (°C)
(mail screw, type A) and W23-14
Reference: t may be assumed to be ambi-
thread (female screw, type B). When
ent temperature.
using a gas cylinder of W23-14 thread
(female screw, type B), connect the
5. If the gas pressure is too high or too low, adjust hose by using the adapter. (The
it referring to "Procedure for charging accumu- adapter is attached to gas charge tool
lator with nitrogen gas". P1.) [For Japan]
a Each time the pressure is measured, some q Use nipple P2 to connect the hose,
nitrogen gas is discharged and the pres- depending on the specification of the
sure lowers. Add nitrogen gas by the loss. nitrogen gas cylinder. [For overseas]
6. Remove gas charge tool P1 from accumulator

(1) and return the removed parts. See "Proce-
dure for charging accumulator with nitrogen
gas".
Procedure for charging accumulator with nitro-

gen gas
a The disconnected from the machine can be
charged with nitrogen gas according to the fol-
lowing procedure, too.
1. Stop the engine and press the brake pedal
repeatedly to lower the oil pressure in the brake
circuit to zero.
a Generally, if the brake pedal is pressed 30
times, the reaction force to the brake pedal
is lost and the oil pressure is lowered to
zero.
2. Remove valve guard (2) and cap (3) from accu-

mulator (1).
4. Open nitrogen gas cylinder (c) slightly to dis-

charge nitrogen gas at pressure of 0.19 – 0.29
MPa {2 – 3 kg/cm²}.
5. After nitrogen gas starts flowing out of handle

(b), close handle (b).
HM300-1 20-133-2
(10)
6. Turn handle (a) slowly to the right to open valve

(4) of accumulator (1) gradually.
a If handle (a) is turned too much, the valve
core of the accumulator will be damaged
and gas will leak. Accordingly, operate
handle (a) carefully.
7. Open the valve of nitrogen gas cylinder (c) fur-

ther to charge the accumulator with nitrogen
gas.
8. During the work, close the valve of nitrogen gas

cylinder (c) and check the nitrogen gas pres-
sure in the accumulator. 13. In a week after charging the accumulator with
a Since the indicated value varies with the nitrogen gas, check that the nitrogen gas pres-
ambient temperature, correct it by the fol- sure has not lowered.
lowing formula. (The unit of each value in a Check the functions in 5 minutes after
the formula is °C.) stopping the engine. (If the engine is
Indicated gas pressure = stopped for more than 5 minutes, the
Standard gas pressure x ((273 + t)/ brake circuit pressure lowers and the func-
(273 + 20)) tions cannot be checked accurately.)
Standard gas pressure = 1) Stop the machine on a level place and set
Indicated gas pressure/((273 + t)/ the parking brake switch in the "PARK"
(273 + 20)) position.
t = Gas temperature at time of charge (°C)
2) Start the engine and run it at medium
Reference: t may be assumed to be ambi-
speed for 1 minute and then stop it.
ent temperature.
3) Turn the starting switch to the ON position
and press the brake pedal repeatedly.
9. After the accumulator is charged to the stan-
Count the number of presses until the
dard pressure, close the valve of nitrogen gas
brake oil pressure caution lamp lights up.
cylinder (c).
q If number of presses is less than 5:
q If the accumulator is charged too much,
Accumulator gas pressure may have
turn handle (b) to the left slowly with the
lowered.
valve of nitrogen gas cylinder (c) closed to
q If number of presses is 5 or more:
release the nitrogen gas gradually to
Accumulator gas pressure is normal.
adjust.
10. Remove gas charge tool P1 from valve (4) of

accumulator (1) according to the following pro-
cedure.
1) Turn handle (a) to the left to close the
valve of the accumulator.
2) Turn handle (b) to the left to open and dis-
charge nitrogen gas remaining in gas
charge tool P1 and hoses.
3) Remove gas charge tool P1 from valve (4)
of the accumulator.
11. Apply soap water to valve (4) of the accumula-

tor to check that nitrogen gas is not leaking.
12. Install cap (3) and valve guard (2) to accumula-

tor (1).
3 Cap: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
20-133-3 HM300-1
(10)
TESTING AND ADJUSTING TESTING BRAKE PERFORMANCE
TESTING BRAKE
PERFORMANCE
¤ Stop the machine on flat ground and turn the
parking brake switch ON.
1. Testing braking performance of foot brake

1) Start the engine and turn the parking brake
switch OFF.
2) Depress the brake pedal fully, then set the
gearshift lever to the D position.
★ Testing of the performance of the foot
4) After completing the inspection, run the en-
brake must be carried out with the gear-
gine at low idle and set the gearshift lever to
shift lever at the D position. Do not place
the N position.
the gearshift lever at any other position.
3) Depress the accelerator pedal gradually and
3. Testing braking performance of parking brake
check that the machine does not move when
the torque converter is stalled at the speci- ¤ If the machine starts to move, it can cause a
fied speed. serious bodily accident. Should the machine
start moving while in inspection work, reduce
the engine speed immediately, move the
gearshift lever to the N position and apply
the brake.
1) Turn the parking brake switch ON and start
the engine.
2) Place the gearshift lever at the [D] position.
★ Testing of the performance of the foot
brake must be carried out with the gear-
shift lever at the D position. Do not place
the gearshift lever at any other position.
the torque converter is stalled at the speci-
4) After completing the inspection, run the en- fied speed.
gine at low idle and set the gearshift lever to 4) If the machine moves at a revolution lower
the N position. than specified, adjust clearance of the brake
pad, referring to “2. Adjusting Clearance in
2. Testing braking performance of retarder Brake Pad” in INSPECTING PARKING
brake (which is not used in E-SPEC) BRAKE WEAR AMOUNT.
1) Start the engine and turn the parking brake
switch OFF.
2) Pull the retarder lever fully, then set the gear-
shift lever to the D position.
★ Testing of the performance of the retard-
er brake must be carried out with the
gearshift lever at the D position. Do not
place the gearshift lever at any other po-
sition.
the torque converter is stalled at the speci-
fied speed.
5) After completing the inspection, run the en-

gine at low idle and set the gearshift lever to
the N position.
20-134 HM300-1
c 4 c
1
(9)
TESTING AND ADJUSTING TESTING BRAKE PERFORMANCE
4. Testing braking performance of overrun pro-

tection brake (E-SPEC)
1) Start the engine and turn the parking brake 3) Depress the accelerator pedal gradually and
switch OFF. check that the machine does not move when
2) Insert a screwdriver in hole (a) on the side of the torque converter is stalled at the speci-
the combination switch box and move it to fied speed.
the lower end and place the gearshift lever at ★ After completing the inspection, move
the D position. the screwdriver inserted in hole (a) to the
★ Testing of the performance of the over- upper end and remove it.
run protection brake must be carried out
with the gearshift lever at the D position.
Do not place the gearshift lever at any
other position.
★ If the screwdriver is inserted in hole (a)
on the side of the combination switch
box and moved to the lower end, the po-
tentiometer in the switch box is rotated
and the overrun protection brake pilot
lamp lights up.
HM300-1 20-134-1
4 c c
TESTING AND ADJUSTING BLEEDING AIR FROM BRAKE CIRCUIT
BLEEDING AIR FROM BRAKE 4) Bleed air from retarder brake circuit in the
following procedure.
CIRCUIT i) Pull the retarder lever fully and hold it in
position.
★ If the equipment in the brake circuit has been re- ii) Loosen air bleeder (1) approx. 1/2 turn,
moved and installed again, bleed the air from the then drain oil mixed with oil.
brake circuit as follows. iii) When no more air comes out with the oil,
★ When bleeding the air from the wheel brake cir- tighten air bleeder (1).
cuit, always bleed the air from the slack adjuster Air bleeder:
first, then bleed the air from the wheel brake. 10 – 20Nm {1 – 2kgm}
5) Bleed air from the overrun protection brake
1. Bleeding air from slack adjuster portion of circuit in the following procedure (E-SPEC).
wheel brake circuit i) Insert a screwdriver in hole (a) on the
★ Use the same procedure to measure the side of the combination switch box and
front brake circuit, and center brake circuit. move it to the lower end and keep it in
In case of bleeding air from the front brake that position.
circuit, however, the brake oil pressure cau- ii) Loosen air bleeder approx. 1/2 turn, then
tion lamp may light up while bleeding air. If drain the air mixed with the oil.
that happens, tighten the air bleeder, accu- iii) When no more air comes out with the oil,
mulate hydraulic oil pressure in the accumu- tighten air bleeder (1).
lator by stepping on the service brake 8 to 10
Air bleeder :
times, and then bleed air. Oil pressure accu-
10 - 20 Nm {1 - 2 kgm}
mulating signals are received from the rear
(center) brake circuit. Hence the circuit is so ★ After bleeding air, be sure to move the
designed that oil pressure is not accumulat- screwdriver inserted in hole (a) to the up-
ed in the front brake (low pressure), even if per end and remove it.
the brake oil pressure caution lamp lights up.
For this reason, air bleeding takes place
without accumulating oil pressure, resulting
in not effective air bleeding.
1) Connect air bleed hose [1] to air bleeder (1).
2) Start the engine and operate at low idle.

3) Bleed the air from the brake pedal circuit as
follows.
i) Depress the brake pedal fully and hold it
in position.
ii) Loosen air bleeder (1) approx. 3/4 turn,
then drain the air mixed with the oil.
iii) When no more air comes out with the oil,
tighten air bleeder (1).
6) After completing the adjustment, set to the
Air bleeder: original condition.
10 – 20Nm {1 – 2kgm}
HM300-1 20-135
1 c
4
(9) c
TESTING AND ADJUSTING BLEEDING AIR FROM BRAKE CIRCUIT
2. Bleeding air from wheel brake portion of foot

brake circuit
★ Use the same procedure to measure the
front brake circuit, and center brake circuit.
1) Connect air bleed hose [1] to air bleeder (2).

3) Bleed the air from the brake pedal circuit as
follows.
i) Depress the brake pedal fully and hold it
in position.
ii) Loosen air bleeder (1) approx. 1/2 turn,
then drain the air mixed with the oil.
4) When no more air comes out with the oil,
tighten air bleeder (1).
3. Bleeding air from parking brake circuit

2) Use the parking brake switch to actuate and
cancel the circuit several times.
★ This operation automatically bleeds the
air.
20-135-1 HM300-1
c 4 c
(9)
TESTING AND ADJUSTING TESTING WEAR OF WHEEL BRAKE DISC
TESTING WEAR OF WHEEL 5. Push in the rod (2) of the gauge until it contacts
the piston and judge the amount of wear.
BRAKE DISC ★ There are three lines (A, B, C) on the rod.
For HM300-1 model, the front brake is ex-
pressed with A mark and the center brake
with B mark.
★ With a new machine, adjust so that initial
¤ Carry out the inspection when the brake oil tem- mark a on the rod (2) is aligned with the end
perature is less than 60°C. face of guide (3).
¤ When the disc comes close to the wear limit, car- The adjustment position will move out of
ry out the inspection more frequently. Be sure to alignment, so do not loosen the locknut of
carry out inspection of the retarder braking per- guide (3) except when replacing the disc.
formance at the same time. ★ Limit mark b indicates the wear limit for the
disc. If limit mark b reaches the end face of
1. Check that the brakes other than parking brake guide (3), the disc has reached the wear lim-
are not being actuated. it.
2. Turn the starting switch ON and check that the

retarder oil pressure caution lamp is not lighted
up.
★ If the lamp is lighted up, the oil pressure in
the brake circuit has dropped, so start the
engine and run it at approx. 2000rpm. When
the lamp goes out, stop the engine.
3. Remove cap nut (1) of the gauge.
3 Cap nut:
6. Install cap nut (1) of the gauge.
14.7 – 19.6Nm {1.5 – 2.0kgm}
4. Depress the brake pedal fully and hold it in posi-

tion.
★ When the engine is started, the brake cool-
ing oil is actuated and the inspection cannot
be carried out accurately, so always stop the
engine before carrying out inspection.
20-136 HM300-1
c 1 c
(9)
TESTING AND ADJUSTING TESTING WEAR OF PARKING BRAKE PAD
TESTING WEAR OF PARKING 2. Adjusting pad clearance

★ When the parking brake does not work prop-
BRAKE PAD erly, or when the brake pads were replaced
with new ones, adjust clearance in the brake
pad in the following manner.
brake switch ON, and block the tires. ¤ Keep hydraulic oil pressure at a high level
while in adjustment so that the parking brake
★ Before carrying out the inspection, start the en-
may not be automatically applied and also
gine and raise the dump body fully. Then insert
hang a warning tag on the parking brake
the lock pin and stop the engine.
switch so that nobody may operate the ma-
chine by mistake.
1. Testing wear of pad
¤ Do not smear the surfaces of brake pads or
1) Remove top cover of parking brake.
brake discs with oil or grease.
2) Measure thickness a of pad (1).
★ Thickness limit of pad: 1.5mm 1) Install 2 pads (5).
★ If either the front or rear pad has reached 2) Install 2 each of springs (3) and (4) to left and
the thickness limit, replace both pads at right brackets (2), then install left and right
the same time. brackets (2).
★ There are two types of springs, so check
the color, and be careful not to mistake
the mounting position.
Spring (3): Black
Spring (4): Yellow
★ Tighten the bracket mounting bolts tem-
porarily by 2 – 3 turns.
3) Turn adjusting nut (1) counter-clockwise until
brake pad (5) comes into close contact with
brake disc (6).
4) While taking measurement of clearances b
and c between brake pad (5) and brake disc
(6), turn adjusting nut (1) clockwise until the
specified clearance in between is obtained.
★ Standard clearance (total of b and c):
1.88 ± 0.08mm
HM300-1 20-137
1 c
(9) c
TESTING AND ADJUSTING METHOD FOR EMERGENCY RELEASE OF PARKING BRAKE
METHOD FOR EMERGENCY

RELEASE OF PARKING
BRAKE
★ If any problem occurs in the electrical system or
hydraulic system of the parking brake and the
parking brake is not released, it is possible to re-
lease the brake temporarily as follows.
¤ If any problem occurs in the hydraulic system,
there is a strong possibility that the wheel brake
will not work properly, so after releasing the park-
5) Start the engine. ing brake, always tow the machine at low speed
6) Release the parking brake and check the to a safe place.
clearance of the pad again. ¤ When carrying out the operation to release the
★ Clearance (total of b and c): parking brake, stop the machine on flat ground
1.88 ± 0.08mm and check that the surrounding area is safe be-
★ If the clearance is not correct, carry out fore starting the operation. If the parking brake
the adjustment again from Step 3). must be released on a slope in an emergency or
7) Tighten the mounting bolts of left and right other unavoidable situation, put blocks securely
brackets (2). under the tires.
★ Be careful not to let the mounting posi-
tion move out of alignment. 1. Turn adjustment screw (1) of the parking brake
8) Check the clearance between pad (5) and clockwise to create a gap between the pad and
disc (6) again. disc.
★ Target clearance (b + c on one side):
Min. 1.88 ± 0.08mm
★ If the clearance on one side is narrow,
move the mounting position of the left
and right brackets to adjust.
2. Tow the machine and move it to a safe place.

★ After moving the machine, fit blocks securely
under the tires.
20-138 HM300-1
c 1 c
(9)
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING CIRCUIT PRESSURE

STEERING CIRCUIT
PRESSURE
1. Measuring steering relief oil pressure

★ Measure the steering relief pressure at re-
mote pressure detection port (1).

inal condition.
2. Adjusting steering relief oil pressure

★ If the steering relief oil pressure is not cor-
rect, adjust relief valve (2) of the flow amp
valve as follows.
1) Install hose [1] and connect oil pressure

gauge F.
gauge.
2) Start engine and operate the steering fully to

one side (either left or right).
3) Measure the oil pressure when the steering
is relieved with the engine at high idle.
HM300-1 20-139
1 c
(9) c
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING CIRCUIT PRESSURE
1) Remove plug (3), then remove locknut (4).

2) Turn adjustment screw (5) and adjust oil
pressure.
★ Adjust with the adjustment screw as fol-
lows.
• To INCREASE pressure, turn clock-
wise
• To DECREASE pressure, turn coun-
terclockwise
3) Fit locknut (4) and install plug (3).
★ After completing the adjustment, repeat the

procedure for measurement to check the oil
pressure again.
20-140 HM300-1
c 1 c
4
TESTING AND ADJUSTING TESTING AND ADJUSTING SUSPENSION CYLINDER
TESTING AND ADJUSTING 2. Releasing nitrogen gas

1) Set a hydraulic jack under the frame of the
SUSPENSION CYLINDER machine and raise the tires slightly from the
ground.
★ Use a 50ton {490,000N} jack.
brake switch ON, and block the tires. ¤ Set the jack securely under the frame.
★ When carrying out work at the front, jack
up the front frame until the front tires
1. Testing cylinder length
come slightly off the ground.
Test the installed length of the suspension cylin-
★ When carrying out work at the rear, jack
der under the following conditions.
up the frame until either the center or
• Machine standing on horizontal road surface
rear tires come slightly off the ground.
• Engine stopped
2) Remove cover (1).
• Dump body unloaded
3) Loosen oil level valve (2) slowly, and when
★ Installed length a of front cylinder:
the nitrogen gas starts to come out, hold the
163 ± 10mm
valve in that position.
★ Installed length b of rear cylinder:
★ If oil spurts out from the valve together
101 ± 5mm
with the nitrogen gas, tighten the valve
★ If the length of the cylinder is not correct, use
slightly until no more oil comes out and
the procedure in Steps 2 to 5 to adjust.
take time to release the nitrogen gas
slowly.
4) Operate the hydraulic jack to lower the frame

slowly until the suspension cylinder is re-
tracted to the specified oil volume length.
¤ Operate the hydraulic jack carefully to
prevent the suspension cylinder from be-
ing retracted too far and suffering dam-
age.
★ Specified front oil volume length a:
113 ± 3mm
★ Specified rear oil volume length b:
56 ± 3mm
HM300-1 20-141
1 c
(9) c
3. Adjusting oil level

★ Adjust the oil level after completing the re-
lease of the nitrogen gas.
1) Check that the suspension cylinder is the
specified oil volume length.
★ Specified front oil volume length a:
113 ± 3mm
★ Specified rear oil volume length b:
56 ± 3mm
¤ Operate the hydraulic jack carefully.
2) Remove oil level valve (2).
3) Remove the valve body from air supply valve
(3), then install joint H6.
4) Install fitting H5 to joint H4, then connect
hose H3 and pump H2.
5) Operate pump H2 to release the gas from
the mounting port of oil level valve (2).
★ Pump the oil out from the mounting port
until no more bubbles come out with the
oil, then fill with oil.
★ Front cylinder oil charge amount
(reference): 3.0¬
★ Rear cylinder oil charge amount
(reference): 2.2¬
6) Install oil level valve (2).
3 Oil level valve:
39.2 – 49.0Nm {4 – 5kgm}
7) Install suspension tools H2 – H5, then re-
move air supply valve (3).
3 Air supply valve:
39.2 – 49.0Nm {4 – 5kgm}
20-142 HM300-1
! 1 !
4. Charging with nitrogen gas 8) Remove suspension tools H7 – H12.

★ Charge with nitrogen gas after completing ★ Be careful not to lose the O-ring of the air
the adjustment of the oil level. supply valve.
1) Remove the cap at the top of air supply valve 9) Install the cap at the top of air supply valve
(3). (3).
2) Connect suspension tools H7 – H12 as shown 10) Install the cover of the suspension cylinder.
in the diagram.
★ Connect joint H10 to the air supply valve.
★ Before installing the regulator, blow the
filter at the mouthpiece thoroughly with
nitrogen gas (min. 0.98MPa {10kg/cm2})
to prevent the entry of dirt or dust.
3) Open the valve of nitrogen gas cylinder [1]
and check the pressure (internal pressure of
the cylinder) indicated by gauge H12.
★ The indicated pressure must not be high-
er than the internal pressure of the cylin-
der (0.98MPa {10kg/cm2}).
★ Internal pressure of cylinder
(both front and rear):
4.03MPa {41.5kg/cm2}
4) Turn the handle of regulator H11 gradually to
the left and set the indicated pressure of
gauge H13.
¤ Never charge the cylinder with nitrogen
gas at a pressure of more than 3.9MPa
{40kg/cm2} and extend the cylinder fully.
5) Operate the handle of joint H10 and valve H7
and the suspension cylinder with nitrogen
gas.
★ Pump nitrogen gas into the left and right
cylinders at the same time.
6) When the length of the left and right cylin-
ders reaches the specified installation
length, turn the handle of regulator H11 to
the left to stop charging with nitrogen gas.
★ Installed length a of front cylinder:
163 ± 10mm
★ Installed length b of rear cylinder:
101 ± 5mm
7) Return the handle of joint H10 fully, loosen
the air bleed plug of valve H7, and discharge
the gas inside the hose.
HM300-1 20-143
1 c
(9) c
5. Adjusting cylinder length Note 1: Checking after changing oil or gas

★ Adjust the cylinder length after completion of If the machine is operated after changing the
charging with nitrogen gas. oil and gas, the gas will dissolve in the oil and
★ When adjusting the cylinder length, stop the saturate the oil inside the cylinder. If this hap-
machine on a horizontal surface with the pens, the volume of the gas will decrease
dump body unloaded. and the length of the cylinder will go below
1) Drive the machine approx. 15m forward, the permissible value.
then stop suddenly. Next, drive in reverse For this reason, check the installed length of
and stop the machine suddenly at the origi- the cylinder again 48 hours after changing
nal point. Repeat this procedure 3 or 4 times. the oil and the gas, and adjust the gas if it is
Finally, apply the retarder brake a little at a below the specified dimension.
time and stop slowly.
★ When using the retarder brake, stop as Note 2: Checking cylinder length according to change
slowly as possible to remove any sliding in ambient temperature
resistance in the cylinder (packing, The gas in the suspension will expand or
catching of the bushing). contract according to the change in the am-
2) Measure the installed length of the cylinder. bient temperature when the machine is
★ Installed length a of front cylinder: working, so the length of the cylinder will
163 ± 10mm change.
★ Installed length b of front cylinder: For this reason, in areas where there is a big
106 ± 5mm difference in temperature during the year,
3) If the installed length is too long, adjust by carry out daily inspection and adjust so that
discharging nitrogen gas from oil level valve the installed length of the cylinder is within
(2). the specified range.
★ Loosen the oil level valve slightly and
discharge a small amount of gas (not
enough to make the cylinder move).
★ If too much gas is discharged and the
cylinder moves, the installed length may
become shorter than the specified in-
stalled length.
4) After completing the adjustment, repeat
Steps 1) – 2) above and check the cylinder
length again.
5) Check for any leakage of gas from oil level
valve (2), air supply valve (3), and the cylin-
der gland.
★ Use soapy water to check for leakage of
gas.
20-144 HM300-1
c 1 c
TESTING AND ADJUSTING METHOD OF TILTING CAB UP
METHOD OF TILTING CAB UP

a Equipment for tilt cylinder
(Uselessness for external crane)
Symbol Part number Part name
R 792-454-1100 Pump assembly
k When tilting the cab, observe the following pre-

cautions to prevent a serious injury or fatal acci-
dent caused by fall of the cab.
k To prevent interference between the cab and
the dump body, set the steering in a straight
ahead position and stop the machine on the 2. Tilting cab up
level ground. Method using tilt cylinder
k Lock the dump lever with the dump lever lock a External hydraulic pump assembly R is nec-
knob. essary.
k Turn the parking brake switch ON and chock the 1) Disconnect cylinder hose (1) at quick coupler
wheels. (Q)
k Set the lock bar to the frame and lock front and
.
rear frame.
• Precautions in tilting cab

k When tilting the cab, check that the lock lever is
fixed securely.
k Do not start the engine while the cab is tilted.
k When it is obliged to start the engine for testing
etc., check that there is nobody under the cab.
k Do not operate the gear shift lever or dump
lever.
k Do not give a large shock to the machine.
k Do not tilt the cab while it is loaded.
a When carrying out inspection and maintenance 2) Exchange female quick coupler (F) to male
work around the hydraulic pump or at the top of quick coupler (M) of external hydraulic pump
the torque converter or transmission, tilt the cab assembly.
up to the rear of the machine as follows. a It is possible to get male quick coupler
a There are the following two methods of tilting the (M) by removing it from (Q) on the
cab up, so select the method to match the oper- machine.
ating conditions. a Connecting adapter (Unit of male and
• Method using tilt cylinder female quick coupler (Q). Both machine
a The external hydraulic pump assembly side and tool side are same.): 56B-54-
R is necessary. 16391 (Size of hose connection end: RC
• Method using external crane 1/4)
1. Preparatory work
1) Open the engine hood.
2) Remove lock bar from the storage place.
3) Remove 4 mounting bolts each from the left
and right mounts at the front of the cab.
4) Move pin (3) at the cab rear mount from hole
(4) to hole (5).
HM300-1 20-145
(10)
1 Å Å
TESTING AND ADJUSTING METHOD OF TILTING CAB UP
3) Connect cylinder hose (1) to the external

hydraulic pump assembly.
4) Operate the external hydraulic pump and tilt
the cab up.
a Operate the pump within the specified
pressure.
Specified pump pressure:
20.6 – 34.3 MPa {210 – 350kg/cm²}
Method using external crane

1) Move pin (3) at the cab rear mount from hole
(4) to hole (5).
2) Fit a sling [1] to a hook on the cab mount.
3) Raise the cab to tilt it up.
3. Fixing cab in position

1) Pull lock lever (2-1) and set lock bar (2) with
the care the direction of the lock bar (2) at the
front left of the cab.
2) Set lock bar (2) at the front left of the cab,
then lower the cab slowly and fix it in posi-
tion.
k Check that the lock lever closes and the
cab (6) is held securely in position by the
lock bar (2).
k When the cab is tilted up with the tilt cyl-
inder, release the hydraulic pressure
gradually, and lower the cab slowly.
4. Tilting cab down
3) Remove the external pump or external
a Tilt the cab down in the reverse order from
crane.
tilting the cab up.
k Check that the cab is held securely in po-
a After tilting the cab down, tighten the mount-
sition by the lock bar. ing bolts and return the lock bar to the stor-
age place.
20-145-1 HM300-1
Å (10)
4 Å
TESTING AND ADJUSTING TESTING AND ADJUSTING DUMP CIRCUIT PRESSURE

DUMP CIRCUIT PRESSURE
1. Testing dump main relief oil pressure
★ The dump main circuit uses both the steering
circuit and hydraulic pump (basic pressure).
The steering is a priority circuit structure, so
check that the steering circuit pressure is
correct before measuring.
★ Measure the dump main relief oil pressure at
remote pressure detection port (1).
the measurement equipment and set to the
original condition.
2. Adjusting dump main relief oil pressure

★ If the dump main relief oil pressure is abnor-
mal, adjust it with relief valve (1) of the hoist
valve according to the following procedure.
1) Install hose [1] and connect oil pressure

gauge F.
gauge.
1) Loosen locknut (2) and rotate adjustment

screw (3).
★ If the adjustment screw is
• rotated to the right, the oil pressure is
heightened.
• rotated to the left, the oil pressure is
lowered.
★ If the adjustment screw is rotated 1 turn,
the pressure is heightened or lowered by
4.2 MPa {42.8 kg/cm2}.
2) Start the engine and operate the dump body

fully to LOWER and RAISE.
3) Run at high idle, operate the dump lever, and
measure the oil pressure when there is
RAISE relief or LOWER relief.
20-146 HM300-1
c 4 c
1
(9)
2) Support adjustment screw (3) with a screw- 4) Run the engine at high idle and measure the
driver and tighten locknut (2). oil pressure. (Set the dump lever in neutral.)
Tightening torque for locknut :
29 - 39 Nm {3 - 4 kgm}
★ After completing the adjustment, check
the oil pressure again according to the
procedure for measurement.
3. Measuring dump pilot relief oil pressure

1) Remove the side cover of the hydraulic tank.
2) Remove oil pressure pickup plug (1).

the measurement equipment and set to the
original condition.
3) Install a nipple and hose [1] and connect oil

pressure gauge F.
★ Use a 5.9 MPa {60 kg/cm2} oil pressure
gauge.
HM300-1 20-146-1
4 c
(9) c
4. Adjusting dump pilot relief oil pressure

★ If the dump pilot relief oil pressure is abnor-
mal, adjust it with relief valve (1) according to
the following procedure.
1) Remove the cap and loosen locknut (2) and

rotate adjustment screw (3).
★ If the adjustment screw is
• rotated to the right, the oil pressure is
heightened.
• rotated to the left, the oil pressure is
lowered.
★ If the adjustment screw is rotated 1 turn,
the pressure is heightened or lowered by
1.8 MPa {18.6 kg/cm2}.
2) Hold adjustment screw (3) and tighten lock-
nut (2).
Tightening torque for locknut:
40 Nm {4.1 kgm}
★ After completing the adjustment, check
the oil pressure again according to the
procedure for measurement.
20-146-2 HM300-1
c 4 c
TESTING AND ADJUSTING ADJUSTING BODY POSITIONER SENSOR
ADJUSTING BODY a Input voltage:

• Becomes lower when the link becomes
POSITIONER SENSOR longer.
• Becomes higher when the link be-
a If the body positioner rod has been disconnected comes shorter.
and connected again or the body positioner sen- a Change in voltage per 1 turn of rod end:
sor has been removed and installed again, in- Approx. 0.04V
spect and adjust the body positioner sensor as 4) Install mounting bolt (2).
follows. 5) Tighten locknut (1).
6) Repeat the checking procedure above to
1. Checking sensor output/input voltage check that the input voltage is within the nor-
1) Switch the machine monitor display to the mal range.
monitoring function of service mode 1 and
display the body positioner sensor input volt-
age.
a Monitoring item
Code No. 34400: BODY POSITION
a For details of the method of operation,
see SPECIAL FUNCTIONS OF MA-
CHINE MONITOR.
3. System calibrating operation

1) Start the engine and raise the hydraulic oil
temperature to 80 – 90°C.
2) While running the engine at low idle, lower
the dump body to the lower stroke end and
keep the dump lever in the “float” position for
at least 5 seconds.
a Check that the body pilot lamp is turned
2) Start the engine.
OFF.
3) Operate the dump lever and check the mon-
3) While running the engine at low idle, raise
itoring voltage when the dump lever is oper-
the dump body to the raise stroke end and
ated fully to the LOWER position and RAISE
keep the dump lever in the “raise” position
position.
for at least 5 seconds.
a When operated fully to LOWER:
4) While running the engine at low idle, lower
0.38 – 0.44V
the dump body to the lower stroke end.
a When operated fully to RAISE:
5) While running the engine at high idle, raise
4.00 – 4.70V
then lower the engine speed to low idle and
2. Adjusting link length
set the dump lever to the “lower” position. Af-
a If the monitoring voltage is not within the nor-
ter the dump body starts lowering, return the
mal range, adjust the length of the link as fol-
dump lever to the “float” position and lower
lows.
1) Loosen locknut (1).
a Repeat the above operation 5 - 10 times.
2) Remove mounting bolt (2).
6) While running the engine at high idle, raise
3) Turn rod end (3) to adjust the length of the
link (4).
then keep the engine speed at high idle and
a Standard installed length (a) of link: 210
set the dump lever to the “lower” position. Af-
mm
ter the dump body starts lowering, return the
a Installed length (a) must be longer than
dump lever to the “float” position and lower
208 mm
a Repeat the above operation 5 - 10 times.
HM300-1 20-147
(13)
PROCEDURE
PROCEDURE FOR ADJUSTING
FOR ADJUSTING LENGTH
LENGTH OF SPRING OF SPRING
IN BODY IN BODY
HEATING HEATING
SPHERICAL JOINT
TESTING AND ADJUSTING SPHERICALCIRCUIT
HANDLING ENGINE CONTROLLER HIGH-VOLTAGE JOINT
PROCEDURE FOR HANDLING ENGINE

ADJUSTING LENGTH OF CONTROLLER HIGH-VOLTAGE
SPRING IN BODY HEATING CIRCUIT
SPHERICAL JOINT
★ When the machine is steered or oscillated, if the
body heating bellows does not operate smoothly,
or when the bellows is replaced, adjust the
length of the spring according to the following
procedure.
1. Adjust length "a" of spring (1) to 60 ± 1 mm.

(On both front side and rear side)
At this time, check that dispersion of dimension
"b" of each stud is 1 mm or less.
★ Standard dimension "b" of stud: 58 mm
(Reference)
¤ The engine controller uses a high-voltage circuit
2. After finishing adjustment (110 – 130V) for the fuel injector drive.
1) Check that exhaust gas does not leak. For this reason, the high-voltage circuit is con-
2) Check that the spherical joint is free from nected to the wiring harness and connectors
sticking and scuffing and it rotates smoothly. from the engine controller to the fuel injector.
★ Normally, high voltage is output from the engine
controller to the fuel injector only when the en-
gine is running. When the engine stops, the out-
put also stops.
¤ If you touch the high-voltage circuit directly, there
is danger of electrocution, so when carrying out
inspection, always obey the following precau-
tions.
1. The connectors included in the high-voltage cir-

cuit are as follows.
• Engine controller connectors:
CN1, CN2, CN4, CN6, CN7
• Relay connectors:
EG4, EG5
• Injector connectors:
CN1, CN2, CN3, CN4, CN5, CN6
• Terminals at injector ahead (inside the head
cover)
2. Always turn the starting switch OFF before dis-

connecting or connecting the connectors.
3. Never start the engine if a T-adapter has been in-

serted or connected to the connector.
★ Operate the starting switch only to the OFF
or ON positions. Never turn it to the START
position.
20-148 HM300-1
c 1 c
(8)
TESTING AND ADJUSTING ADJUSTING TRANSMISSION CONTROLLER
ADJUSTING TRANSMISSION 2. Adjusting transmission

★ After carrying out any of the following opera-
CONTROLLER tions, adjust the transmission in order to ad-
just the fitting between the transmission and
1. Setting rotary switch
• When the transmission has been over-
★ If the transmission controller has been re-
hauled or replaced
placed, set the rotary switches for the net-
• When the transmission control valve has
work data and model selection as follows.
been repaired or replaced
★ Use a precision cross-head screwdriver and
• When the transmission controller has
turn the rotary switch slowly.
been replaced
★ The ▲ mark on the rotary switch is the guide-
• When the power train speed sensor has
line for setting.
been repaired or replaced
1) Remove 2 grommets at the top of the con-
• When the transmission oil temperature
troller.
sensor has been repaired or replaced
2) Align the SW1 rotary switch and SW2 rotary
• When the transmission oil filter has be-
switch with the set position.
come clogged and has been cleaned
★ Rotary switches and set position
★ When adjusting the transmission, use the
Switch Purpose of switch Position
service function of the machine monitor.
SW1 Network data 8 SPECIAL FUNCTIONS OF MACHINE
SW2 Model data 0 MONITOR.
HM300-1 20-149
1 ! !
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN
TESTING AND ADJUSTING ELECTRICAL SYSTEM
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS

FAILURE IN ELECTRICAL SYSTEM
If any problem occurs in the electrical system of the engine control system or transmission control system, it may
become impossible to start the engine or to move the machine off.
If such a problem occurs, temporarily restore the engine electrical system or transmission electrical system,
move the machine to a safe place, then carry out troubleshooting.
1. When problem occurs in engine control system and engine cannot be started
★ Decide the escape method according to the following flowchart.
★ For details of the method of checking the service code, see SPECIAL FUNCTIONS OF MACHINE MON-
ITOR.
1 2
Did [Engine system
caution lamp] on NO NO Tow machine to safe
Is there fuel in fuel tank?
machine monitor flash place (see note)
when engine stopped?
YES YES
3 4 5
Does engine start when If there is no relay to
Is following service code following fuse is replaced? Does engine start when
YES NO NO replace or engine does
displayed or recorded? • Fuse unit (30A) following relay is replaced?
not start, tow machine to
• DB22KK (ENG) • BT2-No. 2 (10A) • R36 (engine power relay)
• BT4-No. 4 (10A) safe place (see note)
NO YES YES
Start engine and move

machine (do not turn
electric power ON except
when absolutely
necessary)
6 7
Is following service code Does engine start when If there is no controller to

YES NO
displayed or recorded? engine controller is replace, tow machine to
• DB20KT (ENG) replaced? safe place (see note)
NO YES
8 9
Is following service code Does engine start when If there is no speed
displayed or recorded? following speed sensor is
YES NO sensor to replace or
• DLE3LC (ENG) (Ne speed replaced? engine does not start, tow
sensor system)
• Ne speed sensor (Ne) machine to safe place
• DLH1LC (ENG) (G speed (see note)
sensor system) • G speed sensor (G)
NO YES
10
Does engine start when Start engine and move
following relay is replaced? YES machine (do not turn
electric power ON except
• R02 (transmission neutral when absolutely
relay) necessary)
NO
Note: If the engine cannot be started and the machine is towed, the parking
Tow machine to safe
brake cannot be released by operating the switch, so carry out the opera-
place (see note)
tion to release it temporarily. For details, see METHOD FOR EMERGEN-
CY RELEASE OF PARKING BRAKE.
20-150 HM300-1
! 1 !
2. When problem occurs in transmission control system and machine cannot be started
★ Check the service code and determine the escape method from the following chart.
★ For details of the method of checking the service code, see SPECIAL FUNCTIONS OF MACHINE MON-
ITOR.
Service Condition when Lever position for speed range to

Escape method Remarks
code failure occurred move off after escape operation
1380MW Occurrence condition 1 Escape procedure 1 D – 1: F2, R1 – R2: R1
Occurrence condition 1:
1500LO Occurrence condition 2 Escape procedure 2 — Speed range remains fixed;
15GOMW Occurrence condition 2 Escape procedure 3 D – 1: F2 when the machine is moved off
15HOMW Occurrence condition 3 Escape procedure 1 D – 1: F1, R1 – R2: R1 again, speed range does not shift
15JOMW Occurrence condition 3 Escape procedure 1 D – 1: F2, R1 – R2: R1 ★ When lever is returned to N,
15KOMW Occurrence condition 2 Escape procedure 3 D – 1: F3, R1 – R2: R2 transmission shifts to neutral
15LOMW Occurrence condition 2 Escape procedure 3 D – 1: F2, R1 – R2: R1 Occurrence condition 2:
15MOMW Occurrence condition 2 Escape procedure 3 D – 1: F2, R1 – R2: R1 Transmission suddenly shifts to
15SBL1 Occurrence condition 3 Escape procedure 1 R1 – R2: R1 neutral when the machine is trav-
15SBMA Occurrence condition 3 Escape procedure 1 D – 1: F2 eling; after machine is stopped,
transmission stays in neutral
15SCL1 Occurrence condition 3 Escape procedure 1 D – 1: F2
even when lever is operated, and
15SCMA Occurrence condition 3 Escape procedure 1 D – 1: F1, R1 – R2: R1
machine does not move off
15SDL1 Occurrence condition 3 Escape procedure 1 D – 1: F1
15SDMA Occurrence condition 3 Escape procedure 1 D – 1: F2, R1 – R2: R1 Occurrence condition 3:
Transmission suddenly shifts to
15SEL1 Occurrence condition 3 Escape procedure 1 D – 1: F2, R1 – R2: R1
neutral
15SEMA Occurrence condition 3 Escape procedure 1 D – 1: F3, R1 – R2: R2
15SFL1 Occurrence condition 3 Escape procedure 1 D – 1: F3, R1 – R2: R2 Occurrence condition 4:
After engine is started, transmis-
15SFMA Occurrence condition 3 Escape procedure 1 D – 1: F2, R1 – R2: R1
sion stays in neutral even when
15SGL1 Occurrence condition 3 Escape procedure 1 D – 1: F5, R1 – R2: R3 or equivalent lever is operated, and machine
15SGMA Occurrence condition 3 Escape procedure 1 D – 1: F2, R1 – R2: R1 does not move off
15SJL1 Occurrence condition 1 Escape procedure 1 D – 1: F2, R1 – R2: R1
Occurrence condition 5:
15SJMA Occurrence condition 1 Escape procedure 1 D – 1: F2, R1 – R2: R1
Response of lever becomes ab-
Normal travel possible if display re- normal; lever does not work as
D1B0KZ Occurrence condition 2 Escape procedure 4
turns to normal (Note 1) operated
Normal travel possible if display re- When lever is operated, trans-
DAQ0KK Occurrence condition 2 Escape procedure 5
turns to normal (Note 1) mission shifts to neutral
Normal travel possible if display re-
DAQ2KK Occurrence condition 2 Escape procedure 4 Occurrence condition 6:
turns to normal (Note 1)
Speed range remains fixed;
Normal travel possible if display re- when the machine is moved off
DAQ3KK Occurrence condition 2 Escape procedure 6
turns to normal (Note 1) again, speed range does not shift
DAQ9KM Occurrence condition 4 Escape procedure 7
Normal travel possible if display re- ★ When lever is returned to N,
turns to normal (Note 1) transmission shifts to neu-
Normal travel possible if display re- tral, but after that, transmis-
DAQ9KQ Occurrence condition 4 Escape procedure 7
turns to normal (Note 1) sion does not shift to any
Normal travel possible if display re- speed range
DAQAKQ Occurrence condition 4 Escape procedure 7
turns to normal (Note 1) Note 1:
DDTGKA Occurrence condition 1 Escape procedure 1 D – 1: F2, R1 – R2: R1 Even when the machine condi-
DDTHKA Occurrence condition 1 Escape procedure 1 D – 1: F2 tion is restored after a failure, the
DDTJKA Occurrence condition 1 Escape procedure 1 D – 1: F1 neutral condition is maintained
DDTKKA Occurrence condition 1 Escape procedure 1 D – 1: F2, R1 – R2: R1 until the lever is returned to the N
DDTLKA Occurrence condition 1 Escape procedure 1 D – 1: F3, R1 – R2: R2 position.
DDTMKA Occurrence condition 1 Escape procedure 1 D – 1: F5, R1 – R2: R3 or equivalent Note 2:
DDTNKA Occurrence condition 1 Escape procedure 1 R1 – R2: R1 This phenomenon applies when
Normal travel possible if display re- there is no display on the ma-
DF10KA Occurrence condition 5 Escape procedure 8 chine monitor and there is also
Normal travel possible if display re- no display in the display window
DF10KB Occurrence condition 2 Escape procedure 8 of the transmission controller.
DLE2KA Occurrence condition 1 Escape procedure 1 D – 1: F2, R1 – R2: R1
DLE2LC Occurrence condition 1 Escape procedure 1 D – 1: F2, R1 – R2: R1
DLF1KA Occurrence condition 1 Escape procedure 1 D – 1: F2, R1 – R2: R1
DLF1LC Occurrence condition 1 Escape procedure 1 D – 1: F2, R1 – R2: R1
HM300-1 20-151
1 c
(9) c
Service Condition when Lever position for speed range to

Escape method Remarks
code failure occurred move off after escape operation
DLF2KA Occurrence condition 1 Escape procedure 1 D – 1: F2, R1 – R2: R1
Note 1:
DLF2LC Occurrence condition 1 Escape procedure 1 D – 1: F2, R1 – R2: R1 Even when the machine condi-
DLT3KA Occurrence condition 6 Escape procedure 3 D – 1: F2, R1 – R2: R1 tion is restored after a failure, the
DLT3LC Occurrence condition 6 Escape procedure 3 D – 1: F2, R1 – R2: R1 neutral condition is maintained
DXH1KB Occurrence condition 1 Escape procedure 1 D – 1: F2, R1 – R2: R1 until the lever is returned to the N
DXH2KA Occurrence condition 3 Escape procedure 1 D – 1: F1, R1 – R2: R1 position.
DXH2KB Occurrence condition 3 Escape procedure 1 D – 1: F1 Note 2:
DXH3KA Occurrence condition 3 Escape procedure 1 D – 1: F2, R1 – R2: R1 This phenomenon applies when
DXH3KB Occurrence condition 3 Escape procedure 1 D – 1: F2, R1 – R2: R1 there is no display on the ma-
DXH4KA Occurrence condition 3 Escape procedure 1 D – 1: F3, R1 – R2: R2 chine monitor and there is also
no display in the display window
DXH4KB Occurrence condition 3 Escape procedure 1 D – 1: F3, R1 – R2: R2
of the transmission controller.
DXH5KA Occurrence condition 3 Escape procedure 1 D – 1: F2, R1 – R2: R1
DXH6KA Occurrence condition 3 Escape procedure 1 D – 1: F2, R1 – R2: R1
DXH7KA Occurrence condition 3 Escape procedure 1 D – 1: F2
DXH7KB Occurrence condition 3 Escape procedure 1 D – 1: F1
Normal travel possible if display re-
— (Note 2) Occurrence condition 2 Escape procedure 5
Escape procedure 1:
1) Stop traveling and return the gearshift lever to the N position.
2) Operate the gearshift lever again and move the machine off.
★ When operating the gearshift lever, release the accelerator pedal.
★ N → D or N → R1 – R2
Escape procedure 2:
Tow the machine.
★ If the engine cannot be started and the machine is towed, the parking brake cannot be released by operating
the switch, so carry out the operation to release it temporarily. For details, see METHOD FOR EMERGEN-
CY RELEASE OF PARKING BRAKE.
Escape procedure 3:
1) Stop traveling and return the gearshift lever to the N position.
2) Connect and disconnect emergency escape connectors A1 (female) and A2 (male), and switch to the emer-
gency escape mode.
★ Connectors A1 and A2 are installed to the front of the transmission controller.
★ Connect and disconnect the connectors with the starting switch at ON or with the engine started.
3) Operate the gearshift lever again and move the machine off.
★ When operating the gearshift lever, release the accelerator pedal.
★ N → D or N → R1 – R2
★ The emergency escape mode is maintained until the starting switch is turned OFF.
20-152 HM300-1
c 1 c
Escape procedure 4:
Replace the transmission cut relay.
• Transmission cut relay: R15
Escape procedure 5:
Check the circuit breaker and fuse, and if they are normal, replace the transmission controller.
• Circuit breaker: No. 64, 65 (80A)
• Fuse: BT3-No. 14 (10A)
Escape procedure 6:
Check the fuse unit and fuse, and if they are normal, replace the transmission controller.
• Fuse unit: Inside battery housing (30A)
• Fuse: BT2-No. 22 (10A)
Escape procedure 7:
Check the model selection setting, and if it is normal, replace the transmission controller.
★ For details of checking the model selection setting, see ADJUSTING TRANSMISSION CONTROLLER.
Escape procedure 8:
Check the fuse, and if it is normal, replace the gearshift lever.
• Fuse: BT3-No. 10 (10A)
HM300-1 20-153
1 ! !
TESTING AND ADJUSTING ADJUSTING MACHINE MONITOR
ADJUSTING MACHINE MONITOR

Machine monitor rotary switches (SW1, SW2, SW3), dipswitches (SW5, SW6), and option setting con-
nectors (OP1 – OP7)
20-154 HM300-1
! 1 !
• In the following cases, check the settings of the rotary switches, dipswitches, and option setting connectors
at the rear face of the machine monitor, and change the settings as necessary.
• When the machine monitor has been removed and installed again
• When the tire size has been changed (travel speed compensation setting)
• When the exhaust brake has been installed or removed (exhaust brake setting)
• When the left and right differential lock has been installed or removed (left and right differential lock set-
ting)
• When parts have been replaced with new parts (service meter, odometer, reverse travel odometer set-
ting)
★ When carrying out of these settings, it is necessary to use the special operation of the character dis-
play and mode switch, so see SPECIAL FUNCTIONS OF MACHINE MONITOR.
• When service code [DAF0KM] is displayed
★ There is probably mistaken connection of the option setting connector, so see TROUBLESHOOT-
ING OF MACHINE MONITOR SYSTEM (MON MODE) for details.
• Condition of switch setting functions and option setting connectors
Switch Position Purpose of switch Connector Remarks
SW1 0–F Travel speed compensation Not needed For standard tires, set to position 7
SW2 0–F Not used (always set to 0) OP3 always released
SW3 0–F Not used (always set to 0) Not needed
OFF Odometer display unit: km Set to ON only in areas where mile

1 Not needed
ON Odometer display unit: Mile display is used
OFF Exhaust brake: Not installed Released

2 OP1
ON Exhaust brake: Installed Connected
SW5
OFF
3 Not used (always set to 0) OP2 always released
ON
OFF Left and right differential lock: Not installed Released

4 OP4
ON Left and right differential lock: Installed Connected
OFF
ON
OFF
ON
SW6
OFF
3 Not used (always set to 0) Not needed
ON
OFF
4 Not used (always set to 0) Not needed
ON
• The condition of each switch and connector can be checked with the special function of the machine monitor
(monitoring function).
• Connector OP7 is used for the special function of the machine monitor.
★ For details, see SPECIAL FUNCTIONS OF MACHINE MONITOR.
HM300-1 20-155
1 c
(9) c
★ All setting operations are carried out with the 1. Setting rotary switch SW1
starting switch OFF and the monitor panel re- Rotary switch SW1 is used to set the travel
moved. speed compensation. The machine monitor
★ Always set each switch and connector as in- uses the size of the standard tire to calculate the
structed. travel speed.
★ Be careful not to touch anything inside the grom- If the tire size is changed, adjust the position of
met except for the switch. the switch to compensate for the speed display.
★ When turning the rotary switch, use a precision ★ Tire size and setting position
cross-head screwdriver and turn slowly.
★ The protruding triangular part of the rotary switch Tire size SW1 Connector Remarks
is the setting arrow. 23.5 R25 7 Not needed HM300-1 standard tire
★ When changing the dipswitch, use a precision
flat-headed screwdriver and turn slowly. ★ The connector in the table indicates the
★ When setting, always avoid foreign matters or number of the connector to be connected or
dust. released when changing the setting. (In the
★ After setting, be sure to install grommet. case of SW1, there is no need to connect or
release the connector.)
★ Travel speed compensation using SW1
Speed Speed
Position Position
compensation compensation
0 + 7% 8 0%
1 + 6% 9 – 1%
2 + 5% A – 2%
3 + 4% B – 3%
4 + 3% C – 4%
5 + 2% D – 5%
6 + 1% E – 6%
7 0% F – 7%
2. Setting rotary switch SW2

Rotary switch SW2 is set as follows. The setting
must not be changed.
• Set position of SW2: 0
• Connector OP3: Released
3. Setting rotary switch SW3

Rotary switch SW3 is set as follows. The setting
• Set position of SW3: 0
• Connector setting: Not needed
20-156 HM300-1
c 1 c
4. Setting dipswitch SW5-1 8. Setting dipswitch SW6-1

Dipswitch SW5-1 is set as follows. The setting Dipswitch SW6-1 is set as follows. The setting
must not be changed. must not be changed.
• Set position of dipswitch SW6-1: OFF
Monitor • Connector OP5: Released
SW5-1 Connector Remarks
Part No.
Distance: 9. Setting dipswitch SW6-2
7831-46-100* OFF
Not Displayed in km Dipswitch SW6-2 is set as follows. The setting
Needed Distance: must not be changed.
7861-46-200* ON • Set position of dipswitch SW6-2: OFF
Displayed in Miles
★ The connector in the table indicates the num-
ber of the connector to be connected or re- 10. Setting dipswitch SW6-3
leased when changing the setting. (In the Dipswitch SW6-3 is set as follows. The setting
case of SW5-1, there is no need to connec- must not be changed.
tor or release the connector.) • Set position of dipswitch SW6-3: OFF
• Connector operation: Not needed
5. Setting dipswitch SW5-2
Use dipswitch SW5-2 to set the exhaust brake. 11. Setting dipswitch SW6-4
When the exhaust brake has been installed or Dipswitch SW6-4 is set as follows. The setting
removed, set as follows. must not be changed.
Connector • Connector operation: Not needed
Exhaust brake SW5-2 Remarks
OP1
Not installed OFF Released
Installed ON Connected

Dipswitch SW5-3 is set as follows. The setting

Use dipswitch SW5-4 to set the left and right dif-
ferential lock.
When the left and right differential lock has been
installed or removed, set as follows.
Left and right Connector

SW5-4 Remarks
differential lock OP4
Not installed OFF Released
Installed ON Connected
HM300-1 20-157
1 ! !
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MACHINE MONITOR
SPECIAL FUNCTIONS OF MACHINE MONITOR
Normal functions and the special functions of machine monitor

The machine monitor is equipped with normal functions and special functions. Various items of data are dis-
played on the character display in the middle of the machine monitor. The display items are divided by the in-
ternal setting of the machine monitor, into automatic display items and items displayed when the machine
monitor switches are operated.
1) Normal functions: Operator mode
Functions for which the content is normally displayed or which can be displayed and operated by the oper-
ator operating the switches.
2) Special functions: Service mode
Functions which the serviceman can display and operate with the special switches to carry out inspection,
maintenance, and troubleshooting.
Operator mode ⇔ Service mode

Service meter, odometer display Electrical system trouble data
1 8
function (default) display function
Distance traveled in reverse dis- Mechanical system trouble data
2 9
play function display function
Filter, oil replacement interval 10 Machine data monitoring function
3
display function 11 Reduced cylinder mode
4 Telephone number input function 12 Adjustment function
5 Language selection function Filter, oil replacement time set-
13
6 Action code display function ting function
7 Failure code display function Initialize function (exclusive func-
14
tion for factory)
20-158 HM300-1
! (7)
1 !
Flow of modes and functions
Operator mode
2 Distance traveled in reverse display function
[>] [<]
Filter, oil replacement interval
3
Service meter, odometer ["] display function
1
display function (default) [>] [<]
[#] 4 Telephone number input function
[>] [<]
5 Language selection function
[>] [<]
(Automatic) 2 Distance traveled in reverse display function 1 Meter display function
[>] [<]
Failure code display func-
6 Action code display function [>] 7
tion
[#] & [ < ] + (ID input: 6491) [#]
Service mode
8 Electrical system trouble data display function
[>] [<]
9 Mechanical system trouble data display function
[>] [<]
10 Machine data monitoring function Sub menu: 5 types
[>] [<]
11 Reduced cylinder mode
[>] [<]
12 Adjustment function Sub menu: 2 types
[>] [<]
Filter, oil replacement time
13
setting function
[>] [<]
14 Initialize function (Exclusive function for factory)
[>] [<]
8 Electrical system trouble data display function
HM300-1 20-159
(7)
1 ! !
Operator mode
★ No. 2 – No. 5 give an endless display according to the operation of the switch.
★ When a failure occurs, the screen changes automatically to No. 6, regardless of the display screen.
★ Regardless of the display screen, if no switch is operated for more than 30 seconds, the screen automati-
cally changes as follows.
• Goes to No. 1: If there is no failure
• Goes to No. 6: If there is a failure
★ From No. 7 the screen changes to No. 1 with the switch operation, and if no switch is operated for more than
10 seconds, the screen automatically changes to No. 6.
Service mode
★ No. 8 – No. 14 give an endless display according to the operation of the switch.
★ Once the ID is input and confirmed, it remains effective until the starting switch is turned OFF.
Character display
The character display consists of a top line and bot-
tom line with 16 characters each. A combination of
the following characters (alphabet and numerals)
and symbols is displayed according to the content.
1) Numerals: 1, 2, 3 . . .
2) Small letters: a, b, c . . .
3) Capital letters: A, B, C . . .
4) Katakana: Japanese display only
5) Symbols: @, ¥, $ . . .
6) Special characters
Control switches
Control of the machine monitor display is all carried
out with machine monitor mode selector switches (1)
and (2).
The following functions are provided for the buttons
of each switch.
1) ": Select, Run
2) #: Cancel, Release, Select (YES/NO only)
3) > : Right, Next, Continue
4) < : Left, Previous, Return
20-160 HM300-1
! (7)
1 !
Operation and displays for operator mode

1. Service meter, odometer display function
When the starting switch is turned ON, the top
line shows the service meter and the bottom line
shows the odometer (Fig. 1)
★ For details, see STRUCTURE AND FUNC-
TION, Machine monitor system.
2. Distance traveled in reverse display function

Use the switch to display the total distance trav-
eled in reverse of the machine monitor (Fig. 2)
3. Filter, oil replacement interval display func-

tion
1) Filter, oil replacement time display (automat-
ic display)
When the replacement interval for the filters
or oil approaches, this information is auto-
matically displayed on the machine monitor
to recommend the operator to carry out
maintenance (Fig. 3: example).
2) Resetting replacement time (selection menu)

When the maintenance operation for the fil-
ters and oil replacement has been complet-
ed, the switches on the machine monitor can
be used to reset the interval (Fig. 4)
★ The replacement time can be set using Ser-
vice mode.
HM300-1 20-161
(7)
1 ! !
4. Telephone number input function

The telephone number set inside the machine
monitor can be input, corrected, or canceled by
operating the switches (Fig. 5).
★ When action code [E03] is displayed, the
telephone number is displayed at the same
time as [CALL].
5. Language selection function

The language used for the machine monitor dis-
play can be selected by operating the switches
(Fig. 6)
★ The functions of Service mode are not in-
cluded in the functions for display selection,
so they are always displayed in English.
6. Action code display function

If any abnormality occurs on the machine, the
degree of the abnormality is automatically dis-
played as a user code on the machine monitor to
recommend appropriate action to the operator
(Fig. 7).
★ The diagram on the right shows an example
of action code [E03] and [CALL+ Telephone
number] being displayed in turn.
★ When action codes [E01] and [E02] are dis-
played, [CALL+ Telephone number] is not
displayed.
★ Correspondence between user code and recommendation to operator
Action code CALL+ Telephone number Action recommended to operator
• Carry out inspection and maintenance after completion of opera-

E01 Not displayed
tions or when changing shifts between operators
• When overrun related display is shown:

Reduce engine speed and machine speed while continuing oper-
ations.
E02 Not displayed
• When overheat related display is shown:
Stop machine and keep engine running at mid-range speed under
no load.
E03 Displayed • Stop engine and machine immediately and contact serviceman.
20-162 HM300-1
! (7)
1 !
7. Failure code display function

While the action code is being displayed on the
machine monitor, press the [ > ] button once to
display the failure codes for the existing failures
(Fig. 8: example).
• [ > ] Button: Displays failure code
★ The failure codes detected in the past are di-
vided into failures of the electrical system
and the mechanical system and are record-
ed as trouble data. (For details, see Service
mode.)
★ If more than one failure is occurring, press
the [ > ] button once more to display the other
failure codes.
★ After pressing the [ > ] button to display all
the existing failures, press the [ > ] button
once more to return to the service meter/
odometer display screen.
If the [ > ] button is pressed once more, the
failure codes will be displayed again from the
beginning.
If the switch is not operated for 10 seconds,
the display will switch automatically to the
action code screen.
★ With the service code display function, the
following data are displayed (Fig. 9).
A: Failure code
(4 digits for location code + 2 digits for
problem code)
B: Controller code
(MON: Machine monitor)
(ENG: Engine controller)
(TM: Transmission controller)
(BK: Retarder controller)
C: System with problem
★ For details of the displayed failure codes,
see FAILURE CODE TABLE.
★ With the failure code display function and
trouble data display function (Service mode),
the data that are displayed are partially dif-
ferent.
★ If no switch is operated on the failure code
display screen for more than 30 seconds, the
display automatically returns to the action
code display screen.
HM300-1 20-163
(7)
1 ! !
Failure code table
Failure Location of failure Nature of failure Action

Controller
code (location, component with failure) (problem, nature of failure) code
1380MW Lock-up clutch Slipping (MW) TM E03
1500LO Transmission clutch q See separate table (L0) TM E03
15BONX Transmission oil filter Clogged (NX) TM E01
15GOMW R clutch Slipping (MW) TM E03
15HOMW Hi clutch Slipping (MW) TM E03
15JOMW Lo clutch Slipping (MW) TM E03
15KOMW 1st clutch Slipping (MW) TM E03
15LOMW 2nd clutch Slipping (MW) TM E03
15MOMW 3rd clutch Slipping (MW) TM E03
15SBL1 ECMV for R clutch q See separate table (L1) TM E03
15SBMA ECMV for R clutch Function impossible (MA) TM E03
15SCL1 ECMV for Hi clutch q See separate table (L1) TM E03
15SCMA ECMV for Hi clutch Function impossible (MA) TM E03
15SDL1 ECMV for Lo clutch q See separate table (L1) TM E03
15SDMA ECMV for Lo clutch Function impossible (MA) TM E03
15SEL1 ECMV for 1st clutch q See separate table (L1) TM E03
15SEMA ECMV for 1st clutch Function impossible (MA) TM E03
15SFL1 ECMV for 2nd clutch q See separate table (L1) TM E03
15SFMA ECMV for 2nd clutch Function impossible (MA) TM E03
15SGL1 ECMV for 3rd clutch q See separate table (L1) TM E03
15SGMA ECMV for 3rd clutch Function impossible (MA) TM E03
15SJL1 ECMV for lock-up clutch q See separate table (L1) TM E03
15SJMA ECMV for lock-up clutch Function impossible (MA) TM E03
15SKL1 ECMV for inter-axle differential lock clutch q See separate table (L1) TM E03
15SKMA ECMV for inter-axle differential lock clutch Function impossible (MA) TM E01
2B61MW Inter-axle differential lock clutch Slipping (MW) TM E01
2C4MNX Brake cooling filter Clogged (NX) BK E01
2D01CA Front brake (right) Wear (CA) BK E01
2D02CA Front brake (left) Wear (CA) BK E01
2D03CA Center brake (right) Wear (CA) BK E01
2D04CA Center brake (left) Wear (CA) BK E01
2F00KM Parking brake Mistaken operation or mistaken setting (KM) TM —
2G42ZG Accumulator (front) Drop in oil pressure (ZG) BK E03
2G43ZG Accumulator (rear) Drop in oil pressure (ZG) BK E03
6014NX Hydraulic tank filter Clogged (NX) TM E01
989A00 Engine overrun prevention command signal Actuated (00) TM E02
989AKZ Engine overrun prevention command signal Disconnection or short circuit (KZ) TM E01
989D00 Rear overturn signal Actuated (00) TM —
A000N1 Engine Overrun (N1) ENG E02
20-164 HM300-1
c 1 c
4

Controller
A570NX Engine oil filter Clogged (NX) ENG E01
AA10NX Air cleaner element Clogged (NX) TM E01
AB00MA Alternator Function impossible (MA) TM E03
AD00L2 Common rail q See separate table (L2) ENG E03
AD00MA Common rail Function impossible (MA) ENG E03
AD10L3 Fuel supply pump q See separate table (L3) ENG E03
AD10MA Fuel supply pump Function impossible (MA) ENG E03
AD10MB Fuel supply pump Drop in function (MB) ENG E03
AD11KA Fuel supply pump solenoid valve 1 Disconnection (KA) ENG E03
AD11KB Fuel supply pump solenoid valve 1 Short circuit (KB) ENG E03
AD51KA Fuel supply pump solenoid valve 2 Disconnection (KA) ENG E03
AD51KB Fuel supply pump solenoid valve 2 Short circuit (KB) ENG E03
ADA1KA No. 1 injector solenoid valve Disconnection (KA) ENG E03
ADAZKB No. 1, 2, 3 injector solenoid valve Short circuit (KB) ENG E03
ADB1KA No. 2 injector solenoid valve Disconnection (KA) ENG E03
ADC1KA No. 3 injector solenoid valve Disconnection (KA) ENG E03
ADD1KA No. 4 injector solenoid valve Disconnection (KA) ENG E03
ADDZKB No. 4, 5, 6 injector solenoid valve Short circuit (KB) ENG E03
ADE1KA No. 5 injector solenoid valve Disconnection (KA) ENG E03
ADF1KA No. 6 injector solenoid valve Disconnection (KA) ENG E03
B@BAZG Engine oil Drop in oil pressure (ZG) ENG E03
B@BAZK Engine oil Drop in level (ZK) ENG E01
B@BCNS Radiator coolant Overheat (NS) ENG E02
B@BCZK Radiator coolant Drop in level (ZK) TM E01
B@C6NS Front brake oil Overheat (NS) MON E02
B@C8NS Center brake oil Overheat (NS) MON E02
B@CENS Torque converter Overheat (NS) MON E02
B@HAZK Hydraulic tank oil Drop in level (ZK) TM E01
B@JANS Steering oil Overheat (NS) TM E02
D181KZ Preheating relay contact Disconnection or short circuit (KZ) ENG E03
D182KZ Preheating relay coil Disconnection or short circuit (KZ) ENG E03
D1B0KZ Transmission cut relay Disconnection or short circuit (KZ) TM E03
D1C0KZ Brake cut relay Disconnection or short circuit (KZ) BK E03
D1D0KB Engine controller load power source relay Short circuit (KB) ENG E01
D5ZAKX Engine throttle correction 1 signal Input signal outside range (KX) ENG E01
D5ZBKX Inter-axle differential lock command signal Input signal outside range (KX) TM E01
D5ZCKZ Exhaust brake command signal Disconnection or short circuit (KZ) TM E01
D5ZDL4 Forced neutral demand signal q See separate table (L4) TM E01
D5ZEKX Engine load signal Input signal outside range (KX) TM E01
HM300-1 20-165
1 c
(9) c

Controller
D5ZFKZ Neutral signal 1 Disconnection or short circuit (KZ) BK E01
D5ZGKZ Neutral signal 2 Disconnection or short circuit (KZ) BK E01
(DAF0KM) Monitor panel Mistaken operation or mistaken setting (KM) MON E03
(DAF9KM) Monitor panel Mistaken operation or mistaken setting (KM) MON E03
DAFSKQ Monitor panel Non match in model selection signal (KQ) MON E03
DAQ0KK Transmission controller Drop in power source voltage, input (KK) TM E03
DAQ1KK Transmission controller main power supply line Drop in power source voltage, input (KK) TM E03
DAQ2KK Transmission controller load power supply line Drop in power source voltage, input (KK) TM E03
DAQ3KK Transmission controller battery direct power supply line Drop in power source voltage, input (KK) TM E03
DAQ5KP Transmission controller power supply output 1 Drop in output voltage (KP) TM E03
(DAQ9KM) Transmission controller wiring harness Mistaken operation or mistaken setting (KM) TM E03
(DAQ9KQ) Transmission controller wiring harness Non match in model selection signal (KQ) TM E03
(DAQAKQ) Transmission controller rotary switch Non match in model selection signal (KQ) TM E03
Defective transmission, abnormality in ap-
DAQSKR Transmission controller S-NET MON E03
plicable component system (KR)
DAQSMA Transmission controller Function impossible (MA) TM E03
DB10KK Retarder controller(q1) Drop in power source voltage, input (KK) BK E03
DB11KK Retarder controller(q1) main power supply line Drop in power source voltage, input (KK) BK E03
DB12KK Retarder controller(q1) load power supply line Drop in power source voltage, input (KK) BK E03
DB13KK Retarder controller(q1) battery direct power supply line Drop in power source voltage, input (KK) BK E03
(DB19KM) Retarder controller(q1) wiring harness Mistaken operation or mistaken setting (KM) BK E03
DB1SKQ Retarder controller(q1) S-NET line Non match in model selection signal (KQ) BK E03
DB1SKR Retarder controller(q1) S-NET MON E03
DB20KT Engine controller Abnormality inside controller (KT) ENG E03
DB22KK Engine controller load power supply line Drop in power source voltage, input (KK) ENG E03
DB29KQ Engine controller connecting wiring harness Non match in model selection signal (KQ) ENG E03
DB2AMA Engine controller fuel injection quantity control switch Function impossible (MA) ENG E01
DB2SKR Engine controller S-NET MON E03
DD11KB Starting switch Short circuit (KB) ENG E03
DDA1L5 Accelerator switch q See separate table (L5) ENG E01
DDE2L6 Engine oil pressure switch q See separate table (L6) ENG E01
DDTFKA Fill switch for inter-axle differential lock clutch Disconnection (KA) TM E01
DDTGKA Fill switch for lock-up clutch Disconnection (KA) TM E03
DDTHKA Fill switch for Hi clutch Disconnection (KA) TM E03
DDTJKA Fill switch for Lo clutch Disconnection (KA) TM E03
DDTKKA Fill switch for 1st clutch Disconnection (KA) TM E03
DDTLKA Fill switch for 2nd clutch Disconnection (KA) TM E03
DDTMKA Fill switch for 3rd clutch Disconnection (KA) TM E03
DDTNKA Fill switch for R clutch Disconnection (KA) TM E03
DF10KA Gearshift lever Disconnection (KA) TM E03
20-166 HM300-1
c 1 c
4

Controller
DF10KB Gearshift lever Short circuit (KB) TM E03
Engine coolant temperature sensor
DGE2KX Input signal outside range (KX) ENG E01
(for high temperature)
DGE3L6 Engine coolant temperature sensor (for low temperature) q See separate table (L6) ENG E01
DGE4KX Fuel temperature sensor Input signal outside range (KX) ENG E01
DGF1KX Transmission valve oil temperature sensor Input signal outside range (KX) TM E03
DGR3L8 Brake oil temperature sensor (center) q See separate table (L8) TM E01
DGR4L8 Brake oil temperature sensor (front) q See separate table (L8) TM E01
DGT1KX Torque converter oil temperature sensor Input signal outside range (KX) TM E01
DH30KX Boost pressure sensor Input signal outside range (KX) ENG E01
DH40KX Common rail pressure sensor Input signal outside range (KX) ENG E03
DHT5KX Torque converter oil pressure sensor Input signal outside range (KX) TM E01
DHT5L6 Torque converter oil pressure sensor q See separate table (L6) TM E01
DHU2KX Accumulator oil pressure sensor (front) Input signal outside range (KX) BK E01
DHU3KX Accumulator oil pressure sensor (rear) Input signal outside range (KX) BK E01
DJF1KA Fuel level sensor Disconnection (KA) TM E01
DK10KX Throttle angle sensor Input signal outside range (KX) ENG E03
DK11KX Throttle angle sensor Input signal outside range (KX) TM E03
DK51L5 Retarder lever potentiometer q See separate table (L5) BK E03
DK52KX Dump lever potentiometer 1 Input signal outside range (KX) BK E03
DK53L8 Dump lever potentiometer 2 q See separate table (L8) BK E03
DK54KX Body position sensor Input signal outside range (KX) BK E03
DLE2KA Engine speed sensor Disconnection (KA) TM E03
DLE2LC Engine speed sensor q See separate table (LC) TM E03
DLE3LC Engine Ne speed sensor q See separate table (LC) ENG E03
DLF1KA Transmission input shaft speed sensor Disconnection (KA) TM E03
DLF1LC Transmission input shaft speed sensor q See separate table (LC) TM E03
DLF2KA Transmission intermediate shaft speed sensor Disconnection (KA) TM E03
DLF2LC Transmission intermediate shaft speed sensor q See separate table (LC) TM E03
DLF4KA Transmission output shaft F speed sensor Disconnection (KA) BK E01
DLH1LC Engine G speed sensor q See separate table (LC) ENG E03
DLT3KA Transmission output shaft R speed sensor Disconnection (KA) TM E03
DLT3KA Transmission output shaft R speed sensor Disconnection (KA) BK E01
DLT3LC Transmission output shaft R speed sensor Separate table (LC) TM E03
DV00KB Alarm buzzer Short circuit (KB) MON E01
DW71KZ Exhaust brake solenoid Disconnection or short circuit (KZ) BK E01
DW72KZ Dump lever kick-out solenoid Disconnection or short circuit (KZ) BK E01
DW73KZ Dump selector valve solenoid Disconnection or short circuit (KZ) BK E03
DX11KA Rear brake reducing pressure valve solenoid Disconnection (KA) BK E03
DX11KB Rear brake reducing pressure valve solenoid Short circuit (KB) BK E03
HM300-1 20-167
(9)
1 ! !

Controller
DX11KY Rear brake reducing pressure valve solenoid Short circuit in power supply line (KY) BK E03
DX12KA Front brake reducing pressure valve solenoid Disconnection (KA) BK E03
DX12KB Front brake reducing pressure valve solenoid Short circuit (KB) BK E03
DX12KY Front brake reducing pressure valve solenoid Short circuit in power supply line (KY) BK E03
DX13KA Dump EPC valve solenoid Disconnection (KA) BK E03
DX13KB Dump EPC valve solenoid Short circuit (KB) BK E03
DX13KY Dump EPC valve solenoid Short circuit in power supply line (KY) BK E03
DXH0KA Solenoid for inter-axle differential lock Disconnection (KA) TM E01
DXH0KB Solenoid for inter-axle differential lock Short circuit (KB) TM E01
DXH1KA Solenoid for lock-up clutch Disconnection (KA) TM E03
DXH1KB Solenoid for lock-up clutch Short circuit (KB) TM E03
DXH2KA Solenoid for Hi clutch Disconnection (KA) TM E03
DXH2KB Solenoid for Hi clutch Short circuit (KB) TM E03
DXH3KA Solenoid for Lo clutch Disconnection (KA) TM E03
DXH3KB Solenoid for Lo clutch Short circuit (KB) TM E03
DXH4KA Solenoid for 1st clutch Disconnection (KA) TM E03
DXH4KB Solenoid for 1st clutch Short circuit (KB) TM E03
DXH5KA Solenoid for 2nd clutch Disconnection (KA) TM E03
DXH5KB Solenoid for 2nd clutch Short circuit (KB) TM E03
DXH6KA Solenoid for 3rd clutch Disconnection (KA) TM E03
DXH6KB Solenoid for 3rd clutch Short circuit (KB) TM E03
DXH7KA Solenoid for R clutch Disconnection (KA) TM E03
DXH7KB Solenoid for R clutch Short circuit (KB) TM E03
20-168 HM300-1
c 1 c
q Separate table: Detailed phenomena of L Series problem codes (L½)
Problem code Nature
L0 Fill signals on 2 or more channels for clutches not forming a set are input at same time
L1 Fill signal is ON when command current to ECMV is OFF
L2 Fuel pressure is higher than maximum set pressure
L3 Corresponding component cannot be controlled
L4 ON/OFF signals for 2 systems do not match
L5 Potentiometer signal and switch signal do not match
Engine speed signal, terminal C signal, signals for oil pressure switch, coolant temperature switch,
L6
etc. do not match operating condition or stopped condition of machine
L8 Analog signals for 2 systems do not match
LC Speed signals for 2 systems do not match
LH Fill signal is OFF when command current to ECMV is ON
★ Failure codes with ( )

These failure codes are not recorded as trouble data for either the electrical system or the mechanical sys-
tem.
★ Controller codes and troubleshooting mode names
The controller code name shown in the Controller column and the troubleshooting mode name in the trou-
bleshooting section are linked, so check the controller code for the failure code displayed, then go to the
applicable troubleshooting mode.
ENG: Troubleshooting of engine controller system (ENG MODE)
TM: Troubleshooting of transmission controller system (TM MODE)
BK: Troubleshooting of retarder controller(q1) system (BK MODE)
MON: Troubleshooting of machine monitor system (MON MODE)
HM300-1 20-169
1 c
4
(9) c
Procedure for switching to Service mode and

screen display
★ When using Service mode, carry out the follow-
ing special operation to switch the screen dis-
play.
1) Checking screen display

With the machine monitor in the operator mode,
check that the screen is one of the following
displays: Service meter/odometer, action code,
or failure code.
2) Initial screen display for ID input

Press the following 2 buttons at the same time
for at least 5 seconds to display the initial screen
display for the ID input (Fig. 1).
• [] button and [ < ] button
★ If the buttons are held pressed for at least 5
sec, the whole screen will give no display, so
check this condition, then release the but-
tons.
3) Inputting ID, confirming

Operate the buttons to input the ID (Fig. 2).
★ ID: 6491
• [ > ] button: Number at cursor goes up
• [ < ] button: Number at cursor goes down
• [] button: Number at cursor is confirmed
• [] button: Returns to initial screen (see Note)
Note: When the cursor is at the left side, the
screen returns to the normal screen (oper-
ator mode).
If the cursor is not at the left side, the cur-
sor returns to the left side.
★ If the switch on the ID input screen is not op-
erated for more than 60 seconds, the screen
returns automatically to the normal screen.
4) Displaying menu initial screen

After confirming all 4 digits of the ID, the menu
initial screen of Service mode is displayed
(Fig. 3).
★ Once the ID has been input and confirmed, it
remains effective until the starting switch is
turned OFF.
20-170 HM300-1
c 1 c
(7)
(9)
5) Menu selection in Service mode

Press the [ > ] or [ < ] buttons on the menu screen
and the menus of Service mode are displayed
endlessly in the following order (Fig. 4).
★ The menu is displayed in the places marked
with [½].
• [ > ] button: Goes on to next menu
• [ < ] button: Goes back to previous menu
(1) ELECTRIC FAULT:
Trouble data display function for electri-
cal system
(2) MACHINE FAULT:
Trouble data display function for me-
chanical system
(3) REAL-TIME MONITOR:
Machine data monitoring function
(4) CYLINDER CUT-OUT:
Reduced cylinder mode
(5) TUNING:
Adjustment function
(6) MAINTENANCE MONITOR:
Filter, oil replacement time setting func-
tion
(7) INITIALIZE:
Initialize function (exclusive function for
factory)
6) Completion of mode, function

When operating at any point in any function, it is
possible to finish the mode or function by using
any of the following methods.
(1) When continuing operations in another
mode or function:
Press the [] button and return to the mode
screen to be used or menu screen to be
used.
★ Note that if the [] button is pressed on
the YES/NO screen, the function will be
executed.
★ If you return to the normal screen (oper-
ator mode) by mistake, repeat the proce-
dure from Step 1) above (there is no
need to input the ID again).
(2) When completing all operations:
Turn the starting switch OFF.
HM300-1 20-171
1 c
(9) c
8. Electrical system trouble data display func-

tion (ELECTRIC FAULT)
The machine monitor retains the data for prob-
lems that occurred in the electrical system in the
past as failure codes. They can be displayed as
follows.
1) Menu selection
Select the display function for trouble data on
the menu screen of Service mode (Fig. 1).
★ The total number of trouble data items
recorded in memory is displayed in the
[**] portion.
2) Trouble data display

With the menu selected, press the [] but-
ton and display the trouble data recorded in
memory (Fig. 2: example).
• [] button: Runs menu
3) Displayed trouble data

With the display function for trouble data of
the electrical system, the following data can
be displayed (Fig. 3).
1: Record number (recorded up to a maxi-
mum of 20 items)
A: Failure code (4-digit location code + 2-
digit problem code)
2: Number of occurrences (number of oc-
currences of same code in past)
3: Elapsed time 1 (time elapsed on service
meter since first occurrence)
meter since last occurrence)
★ Failure codes for problems that are still
existing are shown on a flashing display.
★ For details of the failure codes displayed,
see FAILURE CODE TABLE in the ex-
planation for the failure code display
function.
★ Note that with the trouble data display
function and failure code display function
for the electrical system, the displayed
data are partially different.
★ If no trouble data are recorded, [0] is dis-
played on the display portion for 1, and
[–] is displayed on the display portion for
A, 2, 3, and 4.
20-172 HM300-1
c 1 c
(7)
4) Switching trouble data display

If the [ > ] button or [ < ] button is pressed dur-
ing the display of trouble data, the display
switches to the other recorded trouble data.
• [ > ] button:
Goes on to data for next record num-
ber
• [ < ] button:
Goes back to data for last record
number
5) Deleting individual trouble data

i) Display the trouble data to be deleted,
then press the [] button once to display
the individual item CLEAR screen
(Fig. 4).
• [] button: Display CLEAR screen
ii) Operate the buttons according to the ex-
planation on the screen (Fig. 4).
• [ < ] button: Select YES
• [ > ] button: Select NO
• [] button: Run
★ The data for an existing problem (flash-
ing display) cannot be deleted.
6) Deleting all trouble data

i) Display the trouble data, then press the
[ > ] button or [ < ] button to display the
ALL CLEAR menu (Fig. 5).
ii) Press the [] button once to display the
ALL CLEAR screen (Fig. 6).
• [] button: Run ALL CLEAR menu
iii) Operate the buttons according to the ex-
planation on the screen (Fig. 6).
• [] button: Run
★ The data for an existing problem (flash-
ing display) cannot be deleted.
HM300-1 20-173
1 c c
9. Mechanical system trouble data display func-

tion (MACHINE FAULT)
The machine monitor retains the data for prob-
lems that occurred in the mechanical system in
the past as failure codes. They can be displayed
as follows.
1) Menu selection
Select the display function for trouble data on
the menu screen of Service mode (Fig. 1).
★ The total number of trouble data items
recorded in memory is displayed in the
[**] portion.
2) Trouble data display

With the menu selected, press the [] but-
ton and display the trouble data recorded in
memory (Fig. 2: example).
3) Displayed trouble data

With the display function for trouble data of
the mechanical system, the following data
can be displayed (Fig. 3).
1: Record number
A: Failure code (4-digit location code + 2-
digit problem code)
2: Number of occurrences (number of oc-
currences of same code in past)
meter since first occurrence)
meter since last occurrence)
★ Failure codes for problems that are still
existing are shown on a flashing display.
★ For details of the failure codes displayed,
see FAILURE CODE TABLE in the ex-
planation for the failure code display
function.
★ Note that with the trouble data display
function and failure code display function
for the mechanical system, the displayed
data are partially different.
★ If no trouble data are recorded, [0] is dis-
played on the display portion for 1, and
[–] is displayed on the display portion for
A, 2, 3, and 4.
20-174 HM300-1
c 1 c
(7)
(9)
4) Switching trouble data display

If the [ > ] button or [ < ] button is pressed dur-
ing the display of trouble data, the display
switches to the other recorded trouble data.
• [ > ] button:
Goes on to data for next record num-
ber
• [ < ] button:
Goes back to data for last record
number
5) Deleting trouble data (not permitted)

★ The trouble data for the mechanical sys-
tem cannot be deleted.
HM300-1 20-175
1 ! !
10. Machine data monitoring function (REAL-TIME

MONITOR)
The machine monitor can monitor the condition
of the machine in real time through the signals
from the sensors installed to various parts of the
machine.
In the machine data monitoring function, the fol-
lowing 2 types of display can be shown.
• 1st item independent display (for each con-
troller)
• 2nd item simultaneous display (code input)
1) Menu selection
Select the machine data monitoring function
on the menu screen of Service mode (Fig. 1).
2) Display sub menu

With the menu selected, press the [$] but-
ton and display the initial screen of the sub
menu (Fig. 2).
• [$] button: Runs menu
3) Select sub menu

If the [ > ] button or [ < ] button is pressed on
the sub menu screen, the sub menu displays
endlessly in the following order (Fig. 3).
★ The sub menu is displayed in the ["] por-
tion.
• [ > ] button: Goes on to next menu
• [ < ] button: Goes back to last menu
(1) MONITOR PANEL:
(2) TRANSMISSION:
(3) ENGINE:
(4) BRAKE:
Retarder controller system
(5) 2 ITEMS:
2-item display
20-176 HM300-1
! (7)
1 !
4) Setting 1st item individual monitoring

i) Select the controller system for monitor-
ing on the sub menu screen (Fig. 4: ex-
ample).
ii) With the menu selected, press the []
button and display the monitoring data
initial screen.
• [] button: Runs sub menu
iii) Press the [ > ] button or [ < ] button to se-
lect the item for monitoring (Fig. 5: ex-
ample).
• [ > ] button: Goes on to next item
• [ < ] button: Goes back to last item
★ Scroll the monitoring items to display
in the internally set order.
★ If the button is kept pressed, the
items will scroll at high speed.
★ To hold or cancel monitoring data:
If the [] button is pressed during moni-
toring, the monitor data is held and the
[] mark flashes. If the [] button is
pressed again, it becomes active again.
5) Display data for 1st item individual monitor-

ing
On the 1st item individual monitoring screen,
the following data are displayed (Fig. 6).
A: Item display
B: Monitoring code (5-digit)
1: Monitoring data (including unit)
★ For details, see MONITORING CODE
TABLE.
HM300-1 20-177
1 c c
6) Setting 2 items simultaneous monitoring

i) Select the 2 items display on the sub
menu screen (Fig. 7).
ii) With the menu selected, press the []
button and display the monitoring code
input screen (Fig. 8).
• [] button: Runs sub menu
iii) Operate each button and input the mon-

itoring code for the 2 monitoring items di-
rectly.
• [ > ] button:
Number at cursor goes up
• [ < ] button:
Number at cursor goes down
• [] button:
Number at cursor is confirmed
• [] button:
Returns to code input screen
iv) When both of the monitoring codes have

been confirmed, the screen switches to
the 2 items display screen (Fig. 9: exam-
ple).
★ To hold or cancel monitoring data:
If the [] button is pressed during moni-
toring, the monitoring data is held and
the [] mark flashes. If the [] button is
pressed again, it becomes active again.
7) Display data for 2 items simultaneous moni-

toring
On the 2 items simultaneous monitoring
screen, the following data are displayed
(Fig. 10).
A: Monitoring code 1
1: Monitoring data 1 (including unit)
B: Monitoring code 2
2: Monitoring data 2 (including unit)
★ For details, see MONITORING CODE
TABLE.
20-178 HM300-1
c 1 c
(9)
Monitoring Code Table
MONITOR PANEL [Machine monitor system]

Monitoring
No. Monitoring item Item display Display range Unit
code
1 Engine speed ENG SPEED 01001 0 – 65535 rpm
2 Engine coolant temperature (for high temperature) COOLANT TEMP H 04102 0 – 160 °C
3 Torque converter oil temperature T/C OIL TEMP 30100 0 – 160 °C
4 Brake oil temperature BRAKE OIL TEMP 30200 0 – 160 °C
5 Fuel level sensor input resistance value FUEL SENSOR 04201 0 – 150 Ω
6 Rheostat input voltage RHEOSTAT 30300 0.0 – 51.0 V
7 Operation status of AISS switch AISS SW 30400 ON / OFF Status display
UPPER / NEU-
8 Operation status of exhaust brake switch EXH BRAKE SW 30500 Status display
TRAL / LOWER
UPPER /
9 Operation status of inter-axle differential lock switch INTER AXLE SW 30600 Status display
LOWER
UPPER / NEU-
10 Operation status of left and right differential lock switch L-R DIFF SW 30610 Status display
TRAL / LOWER
11 Operation status of left and right differential lock pedal FOOT DIFF SW 30620 ON / OFF Status display
ON / OFF,
12 Input status of connector check (1 & 2) CONN CHK 1, 2 30700 Status display
ON / OFF
0 – F, 0 – F,
13 Setting status of rotary switch (SW1 & SW2 & SW3) SW1, SW2, SW3 30800 Status display
0–F
ON / OFF,
14 Setting status of dip switch (SW5-1 & SW5-2) SW5-1, SW5-2 30900 Status display
ON / OFF
ON / OFF,
ON / OFF
ON / OFF,
ON / OFF
ON / OFF,
ON / OFF
ON / OFF,
18 Setting status of option selection connector (OP1 & OP2) OPTION 1, 2 31000 Status display
ON / OFF
ON / OFF,
ON / OFF
ON / OFF,
ON / OFF
★ Note: The following monitoring items display data for 2 or 3 systems at the same time.
• No. 12: Input status of connector check (displays 2 items)
• No. 13: Setting status of rotary switch (displays 3 items at same time)
• No. 14: Setting status of dipswitch (displays 2 items at same time)
• No. 18: Setting status of option selection connector (displays 2 items at same time)
HM300-1 20-179
1 c
(9) c
TRANSMISSION [Transmission controller system]

Monitoring
code
1 Transmission service meter SERVICE METER 31100 0 – 65535 h
2 Transmission input shaft speed T/M SPEED : IN 31200 0 – 65535 rpm
3 Transmission intermediate shaft speed T/M SPEED : MID 31300 0 – 65535 rpm
4 Transmission output shaft (R) speed T/M SPEED : OUT 31400 0 – 65535 rpm
5 Actuation status of Lo clutch fill switch FILL SW (L) 31510 ON / OFF Status display
6 Actuation status of Hi clutch fill switch FILL SW (H) 31511 ON / OFF Status display
7 Actuation status of 1st clutch fill switch FILL SW (1st) 31512 ON / OFF Status display
8 Actuation status of 2nd clutch fill switch FILL SW (2nd) 31513 ON / OFF Status display
9 Actuation status of 3rd clutch fill switch FILL SW (3rd) 31514 ON / OFF Status display
10 Actuation status of R clutch fill switch FILL SW (R) 31516 ON / OFF Status display
11 Actuation status of lock-up clutch fill switch FILL SW (L/U) 31509 ON / OFF Status display
12 Actuation status of transmission differential lock clutch fill switch FILL SW (DIFF) 31517 ON / OFF Status display
13 Output current command value for Hi clutch solenoid ECMV H DIR 31600 0 – 1020 mA
14 Output current detection value for Hi clutch solenoid ECMV H 31610 0 – 1020 mA
15 Output current command value for Lo clutch solenoid ECMV L DIR 31601 0 – 1020 mA
16 Output current detection value for Lo clutch solenoid ECMV L 31611 0 – 1020 mA
17 Output current command value for 1st clutch solenoid ECMV 1 DIR 31602 0 – 1020 mA
18 Output current detection value for 1st clutch solenoid ECMV 1 31612 0 – 1020 mA
19 Output current command value for 2nd clutch solenoid ECMV 2 DIR 31603 0 – 1020 mA
20 Output current detection value for 2nd clutch solenoid ECMV 2 31613 0 – 1020 mA
21 Output current command value for 3rd clutch solenoid ECMV 3 DIR 31604 0 – 1020 mA
22 Output current detection value for 3rd clutch solenoid ECMV 3 31614 0 – 1020 mA
23 Output current command value for R clutch solenoid ECMV R DIR 31606 0 – 1020 mA
24 Output current detection value for R clutch solenoid ECMV R 31616 0 – 1020 mA
25 Output current command value for lock-up clutch solenoid ECMV LU DIR 31609 0 – 1020 mA
26 Output current detection value for lock-up clutch solenoid ECMV LU 31619 0 – 1020 mA
Output current command value for transmission differential lock
27 ECMV D DIR 31607 0 – 1020 mA
clutch solenoid
Output current detection value for transmission differential lock
28 ECMV D 31617 0 – 1020 mA
clutch solenoid
29 Hi clutch fill time FILL TIME H 41801 0 – 2550 ms
30 Lo clutch fill time FILL TIME L 41800 0 – 2550 ms
31 R clutch fill time FILL TIME R 41806 0 – 2550 ms
32 1st clutch fill time FILL TIME 1 41802 0 – 2550 ms
33 2nd clutch fill time FILL TIME 2 41803 0 – 2550 ms
34 3rd clutch fill time FILL TIME 3 41804 0 – 2550 ms
35 Hi clutch fill status FILL H 31501 0–2 Status display
36 Lo clutch fill status FILL L 31500 0–2 Status display
37 R clutch fill status FILL R 31506 0–2 Status display
38 1st clutch fill status FILL 1 31502 0–2 Status display
39 2nd clutch fill status FILL 2 31503 0–2 Status display
20-180 HM300-1
c 1 c
(9)
Monitoring
code
40 3rd clutch fill status FILL 3 31504 0–2 Status display
41 Axle sensor input voltage THROTTLE POS 31700 0.00 – 5.10 V
42 Forced neutral command 1 status N DIRECTION 1 31800 ON / OFF Status display
43 Forced neutral command 1 status N DIRECTION 2 31801 ON / OFF Status display
44 Differential lock command voltage INT DIFF SIG 31900 0.00 – 5.10 V
45 Operation status of shift hold switch SHIFT HOLD SW 32000 ON / OFF Status display
ON / OFF,
46 Actuation status of emergency steering (1 & 2) EMERG STRG 1, 2 32100 Status display
ON / OFF
47 Input status of alternator terminal R ALTERNATOR R 04301 ON / OFF Status display
48 Input status of starting switch terminal C KEY SW C 32300 ON / OFF Status display
49 Setting status of emergency escape switch EMERG TRAVEL 32400 ON / OFF Status display
50 ECMV oil temperature ECMV OIL TEMP 32500 0 – 160 °C
51 Torque converter oil pressure T/C OIL PRESS 32600 0.00 – 5.02 MPa
OVERHEAT /
52 Steering oil temperature STRG OIL TEMP 32700 Status display
NORMAL
–0.52 –
53 Tilt angle ANGLE SENSOR 32900 rad
0.00 – 0.37
ON / OFF,
ON / OFF
LOW /
55 Transmission oil level OIL LEVEL 33000 Status display
NORMAL
LOW /
56 Radiator coolant level COOLANT LEVEL 33100 Status display
NORMAL
CLOGGED /
57 Clogging status of air cleaner AIR CLEANER 33200 Status display
NORMAL
CLOGGED /
58 Clogging status of transmission filter T/M FILTER 33300 Status display
NORMAL
CLOGGED /
59 Clogging status of hydraulic oil filter HYD OIL FILTER 33400 Status display
NORMAL
60 Reverse permission accepted condition REVERSE (DUMP) 33500 OK / NO Status display
61 Engine load signal value ENGINE LOAD 33600 0 – 100 %
62 Setting status of rotary switch (SW1 & SW2) ROTARY SW 1, 2 30801 0 – F, 0 – F Status display
63 Input status of model selection wiring harness 1 MACHINE SEL1 02701 GND / OPEN Status display
★ Note: The following monitoring items display data for 2 systems at the same time.
• No. 46: Actuation condition of emergency steering (displays 2 systems at same time)
• No. 54: Input status of connector check (displays 2 systems at same time)
• No. 62: Setting status of rotary switch (displays 2 items at same time)
HM300-1 20-181
1 c
(9) c
ENGINE [Engine controller system]

Monitoring
code
1 Engine speed ENG SPEED 01002 0 – 3000 rpm
2 Accelerator sensor angle THROTTLE POS 31701 0 – 100 %
3 Fuel temperature FUEL TEMP 04203 –30 – 100 °C
4 Transmission throttle correction value MODIFY SIGNAL 36000 –100 – 100 %
5 Axle sensor input voltage THROTTLE POS 31702 0.00 – 5.00 V
6 Target fuel injection level FUEL DELIVERY 36100 –30 – 600 mm3
7 Target common rail pressure RAIL PRESS (C) 36200 0 – 150 MPa
8 Target injection timing INJECT TIMING 36300 –30.0 – 31.0 °CA
9 Common rail pressure RAIL PRESS (A) 36400 0 – 150 MPa
10 Boost pressure BOOST PRESS 36500 0 – 300 kPa
11 Operating mode status ENG STATUS 36600 0 – 255 Status display
12 Coolant temperature for engine high temperature COOLANT TEMP H 04102 0 – 150 °C
13 Coolant temperature for engine low temperature COOLANT TEMP L 04101 –30 – 100 °C
14 Converted torque value TORQUE RATIO 36700 0 – 100 %
15 Setting status of fuel injection quantity control switch (1 & 2) Q ADJUST SW 1, 2 36800 0 – F, 0 – F Status display
16 Input status of model selection 1 MACHINE SEL1 02704 GND / OPEN Status display
19 Controller ROM No. ENGINE ROM 20203 Numeral Status display
★ Note: The following monitoring item displays data for 2 systems at the same time.
• No. 15: Setting status of fuel injection quantity control switch (displays 2 items at same time)
20-182 HM300-1
c 1 c
(9)
q1) system]
BRAKE [Retarder controller(q
Monitoring
code
1 Brake service meter SERVICE METER 31101 0 – 65535 h
2 Output current command value for front brake EPC solenoid F BK OUTP DIR 33700 0 – 1020 mA
3 Output current detection value for front brake EPC solenoid F BRAKE OUTPUT 33701 0 – 1020 mA
4 Output current command value for rear brake EPC solenoid R BK OUTP DIR 33800 0 – 1020 mA
5 Output current detection value for rear brake EPC solenoid R BRAKE OUTPUT 33801 0 – 1020 mA
0.00 – 5.10
6 Retarder lever(q2) input (voltage & conversion amount) RETARD LEVER 33900 V (%)
0 – 100
ON / OFF,
7 Input status of retarder lever(q2) validation switch (1 & 2) RLV SW 1, 2 34000 Status display
ON / OFF
WORKING /
8 Operation status of retarder lever(q2) switch RETARDER 34100 Status display
RELEASE
9 Dump lever potentiometer 1 input voltage DUMP LEVER 1 34300 0.00 – 5.10 V
10 Dump lever potentiometer 2 input voltage DUMP LEVER 2 34301 0.00 – 5.10 V
11 Body position sensor input voltage BODY POSITION 34400 0.00 – 5.10 V
12 Input status of body seat switch BODY SEATING 34600 ON / OFF Status display
13 Output status of dump lever solenoid KICKOUT SOL 34700 ON / OFF Status display
14 Output status of dump selector solenoid SWV FOR HOIST 34800 ON / OFF Status display
15 Output current command value for dump EPC solenoid EPC HOIST DIR 34900 0 – 1020 mA
16 Output current detection value for dump EPC solenoid EPC HOIST 34901 0 – 1020 mA
17 Input status of overrun command OVERRUN SIG 35000 ON / OFF Status display
18 Input status of service brake oil pressure switch SERVICE BRAKE 35100 ON / OFF Status display
19 Input status of starting switch terminal C KEY SW C 32300 ON / OFF Status display
ON / OFF,
ON / OFF
21 Front & rear differential slipping condition INT DIFF SLIDE 35200 SLIDE / NO Status display
22 Input status manual differential lock command INT M DIFF SIG 35300 ON / OFF Status display
23 Transmission output shaft F speed T/M SPEED : OUT 31401 0 – 65535 rpm
24 Transmission output shaft R speed T/M DIFF OUT 31402 0 – 65535 rpm
25 Front accumulator oil pressure ACC OIL PRE F 35500 0.00 – 50.26 MPa
26 Rear accumulator oil pressure ACC OIL PRE R 35501 0.00 – 50.26 MPa
CLOGGED /
27 Clogging status of brake filter BK OIL FILTER 35600 Status display
NORMAL
CLOGGED /
28 Clogging status of brake cooling filter RETARD FILTER 35700 Status display
NORMAL
CLOGGED /
29 Wear status of R.H. front brake DISK WEAR FR 35800 Status display
NORMAL
CLOGGED /
30 Wear status of L.H. front brake DISK WEAR FL 35801 Status display
NORMAL
CLOGGED /
31 Wear status of R.H. center brake DISK WEAR RFR 35802 Status display
NORMAL
CLOGGED /
32 Wear status of L.H. center brake DISK WEAR RFL 35803 Status display
NORMAL
Exhaust brake solenoid output (detection status & command sta- ON / OFF,
33 EXH BRAKE 35900 Status display
tus) (ON / OFF)
q2. The lever is not installed in E-SPEC.
★ Note: The following monitoring items display data for 2 systems at the same time.
• No. 6 : Retarder lever input (displays 2 types at same time; does not display unit for conversion %)
• No. 7 : Retarder lever validation switch input status (displays 2 systems at same time)
• No. 20: Connector check input status (displays 2 systems at same time)
• No. 33: Exhaust brake solenoid output (displays 2 types at same time; output status displayed in ( ))
HM300-1 20-183
1 c
4 c
11. Reduced cylinder mode (CYLINDER CUT-OUT)

As one method of troubleshooting for the engine,
the machine monitor has a reduced cylinder
function that can set the desired cylinder to the
NO INJECTION condition.
1) Starting engine
★ With this function, it is possible to use the
engine speed in the reduced cylinder
mode to judge if there is a problem with
any cylinder, so the engine can be used
during the operation.
2) Menu selection
i) Select the reduced cylinder mode on the
menu screen of Service mode (Fig. 1).
ii) With the menu selected, press the ["]
button and display the cylinder selection
screen (Fig. 2: example).
• ["] button: Runs menu
★ The cylinder No. and engine speed
are display at the same time.
3) Setting cut-out cylinder

Operate each button and select the cylinder
to be cut out (Fig. 3: example).
• [ > ] button: Selector cursor moves to right
• [ < ] button: Selector cursor moves to left
• ["] button: Cylinder is confirmed
• [#] button: Returns to menu screen
★ When the ["] button is used to confirm
the cut-out cylinder, communication is
carried out between the machine monitor
and engine controller. During this time,
the cylinder No. flashes. After comple-
tion of the communication, the segment
under the cylinder No. becomes black to
show that the cylinder has been cut out.
★ Single cylinders or multiple cylinders can
be cut out.
4) Canceling cylinder cut out

★ Cancel the cylinder cut out in the same
way as when setting the cut out (Fig. 4:
example).
20-184 HM300-1
! (7)
1 !
12. Adjustment function (TUNING)

Through the transmission controller, the ma-
chine monitor can carry out the the adjustment
function to correct the difference in operating
feeling to a constant level caused by the the in-
dividual differences in the ECMV. It can also car-
ry out the self-adjusting learning function so that
a constant gearshifting feeling is maintained in
accordance with the wear of the transmission
clutch.
When the following operations related to the
power train have been carried out, perform the
adjustments.
• When the transmission has been overhauled
or replaced
Failure code Component name
• When the transmission valve has been re-
placed DLF1KA Transmission input shaft speed
• When the transmission controller has been DLF1LC sensor
replaced
DLF2KA Transmission intermediate
• When an abnormality has occurred in the
power train speed sensor and it has been re- DLF2LC shaft speed sensor
paired (for details, see the failure code in the DLT3KA Transmission output shaft R
chart on the right) speed sensor
DLT3LC
• When an abnormality has occurred in the
transmission oil temperature sensor and it Transmission valve oil temper-
DGF1KX
has been repaired (for details, see the failure ature sensor
code in the chart on the right) 15BONX Transmission oil filter
• When the transmission oil filter has become
clogged and it has been repaired (for details,
see the failure code in the chart on the right)
For the adjustment operation, operate the ma-

chine monitor and machine itself, and carry out
the following items in order (Fig. 2).
★ ( ) indicates the menu to use for the adjust-
ment operation.
(1) Adjusting individual difference of valve (02:
ECMV TUNING AUTO)
(2) Resetting gearshifting feeling stabilized
learning data (01: TM TRIGGER)
(3) Gearshifting feeling stabilized initial learning
(monitoring function)
★ The MANUAL menu of [02: ECMV TUNING]
is a special function for the factory and is not
used for service.
HM300-1 20-185
1 c c
Preparatory work:
Adjusting ECMV oil temperature
★ It is necessary to carry out the adjustment
operation at the specified oil temperature, so
check that there is no abnormality on the ma-
chine and adjust the ECMV oil temperature
as follows.
1) Start the engine.
2) Display [ECMV oil temperature] with the ma-

chine data monitoring function. (Fig. 1).
• TRANSMISSION No. 50
3) Raise ECMV oil temperature to 60 – 70°C by

raising engine speed.
4) Keep engine speed in low idle for 3 minutes.

Before carrying out adjustment, be sure to
check that ECMV oil temperature is kept
within 60 – 70°C.
20-186 HM300-1
c 1 c
(9)
Adjustment operation (1): Adjusting individ-

ual difference of valve
★ See Preparatory work and check that the
ECMV oil temperature is at the specified
temperature.
★ The adjustment operation is carried out auto-
matically three times for the Lo, Hi, R, 1st,
2nd, and 3rd valves.
1) Set the machine to the following conditions.

• Parking brake switch: ON
• AISS LOW switch: LOW
• Gearshift lever: N position
• Engine: Low idle
• Accelerator pedal: OFF (released)
2) Operate the machine monitor and display

the adjustment menu screen (Fig. 4).
• Adjustment menu:
02: ECMV TUNING AUTO
3) Check the condition of the machine again,

press the [] button, and start the adjust-
ment operation (Fig. 5).
• [] button: Runs adjustment menu
★ The adjustment is carried out consecutively

three times for the applicable clutches and
displays a screen like the one shown on the
No. Valve 1st time 2nd time 3rd time
right.
★ For each adjustment operation, the result is 1 Lo IP L-1 IP L-2 IP L-3
displayed as normal or abnormal, so take ac- 2 Hi IP H-1 IP H-2 IP H-3
tion according to the display (Fig. 6).
3 R IP R-1 IP R-2 IP R-3
• If [3-3 OK] is displayed:
The adjustment operation has been com- 4 1st IP 1-1 IP 1-2 IP 1-3
pleted correctly. 5 2nd IP 2-1 IP 2-2 IP 2-3
(When the starting switch is turned OFF, the
6 3rd IP 3-1 IP 3-2 IP 3-3
adjusted value is recorded in the controller.)
• If [NG 1] (Outside compensation condition) is
displayed:
Adjust the ECMV oil temperature correctly,
check the set conditions of the machine
again, then repeat from Step 1).
• If [NG 2] (No fill) is displayed:
Carry out troubleshooting for failure codes
[15S[]MA] [DDT[]KA], and if it is found to
be normal, repeat from Step 1).
• If [NG 3] (Compensation value over] is dis-
played:
Carry out troubleshooting for failure code
[15S[]L1], and if it is found to be normal,
repeat from Step 1).
HM300-1 20-187
1 c
(9) c
Adjustment operation (2): Resetting gearshift-

ing feeling stabilized learning data
1) Operate the machine monitor and display
the initial menu screen (Fig. 7).
• Initial menu: 01: TM TRIGGER
★ The present initial status is displayed on
the bottom line of the screen.
• Initializing completed: INITIAL STATUS
• Initializing not performed: TUNED
★ With the transmission adjustment, the
learning data is initialized from the fol-
lowing operation, regardless of the
present initial status.
2) With the menu selected, press the [] but-

ton and display the initial screen of the sub
menu (Fig. 7).
• [] button: Runs initialize menu
3) Operate the buttons according to the screen

display (Fig. 8).
• [] button: Run
★ After carrying out initializing, check that
INITIAL STATUS is displayed on the bot-
tom line of the screen.
• Initializing completed: INITIAL STATUS
20-188 HM300-1
c 1 c
(9)
Adjustment operation (3): Initial learning of

gearshifting feeling stabilization
★ Check that the ECMV oil temperature is the
specified temperature. For details, see Pre-
paratory work.
¤ Carry out the adjustment operation in a place
with ample room for traveling and where the
surrounding area is safe.
1) With the machine data monitoring function,

display (R clutch fill status] (Fig. 10).
• TRANSMISSION No. 37
2) Run the engine at low idle, hold the gearshift

lever at the N position for 10 seconds, then
operate the gearshift lever as follows.
★ Gearshift lever operation: N → R1 → N
3) Check the fill status with the monitoring dis-

play.
★ If the display is [0], go on to the next step.
★ If the display is [1], repeat Step 2) until it
becomes [0].
4) Operate the gearshift lever to the D position,

drive the machine, and shift up to F2 – F4.
★ Shift up: F2 → F3 → F4
★ Be careful not to shift up to F5. If the
transmission shifts up to F5, start the
procedure again and move the machine
off in F2.
5) After traveling for 10 seconds in F4, release

the accelerator pedal, and allow the machine
to coast and shift down from F4 to F2.
★ Shift down: F4 → F3 → F2
★ Do not operate the brake while coasting.
6) Use the machine data monitoring function to

display [Lo clutch fill status] and [1st clutch
fill status] and check the fill status (Fig. 11).
• Lo clutch: TRANSMISSION No. 36
• Hi clutch: TRANSMISSION No. 38
★ If the display is [0], the correction is com-
plete.
★ If the display is [1], repeat Steps 4) and
5) until it becomes [0].
HM300-1 20-189
1 c
(9) c
13. Filter, oil replacement time setting function

(MAINTENANCE MONITOR)
The machine monitor can set the maintenance
interval for filters and oil, which form the base for
the filter and oil replacement time and display.
1) Menu selection
Select Filter, oil replacement time setting
function on the menu screen of Service
mode (Fig. 1).
2) Selecting filter, oil replacement time setting

item
i) With the menu selected, press the []
button and display the initial screen of
the set item (Fig. 2).
ii) Press the [ > ] or [ < ] buttons to select the
item to be set.
• [ > ] button: Goes on to next item
• [ < ] button: Goes back to last item
★ The set items are displayed endless-
ly in the internal set order (for details,
see Table of filter and oil replace-
ment time set items).
3) If the maintenance items in the display for

the filter and oil replacement time set items
are selected, the following content is dis-
played (Fig. 3).
1: Code (2 digits)
A: Filter and oil replacement time set items
2: Remaining time to set replacement time
3: Number of times of replacement up to
present
4) Changing replacement interval

i) With the set items selected, press the
[] button and display the interval input
screen (Fig. 4: example).
• [] button: Executes change function
★ The presently set interval is dis-
played on the screen.
20-190 HM300-1
c 1 c
(7)
ii) Operate the buttons to input the interval

(Fig. 4).
• [ > ] button:
Number at cursor goes up
• [ < ] button:
Number at cursor goes down
• [] button:
Number at cursor is confirmed
• [] button:
Returns to item selection screen
★ The time must always be input with
4 digits. For numbers of less than
4 digits, input 0s at the beginning.
iii) When all the interval times are con-
firmed, the change confirmation screen
is displayed, so operate the buttons ac-
cording to the screen display (Fig. 5).
• [] button: Run
Table of filter and oil replacement time set items
No. Item Code Display Replacement time

1 Fuel filter 03 FUEL FILT 0500
2 Engine oil filter 02 ENG FILT 0500
3 Engine oil 01 ENG OIL 0500
4 Corrosion resistor 06 CORR RES 1000
5 Transmission oil 12 TM OIL 1000
6 Transmission oil filter 13 TM FILT 1000
7 Brake oil 17 BK OIL 1000
8 Brake oil filter 14 BK OIL FIL 1000
9 Brake cooling oil filter 16 BK C FIL 1000
10 Hydraulic filter 04 HYD FILT 2000
11 Differential case oil 11 DIFF OIL 2000
12 Final drive oil 08 FNL OIL 2000
13 Hydraulic oil 10 HYD OIL 4000
14. Initialize function (INITIALIZE)

(exclusive function for factory)
★ This is a special function for the factory and
is not used for service.
HM300-1 20-191
1 c
(9) c
TESTING AND ADJUSTING PM-CLINIC INSPECTION SHEET
Pm-CLINIC INSPECTION SHEET

Model: HM300-1 #1001–
Serial # #
Hour inspection Eng. Serial # SAA6D125E-3 #
Work No. Date Service meter Name of inspector

(YYYY/MM/DD) hrs
Questions to operator and inspection around the machine

Was there any abnormality before start of inspection? Ambient temperature
Max. °C (F)
Min. °C (F)
Altitude m
Coolant temperature maximum level? T/C oil temperature maximum level? Retarder oil temperature max. level?
During operation During operation During operation
1234567 1234567 1234567
Failure code
Code / Content Location of failure Result of inspection Sat Us
After starting engine!

Standard Permissible
Item Condition Unit value value Result Sat Us
Low idle 675 – 725 675 – 725
High idle 1,950 – 2,050 1,950 – 2,050
Economy mode Torque converter
1,630 – 1,830 1,630 – 1,830
stall
Engine speed rpm
Low idle 920 – 970 920 – 970
Power mode High idle 2,150 – 2,250 2,150 – 2,250
Torque converter 1,810 – 2,010 1,810 – 2,010
stall
kPa Max. 0.98 Max. 1.96
Blow-by press. Torque converter stall {mmAq} {Max. 100} {Max. 200}
Engine
392 – 588 Min.206

SAE 30 or High idle {3.5 – 5.0} {Min. 2.1}
15W-40 Min 147 Min. 69
Engine lub. Low idle kPa {Min. 1.2} {Min. 0.7}
oil pressure {kg/cm2}
High idle 343 – 539 Min. 176
{3.0 – 5.0} {Min. 1.8}
SAE10W
Low idle Min. 98 Min 69
{Min. 1.0} {Min. 0.7}
Boost pressure kPa Min. 106.7 79.8

Torque converter stall {mmHg} {Min.800} {600}
Ambient temperature ― ―
Exhaust temperature °C
Torque converter stall Max. 650 700
20-192 HM300-1
Å (10)
1 Å
Standard Permissible
Item Condition Unit value value Result Sat Us
2.35 – 2.75 2.35 – 2.75
Engine low idle, T/M in N {24.0 – 28.0} {24.0 – 28.0}
MPa
Main relief pressure {kg/cm2}
Engine high idle, T/M in N 2.35 – 2.75 2.35 – 2.75
{24.0 – 28.0} {24.0 – 28.0}
0.81 – 1.1 0.8 – 1.0
T/C inlet pressure {8.3 – 10.3} {8.2 – 10.2}
Engine high idle, T/M in N MPa
{kg/cm2} 0.49 – 0.69 0.49 – 0.69
T/C outlet pressure
{5.0 – 7.0} {5.0 – 7.0}
Caution! There is no need to measure the below items (*) on T/M, If the surrounding area is not safe.
(When measure the pressure of the each clutch in T/M with machine travel.)
Shift-indicator 1.66 -- 1.96 1.66 -- 1.96
* T/C Lock-up {17.5 -- 19.5} {17.5 -- 19.5}
shows "1"
T/C, T/M
Shift-indicator 2.30 -- 2.60 2.30 -- 2.60

* T/M Lo clutch shows "1" {23.5 -- 26.5} {23.5 -- 26.5}
Shift-indicator 2.30 -- 2.60 2.30 -- 2.60
* T/M Hi clutch shows "2" {23.5 -- 26.5} {23.5 -- 26.5}
Shift-indicator Engine full 2.30 -- 2.60 2.30 -- 2.60
* T/M 1st clutch MPa {23.5 -- 26.5} {23.5 -- 26.5}
shows "1" (Machine travel)
{kg/cm2}
Shift-indicator 2.20 -- 2.50 2.20 -- 2.50
* T/M 2nd clutch shows "3" {22.5 -- 25.5} {22.5 -- 25.5}
Shift-indicator 2.30 -- 2.60 2.30 -- 2.60
* T/M 3rd clutch {23.5 -- 26.5} {23.5 -- 26.5}
shows "5"
Gearshift lever 2.30 -- 2.60 2.30 -- 2.60
* T/M R clutch {23.5 -- 26.5} {23.5 -- 26.5}
to "R1"
Inter-axle differential Gearshift lever 2.20 -- 2.50 2.20 -- 2.50
Engine full {22.5 -- 25.5} {22.5 -- 25.5}
lock clutch to "N"
Change oil, clean inside of transmission case and strainer at every 1000 hours service!
Standard Permissible Result Sat Us
Item Condition Unit value
value
Must be no excessive metallic
T/M
Visual check of transmission strainer

particles or rayflex (Black powder)
Right to left Max. 6.0 Min. 6.0

Steering time lock Through the whole
Steering
sec
to lock area of engine
Left to right Max. 6.0 Min. 6.0
Steering relief MPa 20.59 -- 21.57 20.59 -- 21.57
pressure Engine high idle {kg/cm2} {210 -- 220} {210 -- 220}
Cut-in 11.77 -- 12.06 11.77 -- 12.06

Brake performance
pressure MPa {120 -- 123} {120 -- 123}

Charge valve Engine full {kg/cm2}
Cut-out 20.54 -- 21.57 20.54 -- 21.57
pressure {205 -- 220} {205 -- 220}
Foot brake Apply brake, set gearshift lever 1,440 1,440

to D, gradually raise engine
Retarder brake speed, and check that the rpm 1,440 1,440
machine does not move at
Parking brake specified speed (See right). 1,490 1,490
Hydraulic temperature °C ― ―
Hydraulic system
MPa 20.59 -- 21.57 20.59 -- 21.57

Hoist relief pressure Engine full {kg/cm2} {210 -- 220} {210 -- 220}
Dump body raise
Engine full sec. 10.5 -- 13.5 10.5 -- 13.5
speed
Set dump body and stop engine!
Hydraulic drift of Set dump body with No.2 cylinder mm /
extended 100 mm 5 min Max. 85 170
hoist cylinder
HM300-1 20-193
(10)
1 Å Å
Every 1000 hrs service!

Item Condition Unit Standard Permissible Result Sat Us
value value
L.H.
Front
R.H.
L.H.
Brake
Wheel brake Center mm Within limit mark on wear gauge

R.H.
L.H.
Rear
R.H.
Parking brake Pad thickness Min. 1.5 Min. 1.5
Suspension cylinder length mm 153 -- 173 158 -- 178

Front left
Oil gas leaking ― There must be no leakage
Suspension

Front right
Rear left
Rear right
MEMO: Write any data or phenomena that you noticed during today's check.
20-194 HM300-1
Å (10)
1 Å
TROUBLESHOOTING 20 Troubleshooting
TROUBLESHOOTING
Points to remember when troubleshooting .............................................................................................. 20-202

Sequence of events in troubleshooting ................................................................................................... 20-203
Points to remember when carrying out maintenance .............................................................................. 20-204
Checks before troubleshooting ................................................................................................................ 20-212
Connector types and mounting locations ................................................................................................ 20-213
Connection table for connector pin numbers ........................................................................................... 20-228
T-adapter table ........................................................................................................................................ 20-250
Categories, procedure, and method of using troubleshooting charts ...................................................... 20-253
Troubleshooting of engine controller system (ENG mode) ...................................................................... 20-301

Troubleshooting of transmission controller system (TM mode) ............................................................... 20-401
Troubleshooting of retarder controller (q1) system (BK mode) ............................................................... 20-601
Troubleshooting of machine monitor system (MON mode) ..................................................................... 20-701
Troubleshooting of hydraulic, mechanical system (H mode) ................................................................... 20-801
Troubleshooting of the engine body (S mode) ......................................................................................... 20-901
HM300-1 20-201
1 c
(5) c
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
20-202 HM300-1
c 1 c
(9)
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
Office, shop Jobsite

TEW00180 TEW00181
Step 1
Examination, confirmation of symptoms
1) When a request for repairs is received, first

ask the following points.
• Name of customer
• Type, serial number of machine
• Details of jobsite, etc.
2) Ask questions to gain an outline of the prob-
lem.
• Condition of failure
• Work being carried out at the time of the
failure
• Operating environment
• Past history, details of maintenance, etc.
Step 2
Determining probable location of cause
1) Look at the troubleshooting section of the

shop manual to find locations of possible Step
causes.
Repair at jobsite
Hurray !
It's repalred
Step 3
Preparation of troubleshooting tools
TEW00185
1) Look at the table of troubleshooting tools in
the shop manual and prepare the necessary Step 7
tools. • Pinpoint locations of failure (carry out
• T-adapter troubleshooting)
• Hydraulic pressure gauge kit, etc. • Decide action to take
2) Look in the parts book and prepare the nec-
essary replacement parts. 1) Before starting troubleshooting, locate and
TEW00186 repair simple failures.
• Check before starting items
• Other check items
2) See the Troubleshooting Section of the shop
manual, select a troubleshooting flowchart
that matches the symptoms, and carry out
troubleshooting.
TEW00187
Step 6
Re-enacting failure
• Drive and operate the machine to confirm

the condition and judge if there is really a
failure.
Step 4 Step 5
Go to jobsite Ask operator questions to confirm details of
failure.
ï Was there anything strange about the ma-

chine before the failure occurred?
ï Did the failure occur suddenly?
ï Had any repairs been carried out before the
TEW00189 failure?
TEW00190
HM300-1 20-203
1 c
(9) c
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other
troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and re-
pairs must be carried out. This section deals particularly with correct repair procedures for mechatronics
and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling
electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
1. POINTS TO REMEMBER WHEN HANDLING

ELECTRIC EQUIPMENT
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are more
likely to be affected by the direct effects of rain,
water, heat, or vibration. Furthermore, during
inspection and repair operations, they are fre-
quently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful when handling wiring harnesses.
TEW00191
Main failures occurring in wiring harness

(1) Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces.
(2) Defective crimping or soldering of connec-

tors
The pins of the male and female connectors
are in contact at the crimped terminal or
soldered portion, but if there is excessive
force brought to bear on the wiring, the plat-
ing at the joint will peel and cause improper
connection or breakage.
20-204 HM300-1
c 1 c
(9)
HM300-1 20-205
(9)
1 c c
2) Removing, installing, and drying connectors and

wiring harnesses
• Disconnecting connectors
(1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold the
connectors and not the wires. For connec-
tors held by a screw, loosen the screw fully,
then hold the male and female connectors
in each hand and pull apart. For connectors
which have a lock stopper, press down the
stopper with your thumb and pull the con-
nectors apart.
= Never pull with one hand.
(2) When removing from clips

When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
= If the connector is twisted up and down
or to the left or right, the housing may
break.
TBW00484
(3) Action to take after removing connectors

After removing any connector, cover it with
a vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector portion.
= If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.
TEW00198
20-206 HM300-1
c 1 c
(9)
• Connecting connectors
(1) Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation, de-
fective contact, corrosion, or damage to
the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
= If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has got inside the connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
= If there is any damage or breakage, re-
place the connector.
(2) Fix the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in
the connector until the stopper clicks into
position.
TEW00200
(3) Correct any protrusion of the boot and any
misalignment of the wiring harness
For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the
wiring harness is misaligned, or the clamp
is out of position, adjust it to its correct po-
sition.
= If the connector cannot be corrected eas-
ily, remove the clamp and adjust the
position.
(4) If the connector clamp has been removed,

be sure to return it to its original position.
Check also that there are no loose clamps. TBW00487
• Since the DT 8-pole and 12-pole heavy duty wire

connectors have 2 latches respectively, push them
in until they click 2 times.
1. Male connector, 2. Female connector
• Normal locking state (Horizontal): a, b, d
• Incomplete locking state (Diagonal): c
HM300-1 20-207
1 c
(9) c
• Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in wa-
ter or using steam. If the connector must be
washed in water, do not use high-pressure water
or steam directly on the wiring harness.
If water gets directly on the connector, do as fol-

lows:
(1) Disconnect the connector and wipe off the
water with a dry cloth.
★ If the connector is blown dry with com-
pressed air, there is the risk that oil in the
air may cause defective contact, so re-
move all oil and water from the com-
pressed air before blowing with air.
(2) Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dry-
er to dry the connector.
★ Hot air from the dryer can be used, but
regulate the time that the hot air is used
in order not to make the connector or re-
lated parts too hot, as this will cause de-
formation or damage to the connector.
(3) Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
★ After completely drying the connector,
blow it with contact restorer and reas-
semble.
20-208 HM300-1
c (9)
1 c
3) Handling control box

(1) The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
(2) Do not open the cover of the control box un-
less necessary.
(3) Do not place objects on top of the control

box.
(4) Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with
your hand.
(5) During rainy weather, do not leave the con-
trol box in a place where it is exposed to rain.
(6) Do not place the control box on oil, water, or

soil, or in any hot place, even for a short time.
(Place it on a suitable dry stand)
(7) Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors
connected to the control box. Fit an arc weld-
ing ground close to the welding point.
4. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connecting connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
★ Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
★ If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays
will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current),
move the related wiring and connectors several times and check that there is no change in the reading
of the tester.
★ If there is any change, there is probably defective contact in that circuit.
HM300-1 20-209
(9)
1 c c
5. POINTS TO REMEMBER WHEN HANDLING

HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hy-

draulic equipment, the most common cause of fail-
ure is dirt (foreign material) in the hydraulic circuit.
When adding hydraulic oil, or when disassembling or
assembling hydraulic equipment, it is necessary to
be particularly careful.
1) Be careful of the operating environment

Avoid adding hydraulic oil, replacing filters, or re-
pairing the machine in rain or high winds, or plac-
es where there is a lot of dust.
2) Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and maintenance of hydraulic equipment
should be carried out in a specially prepared
dustproof workshop, and the performance
should be confirmed with special test equipment.
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from enter-
ing. If the opening is left open or is blocked with
a rag, there is danger or dirt entering or of the
surrounding area being made dirty by leaking oil
so never do this.
Do not simply drain oil out on to the ground, col-
lect it and ask the customer to dispose of it, or
take it back with you for disposal.
4) Do not let any dirt, or dust get in during refill-

ing operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil fill-
er and the area around it clean, and also use
clean pumps and oil containers. If an oil cleaning
device is used, it is possible to filter out the dirt
that has collected during storage, so this is an
even more effective method.
20-210 HM300-1
c (9)
1 c
5) Change hydraulic oil when the temperature is

high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is still
warm. When changing the oil, as much as possi-
ble of the old hydraulic oil must be drained out.
(Do not drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain plug
in the circuit.) If any old oil is left, the contami-
nants and sludge in it will mix with the new oil
and will shorten the life of the hydraulic oil.
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to re-
move the contaminants, sludge, and old oil from
the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the machine,
carry out oil cleaning to remove the sludge or
contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove the
ultrafine (about 3µ) particles that the filter built
into the hydraulic equipment cannot remove, so
it is an extremely effective device.
HM300-1 20-211
(9)
1 c c
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Judgement
Item Action
Value
1. Check fuel level — Add fuel
2. Check for impurities in fuel — Clean, drain
Lubricating oil, coolant
3. Check hydraulic oil level — Add oil

Checks before starting
4. Check oil level in damper case — Add oil

5. Check power train oil level — Add oil
6. Check engine oil level (engine oil pan level) — Add oil
7. Check coolant level — Add coolant
8. Check dust indicator for clogging — Clean or replace
9. Check travel of brake pedal — Adjust
mechanical equipment
Electrical
10. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace
11. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace
12. Check for looseness, corrosion of starting motor terminal, wiring — Tighten or replace
equipment
Hydraulic,
13. Check for abnormal noise, smell — Repair

14. Check for oil leakage — Repair
15. Carry out air bleeding — Bleed air
Other check items
16. Check battery voltage (engine stopped) 20 - 30 V Replace

17. Check battery electrolyte level — Add or replace
Electrical equipment
18. Check for discolored, burnt, exposed wiring — Replace

19. Check for missing wiring clamps, hanging wire — Repair
20. Check for water leaking on wiring (pay particularly careful attention — Disconnect connector
to water leaking on connectors or terminals) and dry
21. Check for water on wiring — Replace
22. Check alternator voltage (engine running at 1/2 throttle or above) After running for Replace
several minutes:
27.5 - 29.5 V
23. Check operating sound of battery relay (starting switch ON, OFF) — Replace
20-212 HM300-1
c (9)
1 c
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR TYPES AND MOUNTING LOCATIONS

HM300-1
★ The figures in the column of No. of pins stand for colors of the connector bodies.
Connector No. Type No. of pins Name of component Address

1.PS DT 2 Transmission 1st clutch solenoid AJ-7
1.SW DT 2 Transmission 1st clutch fill switch AJ-7
2.PS DT 2 Transmission 2nd clutch solenoid AH-8
2.SW DT 2 Transmission 2nd clutch fill switch AH-8
3.PS DT 2 Transmission 3rd clutch solenoid AH-8
3.SW DT 2 Transmission 3rd clutch fill switch AI-8
A1 M 1 Emergency escape switch W-4
A2 M 1 Emergency escape switch W-5
AC1 1-pin connector 1 Air conditioner M-3
ACBM YAZAKI 2 Air conditioner blower motor T-2
ACC Terminal 1 Staring switch —
ACM1 AMP 5 Air conditioner temperature adjustment servo motor V-3
ACM2 AMP 5 Air conditioner vent mode selector servo motor M-5
ACM3 AMP 5 Air conditioner FRESH/RECIRC selector servo motor V-3
ACP1 AMP 16 Air conditioner control panel M-6
ACP2 AMP 12 Air conditioner control panel M-5
ACPS SUMITOMO 2 Air conditioner pressure switch U-3
ACR1 AMP 4 Air conditioner blower main relay V-4
ACR2 AMP 4 Air conditioner blower Hi relay W-4
ACR3 AMP 4 Air conditioner blower M2 relay W-4
ACR4 AMP 4 Air conditioner blower M1 relay W-4
ACR5 AMP 4 Air conditioner compressor clutch relay W-4
ACRE AMP 4 Air conditioner blower resistor U-2
ACTH YAZAKI 2 Air conditioner thermistor U-3
AISS M 6 AISS switch M-3
AS1 SWP 6 Accelerator pedal sensor N-2
AS2 X 3 Accelerator pedal sensor O-2
ASS DT-T 2 Air suspension seat T-2
ATC1 MIC 17 Transmission controller W-7
ATC2 MIC 21 Transmission controller W-6
ATC3A AMP040 20 Transmission controller W-7
ATC3B AMP040 16 Transmission controller W-7
ATC4 AMP040 12 Transmission controller W-7
ATC5A AMP040 20 Transmission controller W-6
ATC5B AMP040 16 Transmission controller W-6
ATC6 X 4 Transmission controller W-6
B Terminal 1 Staring switch —
HM300-1 20-213
1 c
(9) c

B01 DT 2 Brake wear switch (FL) (if equipped) F-1
B1 M 1 Clearing memory W-5
B02 DT 2 Brake wear switch (ML) (if equipped) J-9
B2 M 1 Clearing memory W-4
B03 DT 2 Brake cooling filter clogging switch (if equipped) D-1
B09 DT 2 Transmission output shaft sensor (front) F-1, AJ-4
B14 DT 2 Parking brake solenoid valve E-8
B15 DT 2 Service brake switch F-9
B16 DT 2 Retarder switch G-9
B17 DT 2 Parking brake actuation switch D-8
B18 DT 2 Rear brake EPC valve F-9
B20 DT 2 Rear accumulator oil pressure switch C-7
B21 DT 2 Front accumulator oil pressure switch C-7
B24 DT 3 Rear accumulator oil pressure sensor D-7
B25 DT 3 Front accumulator oil pressure sensor B-7
B26 DT 2 Center brake wear switch (MR) (if equipped) L-5
B27 DT 3 Steering angle sensor (if equipped) H-2
B28 DT 2 Brake wear switch (FR) A-4
B29 DT 2 Exhaust brake solenoid valve (if equipped) A-4
B30 DT 2 Exhaust brake actuation switch (if equipped) A-2
B31 DT 2 Dump selector solenoid I-9
B32 DT 2 Dump EPC solenoid I-2
B34 DT 3 Body positioner sensor K-9
BL47 DT 2 Back-up lamp L-8
BLS M 6 Rotating lamp O-2
BR Terminal 1 Starting switch —
BRC1 MIC 17 Brake controller V-3
BRC2 MIC 21 Brake controller W-7
BRC3A AMP040 20 Brake controller V-8
BRC3B AMP040 16 Brake controller V-8
BRC4 AMP040 12 Brake controller V-8
BRC5A AMP040 20 Brake controller W-8
BRC5B AMP040 16 Brake controller V-8
BRC6 X 4 Brake controller W-7
BT1 — — Fuse box V-8
BT2 — — Fuse box U-9
BT3 — — Fuse box T-9
BT4 — — Fuse box T-9
BZ2 M 2 Buzzer R-1
C Terminal 1 Starting switch —
CAB1 DT 8 (Gr) Cab wiring harness R-9
20-214 HM300-1
c 4 c
1
(9)

CAB2 DT 8 (B) Cab wiring harness Q-8
CAN1 DT-T 3 Resistor Q-9
CAN2 DT-T 3 Resistor Q-1
CG1 1-pin connector 1 Cigarette lighter M-4
CG2 Terminal 1 Cigarette lighter M-5
CH1 S 8 Machine monitor mode selector switch 1 M-1
CH2 S 8 Machine monitor mode selector switch 2 M-1
CJA DT 8 (B) Joint connector A-6
CJAB DT-T 6 Joint connector G-1
CJAC DT-T 6 Joint connector F-9
CJB DT 6 Joint connector A-6
CJD DT 8 (B) Joint connector A-6
CJF DT 8 (B) Joint connector B-6
CJG DT 8 (B) Joint connector B-6
CJH DT 6 Joint connector B-6
CJK DT 8 (B) Joint connector L-7
CJL DT 8 (B) Joint connector E-1
CJM DT 6 Joint connector A-5
CJP DT 6 Joint connector B-2
CJR DT 8 (B) Joint connector B-6, L-7
CJS DT 8 (B) Joint connector F-1
CJT DT 6 Joint connector F-1
CJU DT 6 Joint connector B-6
CJX DT 6 Joint connector B-2
CJY DT 8 (B) Joint connector B-1
CK1 YAZAKI 6 Blown bulb checking switch M-2
CM X 2 Oil pressure switch D-1
CM DT-T 8 (G) Lighting switch P-8
CN1 DT 2 Injector A Z-6
CN1 AMP070 12 Engine controller S-9
CN2 DT 2 Injector E Z-7
CN3 DT 2 Injector C AA-7
CN4 DT 2 Injector F AA-7
CN5 DT 2 Injector B AB-7
CN-5 M 1 Brake controller (Selecting model) —
CN-13 M 1 Brake controller (Selecting model) —
CN-41 Terminal 1 Backing-up alarm buzzer L-8
CN-49 Terminal 1 Backing-up alarm buzzer L-8
CN-86 DT 2 Side lamp, left I-3
HM300-1 20-215
1 c
(9) c

CN6 DT 2 Injector D AC-7
CN7 AMP070 14 Engine controller T-9
CNS1 DT-T 12 (Br) Console wiring harness S-1
CNS2 DT-T 12 (G) Console wiring harness S-2
CNS3 DT-T 12 (B) Console wiring harness S-1
COM 1-pin connector 1 Air conditioner unit N-3
D/L PS DT 2 Inter-axle differential lock clutch solenoid AJ-6
D/L SW DT 2 Inter-axle differential lock clutch fill switch AJ-6
D01 DT-T 2 Diode U-9
D04 DT-T 2 Diode M-5
D07 DT-T 2 Diode P-1
D08 DT-T 2 Diode P-2
D09 DT-T 2 Diode Q-1
DL DT-T 12 Intermediate connector W-6
DPC1 AMP070 20 Machine monitor O-7
DPC2A AMP070 18 Machine monitor O-7
DPC2B AMP070 12 Machine monitor O-7
DPC3A AMP070 18 Machine monitor N-7
DPC4 AMP070 12 Machine monitor P-7
DPC6 AMP070 8 Machine monitor N-7
DPC7 X 4 Machine monitor P-2
DT DT 8 (B) Intermediate connector D-1
DT1 DT 6 Intermediate connector A-4
DT2 DT 12 (B) Intermediate connector A-5
DT4 DT 2 Intermediate connector G-1
DT5 DT 8 (B) Intermediate connector D-8
DT7 DT 12 (B) Connector (if equipped) A-2
DT7 DT-T 12 (Gr) Intermediate connector (dump lever) T-2
DT8 DT-T 4 Intermediate connector T-2
E02 DT 2 Flow switch E-1
E-2 Terminal 1 Emergency steering motor E-1
EG1 DT-T 12 (Gr) Engine wiring harness R-9
EG2 DT-T 12 (B) Engine wiring harness R-9
EG3 DT-T 12 (G) Engine wiring harness R-9
EG4 HD-24 23 Intermediate connector A-4
EG5 HD-24 31 Intermediate connector A-4
20-216 HM300-1
c 1 c

EMR2 — 2 Fuse (30A) E-1
ER1 Terminal 1 Ground Q-1
ER2 Terminal 1 Ground X-2
ER3 Terminal 1 Ground O-2
EREV DT-T 2 Engine speed sensor AD-5
EXH M 6 Exhaust brake switch N-3
FLB Terminal 1 Flasher R-1
FLL Terminal 1 Flasher R-1
FOG M 6 Fog lamp switch N-1
FS2 1-pin connector 1 Spare power source connector U-9
FS3 1-pin connector 1 Spare power source connector T-9
FU — 2 Fuse (30A) E-1
G DENSO 2 G sensor AB-2
G2 Terminal 1 Ground E-8
G21 Terminal 1 Ground S-2
H.PS DT 2 Transmission Hi clutch solenoid AJ-7
H.SW DT 2 Transmission Hi clutch fill switch AJ-6
H1 Terminal 1 Horn valve B-1
H2 Terminal 1 Horn valve A-3
H10 1-pin connector 1 Heater unit M-4
H20 1-pin connector 1 Heater unit M-4
HAZ M 6 Hazard switch N-6
HN 1-pin connector 1 Horn switch P-8
HSL DT-T 4 Dump lever (potentiometer) U-3
JO1 HD-24 9 Intermediate connector L-2
JO2 HD-24 23 Intermediate connector J-3
JO4 HD-24 21 Intermediate connector K-3
JO11 HD-24 31 Intermediate connector L-1
JO12 DT 8 (B) Intermediate connector H-1
JO13 DT 8 (B) Intermediate connector J-3
HM300-1 20-217
1 c
(9) c

JO14 DT 8 (G) Intermediate connector H-9
JO15 DT 8 (G) Intermediate connector I-9
JO18 DT 12 (B) Intermediate connector D-1
J19 HD-24 9 Intermediate connector D-1
JCA DT-T 8 (B) Joint connector V-3
JCB DT-T 8 (B) Joint connector V-3
JCC DT-T 8 (B) Joint connector S-2
JCD DT-T 8 (B) Joint connector T-2
JCE DT-T 8 (B) Joint connector V-8
JCF DT-T 8 (B) Joint connector V-4
JCG DT-T 8 (B) Joint connector W-6
KAI 1-pin connector 1 Rotating lamp B-8
L.PS DT 2 Transmission Lo clutch solenoid AI-8
L.SW DT 2 Transmission Lo clutch fill switch AJ-7
L/C PS DT 2 Torque converter lock-up clutch solenoid AG-8
L/C SW DT 2 Torque converter lock-up clutch fill switch AG-8
LKO DT-T 2 Control lever kick-out solenoid U-3
LS M 3 Rheostat M-2
LUB.T DT 2 Transmission oil temperature sensor AI-2
M-2 Terminal 1 Emergency steering motor E-1
MC1 M 1 Memory clear T-9
MC2 M 1 Memory clear T-9
MON1 1-pin connector 1 Rear view monitor M-6
MS M 4 Model selection connector U-9
MS11 M 4 Model selection connector W-5
N1 DT 2 Transmission input shaft speed sensor AF-7
N2 DT 2 Transmission intermediate shaft speed sensor AJ-5
N3 DT 2 Transmission output shaft speed sensor AJ-6
NE DENSO 2 Engine NE speed sensor AD-4
OF — 1 Engine oil filter clogging switch AC-7
OL DT 2 Engine oil level sensor AC-3
OP1 M 1 Machine monitor setting connector M-8, N-9
OP2 M 1 Machine monitor setting connector M-8, N-9
OP3 M 1 Machine monitor setting connector M-8, O-9
OP4 M 1 Machine monitor setting connector M-8, O-9
OP5 M 1 Machine monitor setting connector N-7, O-9
OPS DT-T 3 Seat heater (if equipped) T-2
20-218 HM300-1
c 1 c

P01 M 3 Left head lamp C-1
P02 1-pin connector 1 Clearance lamp, left C-1
P03 1-pin connector 1 Left combination ground C-1
P04 1-pin connector 1 Turning signal lamp, left C-1
P07 X 2 Left fog lamp (L.H.) (if equipped) D-1
P13 Terminal 1 Horn valve C-1
P14 Terminal 1 Horn valve A-3
P20 M 6 Rear combination lamp (L.H.) K-9
P21 M 6 Rear combination lamp (R.H.) L-8
P22 DT 2 Side lamp, right (if equipped) C-7
P06 DT 2 Turning signal lamp, right —
P05 DT 2 Turning signal lamp, left —
P30 1-pin connector 1 Right combination ground A-3
P31 1-pin connector 1 Clearance lamp, right A-3
P32 M 3 Right head lamp A-3
P33 X 2 Right fog lamp (if equipped) A-3
PCV1 DENSO 2 Fuel supply pump 1 AB-2
PCV2 DENSO 2 Fuel supply pump 2 AB-3
PFUEL AMP174357-2 3 Engine common rail pressure sensor AD-4
PHO Terminal 1 Heater relay —
PIM DENSO 3 Engine boost pressure sensor AD-6
PSH 1-pin connector 1 Engine oil high-pressure sensor AA-2
PSL 1-pin connector 1 Engine oil low-pressure sensor Z-2
PWM M 6 Power mode switch M-4
R.PS DT 2 Transmission R clutch solenoid AI-8
R.SW DT 2 Transmission R clutch fill switch AI-8
R01 KES0 5 Engine drive relay V-3
R02 KES0 5 Transmission neutral relay V-3
R03 KES0 5 Parking brake relay V-2
R04 KES0 6 Rear brake relay V-2
R05 KES0 6 Back-up buzzer relay W-3
R06 KES0 6 Fog lamp relay (if equipped) V-2
R07 KES0 6 Front working lamp relay V-1
R08 KES0 6 Rear working lamp relay (if equipped) W-3
R11 KES0 5 Horn relay W-3
R14 KES0 5 Brake cut relay W-1
R15 KES0 5 Transmission cut relay W-3
R16 KES0 6 Hazard relay 1 W-1
R17 KES0 5 Hazard relay 2 W-1
R19 KES0 5 Parking brake safety relay X-3
R21 KES0 6 Side lamp relay (if equipped) W-1
HM300-1 20-219
1 c
(9) c

R22 KES0 5 Rotating lamp relay (if equipped) X-2
R25 KES0 5 Right power window down relay X-1
R26 KES0 5 Right power window up relay W-1
R27 KES0 5 Left power window down relay X-2
R28 KES0 5 Left power window up relay X-1
R29 KES0 6 Head lamp Hi relay X-1
R30 KES0 5 Head lamp Lo relay X-2
R31 S 10 Passing relay Q-1
R32 KES0 5 Dust indicator relay X-1
R33 M 6 Parking brake manual switch Q-8
R34 YAZAKI (FA) 7 Left power window switch S-9
R35 YAZAKI (FA) 7 Right power window switch S-9
R36 KES0 5 Engine power relay V-2
R37 KES0 5 Auto preheat relay V-2
RAD PA 9 Cassette stereo P-2
RDC PA 9 Radio P-1
RE1 KES1 2 Resistor W-6
R-L2 1-pin connector 1 Room lamp 2 E-8
RT2 Terminal 1 Emergency steering timer —
RTL DT-T 6 Retarder lever potentiometer P-8
RWL 1-pin connector 2 Left rear working lamp A-8, G-9
RWR 1-pin connector 2 Right rear working lamp B-8, E-9
SBS DT-T 2 Seat belt switch U-3
SDE M 6 Side lamp switch N-2
SF1 DT-T 12 (G) Gearshift lever Q-8
SF2 DT-T 2 Gearshift lever P-8
S-NET MIC 5 S-NET monitoring connector V-8
ST1 Terminal 1 Emergency steering timer —
T01 DT 2 Radiator coolant level switch B-2
T03 DT 2 Transmission oil filter switch E-8
T04 DT 2 Steering oil temperature switch H-9
T05 DT 2 Hydraulic oil filter switch H-2
T06 DT 2 Hydraulic oil level switch H-9
T08 DT 2 Fuel level sensor A-2
T10 DT 3 Inclination sensor K-9
20-220 HM300-1
c 1 c
(9)

T11 DT 2 Air cleaner clogging sensor A-4
T14 DT 2 Retarder oil temperature sensor (M) L-4
T15 DT 2 Front brake oil temperature sensor A-2
TC.INT DT 3 Torque converter oil pressure sensor AF-6
TC.SE DT 2 Torque converter oil temperature sensor AF-7
TEL DT-T 12 (B) Tele-management Q-8
TG 1-pin connector 1 Tachograph C-9
TG2 1-pin connector 1 Tachograph C-9
TM1 HD-18 14 Intermediate connector AF-8
TM2 HD-24 31 Intermediate connector AF-8
TMF M 1 Intermediate connector V-3
TMO M 1 Intermediate connector W-7
TWH DT 2 Engine coolant high-temperature sensor Y-6
TWL DT 2 Engine coolant low-temperature sensor AB-8
WFM M 6 Front wiper motor Q-1
WFR KES0 6 Intermittent windshield wiper relay R-1
WM M 4 Washer motor A-4
WPS DT-T 12 (B) Wiper switch P-7
WRF M 6 Front working lamp switch N-2
WRR M 6 Rear working lamp switch N-2
HM300-1 20-221
1 c
(9) c
20-222 HM300-1
c 1 c
HM300-1 20-223
1 ! !
20-224 HM300-1
! 1 !
HM300-1 20-225
1 ! !
20-226 HM300-1
! 1 !
HM300-1 20-227
1 ! !
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

★ The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.
X type connector
No. of
pins T-adapter
Male (female housing) Female (male housing) Part No.
1 Part number: 08055-00181 Part number: 08055-00191 799-601-7010
2 799-601-7020
Part number: 08055-00282 Part number: 08055-00292
3 799-601-7030
4 799-601-7040
Terminal part number: 79A-222-3370 Terminal part number: 79A-222-3390
— • Electric wire size: 0.85 • Electric wire size: 0.85 —

• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty: 20

• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
20-228 HM300-1
! 1 !
SWP type connector

No. of
pins T-adapter
6 799-601-7050
8 799-601-7060
12 799-601-7310
14 799-601-7070
HM300-1 20-229
1 ! !
X type connector
No. of
pins T-adapter
16 799-601-7320
Terminal part number: Terminal part number:

• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty: 20
Terminal part number: Terminal part number:

• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
20-230 HM300-1
! 1 !
M type connector
No. of
pins T-adapter
1 Part number: 08056-00171 Part number: 08056-00181 799-601-7080
2 799-601-7090
3 799-601-7110
4 799-601-7120
6 799-601-7130
8 799-601-7340
HM300-1 20-231
1 !
(5) !
S type connector
No. of
pins T-adapter
8 799-601-7140
10
799-601-7150
(White)
12
799-601-7350
(White)
16
799-601-7330
(White)
20-232 HM300-1
! 1 !
S type connector
No. of
pins T-adapter
10
—
(Blue)
— —
12
799-601-7160
(Blue)
16
799-601-7170
(Blue)
HM300-1 20-233
1 ! !
MIC type connector

No. of
pins T-adapter
Body part number: 79A-222-2640 Body part number: 79A-222-2630

7 —
(Q’ty: 5) (Q’ty: 5)

11 (Q’ty: 5) (Q’ty: 5) —
5 799-601-2710

(Q’ty: 5) (Q’ty: 5)
9 799-601-2950

(Q’ty: 5) (Q’ty: 5)
13 799-601-2720

(Q’ty: 2) (Q’ty: 2)
20-234 HM300-1
! 1 !
MIC type connector

No. of
pins T-adapter
17 799-601-2730

(Q’ty: 2) (Q’ty: 2)
21 799-601-2740

(Q’ty: 2) (Q’ty: 2)

—
(Q’ty: 50) (Q’ty: 50)
HM300-1 20-235
1 ! !
MIC type connector

No. of
pins T-adapter
8 799-601-7180
Housing part number: 79A-222-3430

—
(Q’ty: 5)
12 799-601-7190

—
(Q’ty: 5)
16 799-601-7210

—
(Q’ty: 5)
20 799-601-7220

—
(Q’ty: 5)
★ Terminal part number: 79A-222-3470 (No relation with number of pins)
20-236 HM300-1
! 1 !
AMP070 type connector

No. of
pins T-adapter
10 799-601-7510
— Part number: 7821-92-7330
12 799-601-7520
— Part number: 7821-92-7340
14 799-601-7530
— Part number: 7821-92-7350
18 799-601-7540
— Part number: 7821-92-7360
20 799-601-7550
— Part number: 7821-92-7370
HM300-1 20-237
(7)
1 ! !
L type connector
No. of
pins T-adapter
2 —
— —
Connector for PA
No. of
pins T-adapter
9 —
— —
Bendix MS connector
No. of
pins T-adapter
10 799-601-3460
— —
20-238 HM300-1
! 1 !
KES 1 (Automobile) connector

No. of
pins T-adapter
2 —
Part number: 08027-10210 (Natural color) Part number: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
4 —
08027-10420 (Black) 08027-10470 (Black)
6 —
08027-10620 (Black) 08027-10670 (Black)
HM300-1 20-239
1 ! !
KES 1 (Automobile) connector

No. of
pins T-adapter
8 —
08027-10820 (Black) 08027-10870 (Black)
20-240 HM300-1
! 1 !
Connector for relay (Socket type)

No. of
pins T-adapter
5 799-601-7360
— —
6 799-601-7370
— —
F type connector
No. of
pins T-adapter
4 —
— —
HM300-1 20-241
1 ! !
[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 Series connector

(shell size T-adapter
code) Body (plug) Body (receptacle)
Part No.
Pin (male terminal) Pin (female terminal)
799-601-9210
Part number: 08191-11201, 08191-11202, Part number: 08191-14101, 08191-14102,

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male terminal)
799-601-9210

08191-11205, 08191-12206 08191-13105, 08191-13106
799-601-9220

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220

08191-22205, 08191-22206 08191-23105, 08191-23106
20-242 HM300-1
! 1 !

Part No.
799-601-9230
18-20 Part number: 08191-31201, 08191-31202 Part number: 08191-34101, 08191-34102

799-601-9230
Part number: 08191-32201, 08191-32202 Part number: 08191-33101, 08191-33102

799-601-9240

799-601-9240
HM300-1 20-243
1 ! !

Part No.
799-601-9250

799-601-9250

799-601-9260

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260

08191-62205, 08191-62206 08191-63105, 08191-63106
20-244 HM300-1
! 1 !

Part No.
799-601-9270

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280

08191-81203, 08191-81204, 08191-84103, 08191-84104,
24-23 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280

08191-82203, 08191-82204, 08191-83103, 08191-83104,
08191-82205, 08191-82206 08191-83105, 08191-83106
HM300-1 20-245
(6)
1 ! !

Part No.
799-601-9290

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290

08191-92205, 08191-92206 08191-93105, 08191-93106
20-246 HM300-1
! 1 !
DT Series connector
No. of
pins T-adapter
Body (plug) Body (receptacle) Part No.
2 799-601-9020
Part number: 08192-12200 (normal type) Part number: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
HM300-1 20-247
1 ! !
DT Series connector
No. of
pins T-adapter
8GR : 799-601-9060
8B : 799-601-9070
8
8G : 799-601-9080
8BR : 799-601-9080
Part number: 08192-1820 " (normal type) Part number: 08192-1810 " (normal type)
08192-2820 " (fine wire type) 08192-2810 " (fine wire type)
12GR : 799-601-9110
12B : 799-601-9120
12
12G : 799-601-9130
12BR : 799-601-9140
Part number: 08192-1920 " (normal type) Part number: 08192-1910 " (normal type)
08192-2920 " (fine wire type) 08192-2910 " (fine wire type)
20-248 HM300-1
! 1 !
(5)
DTM Series connector

No. of
pins T-adapter
2 799-601-9010
DTHD Series connector

No. of
pins T-adapter
1 —
Part number: 08192-31200 (Contact size #12) Part number: 08192-31100 (Contact size #12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
HM300-1 20-249
(6)
1 ! !
20 Troubleshooting
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

DRC26 Series connector

No. of
pins T-adapter
24 799-601-9360
— Part No.: 7821-93-3110
40
799-601-9350
(A)
— Part No.: 7821-93-3120
40
799-601-9350
(B)
— Part No.: 7821-93-3130
20-249-1 HM300-1
! (7) !
TROUBLESHOOTING T-ADAPTER TABLE
T-ADAPTER TABLE
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Port No. Connector type Pin No.
—
799-601-2600 For measuring box Econo-21P ! ! ! ! ! !
799-601-3100 For measuring box MS-37P !
799-601-3200 For measuring box MS-37P !
799-601-3300 For measuring box Econo-24P !
799-601-3360 Plate For MS box
799-601-3410 BENDIX (MS) 24P ! !
799-601-3420 BENDIX (MS) 24P ! !
799-601-3430 BENDIX (MS) 17P ! !
799-601-3440 BENDIX (MS) 17P ! !
799-601-3450 BENDIX (MS) 5P ! !
799-601-3460 BENDIX (MS) 10P ! !
799-601-3510 BENDIX (MS) 5P ! !
799-601-3520 BENDIX (MS) 14P ! !
799-601-3530 BENDIX (MS) 19P ! !
799-601-2910 BENDIX (MS) 14P ! !
799-601-3470 CASE !
799-601-2710 MIC 5P ! ! ! !
799-601-2720 MIC 13P ! ! ! !
799-601-2730 MIC 17P ! ! ! ! ! ! !
799-601-2740 MIC 21P ! ! ! ! ! ! !
799-601-2950 MIC 9P ! ! ! !
799-601-2750 ECONO 2P ! !
799-601-2760 ECONO 3P ! !
799-601-2770 ECONO 4P ! !
799-601-2780 ECONO 8P ! !
799-601-2790 ECONO 12P ! !
799-601-2810 DLI 8P ! !
799-601-2820 DLI 12P ! !
799-601-2830 DLI 16P ! !
799-601-2840 Extension cable ! ! !
799-601-2850 CASE !
799-601-7010 X 1P ! !
799-601-7020 X 2P ! ! ! !
799-601-7030 X 3P ! ! ! !
799-601-7040 X 4P ! ! ! !
799-601-7050 SWP 6P ! ! !
799-601-7060 SWP 8P ! ! !
799-601-7310 SWP 12P !
799-601-7070 SWP 14P ! !
799-601-7320 SWP 16P !
20-250 HM300-1
! (5)
1 !
KIT No.
799-601-7080 M 1P ! !
799-601-7090 M 2P ! ! ! !
799-601-7110 M 3P ! ! ! !
799-601-7120 M 4P ! ! ! !
799-601-7130 M 6P ! ! ! !
799-601-7340 M 8P !
799-601-7140 S 8P ! ! ! !
799-601-7150 S 10P-White ! ! ! !
799-601-7160 S 12P-Blue ! ! !
799-601-7170 S 16P-Blue ! ! ! !
799-601-7330 S 16P-White !
799-601-7350 S 12P-White !
799-601-7180 AMP040 8P !
799-601-7190 AMP040 12P ! !
799-601-7210 AMP040 16P ! ! ! !
799-601-7220 AMP040 20P ! ! ! !
799-601-7230 Short connector X-2 ! ! ! !
799-601-7240 Case ! !
799-601-7270 Case !
799-601-7510 070 10P !
799-601-7520 070 12P !
799-601-7530 070 14P !
799-601-7540 070 18P !
799-601-7550 070 20P !
799-601-7360 Relay connector 5P !
799-601-7370 Relay connector 6P !
799-601-7380 JFC connector 2P !
799-601-9010 DTM 2P ! !
799-601-9020 DT 2P ! !
799-601-9030 DT 3P ! !
799-601-9040 DT 4P ! !
799-601-9050 DT 6P ! !
799-601-9060 DT 8P-Gray ! !
799-601-9070 DT 8P-Black ! !
799-601-9080 DT 8P-Green ! !
799-601-9090 DT 8P-Blown ! !
799-601-9110 DT 12P-Gray ! !
799-601-9120 DT 12P-Black ! !
799-601-9130 DT 12P-Green ! !
799-601-9140 DT 12P-Blown ! !
799-601-9210 HD30 18-8 ! !
799-601-9220 HD30 18-14 ! !
HM300-1 20-251
1 !
(5) !
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
799-601-9230 HD30 18-20 ! !
799-601-9240 HD30 18-21 ! !
799-601-9250 HD30 24-9 ! !
799-601-9260 HD30 24-16 ! !
799-601-9270 HD30 24-21 ! !
799-601-9280 HD30 24-23 ! !
799-601-9290 HD30 24-31 ! !
799-601-9310 Plate For HD30 ! ! !
799-601-9320 For measuring box For DT, HD ! ! !
799-601-9330 Case !
799-601-9340 Case !
799-601-9350 DRC26 40P !
799-601-9360 DRC26 24P !
799-601-9410 For NE, G sensor 2P !
799-601-9420 For boost pressure, fuel 3P !
799-601-9430 PVC socket 2P !
20-252 HM300-1
! (7)
1 !
CATEGORIES, PROCEDURE, AND METHOD OF USING
TROUBLESHOOTING TROUBLESHOOTING CHARTS

TROUBLESHOOTING CHARTS
1. Category of troubleshooting code
★ If the machine monitor displays a failure code, it also displays the controller name at the same time, so
the troubleshooting codes are categorized to match each controller name (this may also include the
electrical system, where some failure codes are not displayed).
★ The hydraulic and mechanical system, for which the machine monitor cannot display a failure code, is
categorized as H Mode.
Troubleshooting Code Troubleshooting system
ENG Troubleshooting of engine controller system
TM Troubleshooting of transmission controller system
BK Troubleshooting of retarder controller(q1) system
MON Troubleshooting of machine monitor system
H Troubleshooting of hydraulic, mechanical system
S Troubleshooting of the engine body
2. Troubleshooting procedure
★ If a problem occurs on the machine, or if it is felt that there is a problem, carry out troubleshooting as
follows.
1) When machine monitor displays failure code

If a failure code is displayed on the machine monitor at the same time as the problem occurs, check the
content of the display, then go to the applicable troubleshooting chart for the failure code.
2) When machine monitor does not display failure code, but trouble data is recorded
If a problem occurs but the failure code display cannot be checked on the machine monitor, use the trou-
ble data display function in the machine monitor service mode to check for a failure code.
If a failure code is recorded, there is a high probability that this is the cause, so go to the applicable trou-
bleshooting chart.
3) When machine monitor does not display failure code and trouble data is also not recorded
If a problem occurs but the failure code display cannot be checked on the machine monitor, and the
problem is also not recorded by the trouble data display function in the machine monitor service mode,
there is a probability that it is a problem in the electrical system that cannot be detected by a controller
or that a problem has occurred in the hydraulic and mechanical system.
In this case, check the nature of the problem and go to the applicable troubleshooting chart.
HM300-1 20-253
1 c
(5) c
3. Method of using YES/NO troubleshooting flowchart (ENG mode, TM mode, BK mode, MON mode)
1) Failure code number and problem
The title at the top of the troubleshooting chart gives the failure code and problem with the machine.
Example: M-13 Abnormality in buzzer
2) General precautions
When carrying out troubleshooting, precautions are given at the top of the page under the title and
marked with ★.
The precautions common to all troubleshooting are marked ★ in the Contents, so they must always be
followed checked before carrying out the troubleshooting.
Example: ★ Before carrying out troubleshooting, check that all the related connectors are properly in-
serted.
★ Always connect any disconnected connectors before going on the next step.
3) Distinguishing conditions
Even with the same problem, the method of troubleshooting may differ according to the model, compo-
nent, or problem. In such cases, the failure mode is further divided into sections marked with small let-
ters (for example, a)), so go to the appropriate section to carry out troubleshooting.
If the troubleshooting chart is not divided into sections, start troubleshooting from the first check item in
the flowchart.
Example: a) When starting switch is turned ON (3 sec), buzzer does not sound
b) Buzzer always sounds
4) Method of following troubleshooting chart NO
• Check or measure the item inside YES
, and according to the answer follow either the YES line
or the NO line to go to the next . (Note: The number written at the top right corner of
the is an index number; it does not indicate the order to follow.)
• Following the YES or NO lines according to the results of the check or measurement will lead finally
to the Cause box. Check the cause and take the action given in the Remedy box on the right.
• To the left of the there is (a box formed by a broken line). This contains the methods
for inspection or measurement, and the judgement values. If the judgment values to the left of the
[ ] are correct or the answer to the question inside the is YES, follow the YES line; if the
judgement value is not correct, or the answer to the question is NO, follow the NO line.
• The gives the preparatory work needed for inspection and measurement, and the judge-
ment values. If this preparatory work is neglected, or the method of operation or handling is mistak-
en, there is danger that it may cause mistaken judgment, or the equipment may be damaged.
Therefore, before starting inspection or measurement, always read the instructions carefully, and
start the work in order from the first item.
5) Mounting location, pin number
For details of the connector pin number and check and measurement locations of the connector pin
numbers appearing in the flowchart, see CONNECTOR TYPE AND MOUNTING LOCATION.
20-254 HM300-1
c 1 c
(9)
4. Method of using YES-NO type troubleshooting (H mode)
Step 1. Questioning the operator 1. Steering does not work Symptom [Example]
The questions to ask the operator are given be-
low the failure symptom. If the answers to the Ask the operator about the following points.
questions match the information given, follow • Did the steering suddenly stop working?
the arrow to reach the probable cause of the fail- Breakage in steering equipment
ure. • Had the steering gradually been becom-
Consider the contents of the questions and con- ing heavy?
sult the table while proceeding to Steps 2 and 3 Internal wear of steering equipment,
to grasp the true cause. defective seal
Checks before staring [Example]

Step 2. Checks before troubleshooting
Before starting the main troubleshooting and • Is the oil level in the hydraulic tank correct?
measuring the hydraulic pressure, first check the Is the type of oil correct?
Checks before Starting items, and check for oil • Is there any leakage of oil from the steer-
leakage and loose bolts. These checks may ing valve or Orbit-roll?
avoid time wasted on unnecessary troubleshoot- • Has the safety bar been removed from the
ing. frame?
The items given under Checks before Starting
are items which must be considered particularly
for that symptom before starting troubleshooting.
[Example 1]
Step 3. Using cross-reference table
1) Operate the machine to carry out the checks No. Problems Remedy
in the troubleshooting item column.
Mark the items where the results match the 1 Steering does not work to the left or right.
symptom. Same as Item 1, but abnormality in actuation of
2
★ It is not necessary to follow the trouble- work equipment.
shooting checks in order; follow an order 3 Steering can only be operated to one side.
which is easiest to carry out trouble-
shooting. 4 Steering wheel is heavy and cannot be turned.
[Example 2]
2) Find the appropriate cause from the cause
column. If the symptom appears, the c
marks on that line indicate the possible caus-
es. (For item No. 2 in the table on the right,
the possible causes are c or e.)
If there is only one c:
Carry out the other troubleshooting items
(where the same cause is marked with c),
check if the symptom appears, then repair.
If there are two c:
Go on to Step 3) to narrow down the possible
causes.
HM300-1 20-255
1 c
(9) c
3) Operate the machine and check the trouble-

shooting items other than those in 1).
Operate the machine and check the items in
the same way as in 1), and if the symptom
appears, mark that item. (In the chart on the
right, the symptom appears again for item 5).
4) Find the appropriate cause from the cause

column. In the same way as in Step 2), if the
symptom appears, the c marks on that line
indicate the possible causes. (For item No. 5
in the table on the right, the possible causes
are b or e.)
5) Narrow down the possible causes.

There is one common cause among the
causes located in Steps 2) and 4). (One
cause marked c appears on the line for both
items.) This cause is common to both the
symptoms in troubleshooting Steps 1) and
3).
★ The causes which are not common to
both troubleshooting items (items which
are not marked c for both symptoms)
are unlikely causes, so ignore them.
(In the example given on the right, the
causes for Troubleshooting Item 2 are c
or e, and the cause for Troubleshooting
Item 5 are b or e, so cause e is common
to both.)
6) Repeat the operations in Steps 3), 4) and 5)

until one cause (one common cause) re-
mains.
★ If the causes cannot be narrowed down
to one cause, narrow the causes down
as far as possible.
7) Remedy
If the causes are narrowed down to one
common cause, take the action given in the
remedy column.
The symbols given in the remedy column in-
dicate the following:
: Replace, : Repair, A: Adjust, C: Clean
20-256 HM300-1
c 1 c
(5)
TROUBLESHOOTING 20 TROUBLESHOOTING
TROUBLESHOOTING OF
ENGINE CONTROLLER SYSTEM
(ENG MODE)
ENG mode related electrical circuit diagram ........................................................................................... 20-303

Content of display and problem that appears on machine for each failure code...................................... 20-308
ENG-1 Failure code [A000N1] (Engine: Overrun N1)) ....................................................................... 20-320
ENG-2 Failure code [A570NX] (Engine oil filter: Clogged (NX)) ........................................................ 20-321
ENG-3 Failure code [AD00L2] (Common rail: * See Contents (L2)) .................................................. 20-322
ENG-4 Failure code [AD00MA] (Common rail: Function impossible (MA)) ........................................ 20-322
ENG-5 Failure code [AD10L3] (Fuel supply pump: * See Contents (L3)) .......................................... 20-323
ENG-6 Failure code [AD10MA] (Fuel supply pump: Function impossible (MA)) ................................ 20-325
ENG-7 Failure code [AD10MB] (Fuel supply pump: Drop in function (MB)) ...................................... 20-325
ENG-8 Failure code [AD11KA] (Fuel supply pump solenoid valve 1: Disconnection (KA)) ................ 20-326
ENG-9 Failure code [AD11KB] (Fuel supply pump solenoid valve 1: Short circuit (KB)) ................... 20-327
ENG-10 Failure code [AD51KA] (Fuel supply pump solenoid valve 2: Disconnection (KA)) ............... 20-328
ENG-11 Failure code [AD51KB] (Fuel supply pump solenoid valve 2: Short circuit (KB)) ................... 20-329
ENG-12 Failure code [ADA1KA] (No. 1 injector solenoid valve: Disconnection (KA)) ......................... 20-330
ENG-13 Failure code [ADAZKB] (No. 1, 2, 3 injector solenoid valve: Short circuit (KB)) .................... 20-431
ENG-14 Failure code [ADB1KA] (No. 2 injector solenoid valve: Disconnection (KA)) ......................... 20-335
ENG-15 Failure code [ADC1KA] (No. 3 injector solenoid valve: Disconnection (KA)) ......................... 20-336
ENG-16 Failure code [ADD1KA] (No. 4 injector solenoid valve: Disconnection (KA)) ......................... 20-337
ENG-17 Failure code [ADDZKB] (No. 4, 5, 6 injector solenoid valve: Short circuit (KB)) .................... 20-338
ENG-18 Failure code [ADE1KA] (No. 5 injector solenoid valve: Disconnection (KA)) ......................... 20-342
ENG-19 Failure code [ADF1KA] (No. 6 injector solenoid valve: Disconnection (KA)) ......................... 20-343
ENG-20 Failure code [B@BAZG] (Engine oil: Drop in oil pressure (ZG)) ............................................ 20-344
ENG-21 Failure code [B@BAZK] (Engine oil: Drop in level (ZK)) ........................................................ 20-345
ENG-22 Failure code [B@BCNS] (Radiator coolant: Overheat (NS)) .................................................. 20-346
ENG-23 Failure code [D181KZ] (Preheating relay contact: Disconnection or short circuit (KZ)) ......... 20-347
ENG-24 Failure code [D182KZ] (Preheating relay coil: Disconnection or short circuit (KZ)) ............... 20-349
ENG-25 Failure code [D1D0KB] (Engine controller load power source relay: Short circuit (KB)) ........ 20-350
ENG-26 Failure code [D5ZAKX] (Engine throttle modify 1 signal: Input signal outside range (KX)) .... 20-352
ENG-27 Failure code [DB20KT] (Engine controller: Abnormality inside controller (KT)) ..................... 20-353
ENG-28 Failure code [DB22KK] (Engine controller load power source relay:
Drop in power supply voltage, input (KK)) ....................................... 20-355
ENG-29 Failure code [DB29KQ] (Engine controller connection wiring harness:
Model selection signal mismatch (KQ)) ........................................... 20-357
ENG-30 Failure code [DB2AMA] (Engine controller fuel injection quantity control switch:
Function impossible (MA)) ............................................................... 20-358
ENG-31 Failure code [DD11KB] (Starting switch: Short circuit (KB)) ................................................... 20-359
ENG-32 Failure code [DDA1L5] (Acceleration switch: * See Contents (L5)) ....................................... 20-360
ENG-33 Failure code [DDE2L6] (Engine oil pressure switch: * See Contents (L6)) ............................ 20-362
ENG-34 Failure code [DGE2KX] (Engine coolant temperature sensor (for high-temperature):
Input signal outside range (KX)) ...................................................... 20-364
ENG-35 Failure code [DGE3L6] (Engine coolant temperature sensor (for low-temperature):
* See Contents (L6)) ......................................................................... 20-365
ENG-36 Failure code [DH30KX] (Boost pressure sensor: Input signal outside range (KX)) ................ 20-366
ENG-37 Failure code [DH40KX] (Common rail pressure sensor: Input signal outside range (KX)) ..... 20-368
ENG-38 Failure code [DK10KX] (Throttle angle sensor: Input signal outside range (KX)) .................. 20-370
ENG-39 Failure code [DLE3LC] (Engine Ne speed sensor: * See Contents (LC)) .............................. 20-372
ENG-40 Failure code [DLH1LC] (Engine G speed sensor: * See Contents (LC)) ................................ 20-373
ENG-41 Engine does not start (starting motor does not turn) .............................................................. 20-374
HM300-1 20-301
1 c
(9) c
TROUBLESHOOTING
Appendix: Table for Failure Phenomenon Code
Failure Failure
Phenomenon Summary of Failure Phenomenon Summary of Failure
Code Code
An impossible combination of clutch fill signals turn ON more
KA Disconnection L0
than 2 channels simultaneously.
KB Short-circuiting L1 While the order current to ECMV is off, the fill signal is ON.
Power source voltage and
KK L2 The fuel pressure exceeds the specified max. value.
input lowered
Model selection signal
KQ L3 The intended unit is out of control.
wrong
ON and OFF signals in two systems do not concur with each
KR Communication ineffective L4
other.
Signals from engine revolution, C terminal, hydraulic pressure
Controller internally abnor-
KT L6 switch and coolant temperature sensor do not match up with
mal
the respective actual condition.
KX Input signal out of range L8 Analog signals in two systems do not concur with each other.
Disconnection or short-cir- Signals of revolution speed in two systems do not concur with
KZ LC
cuiting each other.
MA Function ineffective LD The switch is kept depressed for an unusually long time.
MB Function lowered LH While the order current to ECMV is on, the fill signal is OFF.
MW Sliding
20-302 HM300-1
c 1 c
(9)
TROUBLESHOOTING
TROUBLESHOOTING ENG MODE RELATED ELECTRICAL CIRCUIT DIAGRAM
ENG MODE RELATED ELECTRICAL CIRCUIT DIAGRAM

★ This circuit diagram has been made by extracting the engine controller related circuits and starting motor
related circuits from the overall electrical circuit diagram.
20-304 HM300-1
c 1 c
(9)
TROUBLESHOOTING
HM300-1 20-305
1 ! !
TROUBLESHOOTING
20-306 HM300-1
! 1 !
CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE
TROUBLESHOOTING
TROUBLESHOOTING FOR EACH FAILURE CODE
CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON

MACHINE FOR EACH FAILURE CODE
Failure code Location of failure Nature of failure Probable cause
A000N1 Engine: Overrun (N1) Engine speed went above oper-

(ENG-1) ating range
A570NX Engine oil filter: Clogged (NX) Signal circuit of engine oil filter • Clogged engine oil filter (when system is
(ENG-2) clogging switch became open working normally)
(shut off from GND) while en- • Defective engine oil filter clogging switch
gine was running • Disconnection in switch signal circuit wir-
ing harness
• Defective engine controller
AD00L2 Common rail: * See Contents Common rail fuel pressure has • Viscosity of fuel is too high (unsuitable
(ENG-3) (L2) risen to high pressure (level 1) fuel)
• Defective overflow valve
• Clogged overflow piping
• Defective pressure limiter
• Defective common rail fuel pressure sen-
sor
AD00MA Common rail: Function im- Common rail fuel pressure has • Same as failure code [AD00L2]
(ENG-4) possible (MA) risen to high pressure (level 2)
AD10L3 Fuel supply pump: * See Non-force feed (level 1) has oc- • Defective fuel low-pressure circuit (etc.)
(ENG-5) Contents (L3) curred in fuel supply pump • Defective fuel supply pump PCV
• Defective pressure limiter
• Defective common rail fuel pressure sen-
sor
• Defective fuel injector
• Leakage from high-pressure fuel piping
AD10MA Fuel supply pump: Function Abnormal pressure has oc- • Same as failure code [AD00L2]
(ENG-6) impossible (MA) curred in common rail fuel pres-
sure
AD10MB Fuel supply pump: Drop in Non-force feed (level 2) has oc- • Same as failure code [AD10L3]
(ENG-7) function (MB) curred in fuel supply pump
AD11KA Fuel supply pump solenoid Disconnection has occurred in • Defective fuel supply pump PCV1
(ENG-8) valve 1: Disconnection (KA) PCV1 circuit of fuel supply pump • Disconnection in PCV1 (+) circuit wiring
harness
• Disconnection or short circuit with chas-
sis ground in PCV1 (–) circuit wiring har-
ness
AD11KB Fuel supply pump solenoid Excessive current has flowed in • Defective fuel supply pump PCV1
(ENG-9) valve 1: Short circuit (KB) PCV1 circuit of fuel supply pump • Short circuit with chassis ground or hot
short in PCV1 (+) circuit wiring harness
• Hot short in PCV1 (–) circuit wiring har-
ness
20-308 HM300-1
c 1 c
(9)
TROUBLESHOOTING
★ The code (ENG-**) given below the failure code is the troubleshooting number.
Condition when normal Action by controller Problem that appears on machine Action code
• Stops fuel injection until engine Engine speed varies abnormally E02
speed goes down to operating
range
• Sensor resistance value • Carries out operation under • If machine continues to be used E01
OF terminal - terminal normal control as it is, there is danger that dirt will
• When normal: Max. 1 Ω circulate inside engine
• When clogged: Min. 1 MΩ
• Carries out operation with lim- • Engine output is reduced E03

ited output
• Carries out operation with lim- • Engine output and speed are re- E03
ited output and engine speed duced
• Carries out operation with lim- • Engine output is reduced E03

ited output
• Carries out operation under • Engine output is reduced E03

normal control
• Carries out operation with lim- • Engine output and speed are re- E03
ited output and engine speed duced
• Solenoid resistance value • Turns output to PCV1 OFF • No great effect on machine E03
PCV1 (male) (1) – (2): 2.3 – 5.3Ω (however, if failure code
[AD51KA] occurs at the same
time, the engine stops)
PCV1 (male) (1) – (2): 2.3 – 5.3Ω (however, if failure code
[AD51KB] occurs at the same
HM300-1 20-309
1 c
(9) c
TROUBLESHOOTING
AD51KA Fuel supply pump solenoid A disconnection has occurred in • Defective fuel supply pump PCV2
(ENG-10) valve 2: Disconnection (KA) the PCV2 circuit of the fuel sup- • Disconnection in PCV2 (+) circuit wiring
ply pump harness
sis ground in PCV2 (–) circuit wiring har-
ness
AD51KB Fuel supply pump solenoid Excessive current has flowed in • Defective fuel supply pump PCV2
(ENG-11) valve 2: Short circuit (KB) PCV2 circuit of fuel supply pump • Short circuit with chassis ground or hot
short in PCV2 (+) circuit wiring harness
• Hot short in PCV1 (–) circuit wiring har-
ness
ADA1KA No. 1 injector solenoid valve: Disconnection has occurred in • Defective No. 1 injector solenoid
(ENG-12) Disconnection (KA) No. 1 injector solenoid circuit • Disconnection in solenoid (+) circuit wir-
ing harness
• Disconnection in solenoid (–) circuit wir-
ing harness
ADAZKB No. 1, 2, 3 injector solenoid Excessive current has flowed in • Defective No. 1 injector solenoid
(ENG-13) valve: Short circuit (KB) No. 1 injector solenoid circuit, • Defective No. 2 injector solenoid
No. 2 injector solenoid circuit, or • Defective No. 3 injector solenoid
No. 3 injector solenoid circuit • Short circuit with chassis ground or hot
short in No. 1 solenoid (+) circuit and (–)
circuit wiring harness
• Short circuit with chassis ground or hot
ADB1KA No. 2 injector solenoid valve: Disconnection has occurred in • Defective No. 2 injector solenoid
ing harness
ing harness
ADC1KA No. 3 injector solenoid valve: Disconnection has occurred in • Defective No. 3 injector solenoid
ing harness
ing harness
ADD1KA No. 4 injector solenoid valve: Disconnection has occurred in • Defective No. 4 injector solenoid
ing harness
ing harness
20-310 HM300-1
c 1 c
(9)
TROUBLESHOOTING
PCV2 (male) (1) – (2): 2.3 – 5.3 Ω (however, if failure code
[AD11KA] occurs at the same
PCV2 (male) (1) – (2): 2.3 – 5.3 Ω (however, if failure code
[AD11KB] occurs at the same
• Solenoid resistance value • Turns output to No. 1 injector • Engine output is reduced E03
CN1 (male) (1) – (2): 0.4 – 1.1 Ω solenoid OFF
• Solenoid resistance value • Turns output to No. 1 injector • Engine output is greatly reduced E03
CN2 (male) (1) – (2): 0.4 – 1.1 Ω • Turns output to No. 2 injector
• Turns output to No. 3 injector
solenoid OFF
HM300-1 20-311
1 c
(9) c
TROUBLESHOOTING
ADDZKB No. 4, 5, 6 injector solenoid Excessive current has flowed in • Defective No. 4 injector solenoid
(ENG-17) valve: Short circuit (KB) No. 4 injector solenoid circuit, • Defective No. 5 injector solenoid
No. 5 injector solenoid circuit, or • Defective No. 6 injector solenoid
No. 6 injector solenoid circuit • Short circuit with chassis ground or hot
short in No. 4 solenoid (+) circuit and
(–) circuit wiring harness
ADE1KA No. 5 injector solenoid valve: Disconnection has occurred in • Defective No. 5 injector solenoid
ing harness
ing harness
ADF1KA No. 6 injector solenoid valve: Disconnection has occurred in • Defective No. 6 injector solenoid
ing harness
ing harness
B@BAZG Engine oil: Drop in oil pres- When running at low idle, signal • Drop in engine oil pressure (when sys-
(ENG-20) sure (ZG) circuit of engine oil pressure tem is working normally)
low-pressure switch became • Defective engine oil low-pressure switch
closed (connected to GND), or • Defective engine oil high-pressure
when engine speed was more switch
than 1300 rpm, signal circuit of • Short circuit with chassis ground in low-
oil pressure high-pressure pressure switch signal circuit wiring har-
switch became closed (connect- ness
ed to GND) • Short circuit with chassis ground in high-
pressure switch signal circuit wiring har-
ness
B@BAZK Engine oil: Drop in level (ZK) Signal circuit of engine oil pres- • Drop in engine oil level (when system is
(ENG-21) sure switch became open (shut working normally)
off from GND) • Defective engine oil level switch
• Disconnection in switch circuit wiring
harness
B@BCNS Radiator coolant: Overheat Engine coolant temperature • Engine coolant temperature overheats
(ENG-22) (NS) went above operating range (when system is working normally)
20-312 HM300-1
c 1 c
(9)
TROUBLESHOOTING
• Solenoid resistance value • Turns output to No. 4 injector • Engine output is greatly reduced E03
CN4 (male) (1) – (2): 0.4 – 1.1Ω solenoid OFF
CN5 (male) (1) – (2): 0.4 – 1.1Ω • Turns output to No. 5 injector
CN6 (male) (1) – (2): 0.4 – 1.1Ω solenoid OFF
• Turns output to No. 6 injector
solenoid OFF
• Low-pressure switch resistance • Carries out operation under • If the machine continues to be E03
value normal control used as it is, the engine may seize
PSL – ground up
• When engine is stopped:
Max. 1Ω
• When engine speed is 600 rpm
or more: Min. 1 MΩ
• High-pressure switch resistance
value
PSH – ground
Max. 1Ω
• When engine speed is 1300
rpm or more: Min. 1 MΩ
• Switch resistance value • Carries out operation under • If the machine continues to be E01
OL (male) (1) – ground normal control used as it is, the engine may seize
• When oil level is normal: up
Max. 1 Ω
• When oil level is low: Min. 1 MΩ
• Limits fuel injection until tem- • Engine output is reduced E02

perature goes down to operat-
ing range
HM300-1 20-313
1 c
(9) c
TROUBLESHOOTING
D181KZ Preheating relay contact: Dis- Disconnection, short circuit with • Defective heater relay
(ENG-23) connection or short circuit ground, or hot short has occurred • Defective preheater relay
(KZ) in signal circuit of heater relay • Disconnection, short circuit with chassis
ground, or hot short in relay signal circuit
wiring harness
D182KZ Preheating relay coil: Discon- Disconnection or short circuit • Defective preheater relay
(ENG-24) nection or short circuit (KZ) with ground has occurred in • Disconnection or short circuit with chas-
drive circuit of preheater relay sis ground in relay power source circuit
wiring harness
sis ground in relay drive circuit wiring
harness
D1D0KB Engine controller load power Voltage was generated in power • Defective engine power source relay
(ENG-25) source relay: Short circuit supply circuit of controller when • Hot short circuit wiring harness
(KB) starting switch was OFF • Defective engine controller
D5ZAKX Engine throttle modify 1 sig- Voltage in throttle modify signal • Defective transmission controller
(ENG-26) nal: Input signal outside circuit went outside normal • Disconnection or short circuit with chas-
range (KX) range (6 – 15 V) sis ground in signal circuit wiring harness
DB20KT Engine controller: Abnormali- Abnormality has occurred inside • Disconnection in GND circuit wiring har-
(ENG-27) ty inside controller (KT) controller ness
DB22KK Engine controller load power Voltage in controller power sup- • Defective engine power source relay
(ENG-28) source relay: Drop in power ply voltage circuit dropped when • Disconnection or short circuit with chas-
source voltage (KK) starting switch was ON sis ground in relay (1) circuit wiring har-
ness
sis ground in relay (2) circuit wiring har-
ness
ness
ness
DB29KQ Engine controller connecting Model selection signal does not • Defective model selection connector
(ENG-29) wiring harness: Model selec- match setting inside controller • Disconnection in signal 1 circuit wiring
tion signal mismatch (KQ) harness
• Disconnection in signal 2 circuit wiring
harness
• Disconnection in signal 3 circuit wiring
harness
• Disconnection in GND circuit wiring har-
ness
20-314 HM300-1
c 1 c
(9)
TROUBLESHOOTING
• Preheating input signal • Carries out operation under • It is difficult to start the engine in E03
voltage normal control low temperatures
CN4 (3) – ground
• When preheating is stopped:
Max. 1 V
• When preheating is being
used: 20 – 30 V
• Relay resistance value • Cannot turn preheater relay • It is difficult to start the engine in E03
R37 (male) (1) – (2): ON low temperatures
100 – 500Ω
• Power source voltage • Carries out operation under • No great effect on machine E01
CN7 (6)(14) – (5)(13) normal control
When starting switch is OFF:
Max. 1 V
When starting switch is ON:
20 - 30 V
• Signal voltage • Does not modify throttle • There is shock when shifting E01
CN4 (16) – ground: 6 – 15 V transmission
• Unable to drive injectors prop- • If the machine continues to be E03

erly used as it is, the engine may seize
• Stop driving injectors up
• Engine stops during operation
• Engine cannot be started
• Power source voltage • Engine stops during operation E03

CN7 (6)(14) – (5)(13) • Engine cannot be started
When starting switch is OFF:
Max. 1 V
20 – 30 V
• Signal voltage • Uses model with default set- • Does not give specified engine E03
CN4 (13) – ground: Max. 1 V ting to carry out control output
CN4 (14) – ground: 20 – 30 V
CN4 (15) – ground: Max. 1 V
HM300-1 20-315
1 c
(9) c
TROUBLESHOOTING
DB2AMA Engine controller fuel injec- Fuel injection quantity control • Defective setting of fuel injection quantity
(ENG-30) tion quantity control switch: set switch inside controller is not control setting switch
Function impossible (MA) set at correct position • Defective engine controller
DD11KB Starting switch: Short circuit Terminal C signal from starting • Defective starting switch
(ENG-31) (KB) switch came ON when engine • Hot short in signal circuit wiring harness
was running • Defective engine controller
DDA1L5 Acceleration switch: * See Idle validation switch of acceler- • Defective accelerator pedal
(ENG-32) Contents (L5) ator pedal does not match throt- • Disconnection, short circuit with chassis
tle angle signal ground, or hot short in switch signal 2
wiring harness
• Disconnection, short circuit with chassis
ground, or hot short in switch signal 3
wiring harness
• Disconnection in switch GND circuit wir-
ing harness
DDE2L6 Engine oil pressure switch: Engine oil pressure switch sig- • Defective engine oil low-pressure switch
(ENG-33) * See Contents (L6) nal does not match condition of • Defective engine oil high-pressure
engine switch
sis ground in low-pressure switch signal
• Disconnection in high-pressure switch
signal circuit wiring harness
DGE2KX Engine coolant temperature Signal from engine coolant high- • Defective engine coolant high-tempera-
(ENG-34) sensor (for high tempera- temperature sensor is outside ture sensor
ture): Input signal outside normal range • Disconnection or short circuit with chas-
range (KX) sis ground in sensor signal circuit wiring
harness
• Disconnection in sensor GND circuit wir-
ing harness
DGE3L6 Engine coolant temperature Signal from the engine coolant • Defective engine coolant low-tempera-
(ENG-35) sensor (For low-tempera- high-temperature sensor has ture sensor
ture): * See Contents (L6) not been input • Disconnection or short circuit with chas-
sis ground in sensor signal circuit wiring
harness
ing harness
20-316 HM300-1
! (9)
1 !
TROUBLESHOOTING
• Carries out operation under • Fuel injection quantity control set- E01
normal control ting cannot be changed
• Signal voltage • Carries out operation under • Operates normally 10 seconds af- E03
CN4 (2) – ground normal control ter starting
Max. 1 V
When starting switch is at
START: 20 – 30 V
• CN4 (11) – ground (signal 2) • Carries out operation under • No great effect on machine E01
Throttle voltage normal control
• When less than 0.446 V:
Max. 1 V
• When more than 0.446 V:
15 – 30 V
• CN4 (12) – ground (signal 3)
Throttle voltage
• When less than 0.446 V:
20 – 30 V
• When more than 0.446 V:
Max. 1 V
• Low-pressure switch resis- • Carries out operation under • If the machine continues to be E01
tance value normal control used as it is, the engine may seize
PSL – ground up
Max. 1 Ω
• High-pressure switch resis-
tance value
PSH – ground
Max. 1Ω
• Sensor resistance value • Carries out operation under • Coolant temperature display on E01
(coolant temperature: normal control machine monitor is not correct
10 – 100°C) • Fixes coolant temperature sig-
• TWH (male) (1) – (2): nal output to machine monitor
90 – 3.5 kΩ to 90°C
• Sensor resistance value • Carries out operation under • Exhaust gas color in low tempera- E01
(coolant temperature: normal control tures is poor
10 – 100°C) • It is difficult to start the engine in
• TWL (male) (1) – (2): low temperatures
9 – 0.3 kΩ
HM300-1 20-317
1 c
(9) c
TROUBLESHOOTING
DH30KX Boost pressure sensor: Input Signal from boost sensor is out- • Defective boost pressure sensor
(ENG-36) signal outside range (KX) side normal range • Disconnection or short circuit with chas-
sis ground in sensor power source circuit
wiring harness
sis ground in sensor GND circuit wiring
harness
harness
DH40KX Common rail pressure sen- Signal from common rail fuel • Defective common rail fuel pressure sen-
(ENG-37) sor: Input signal outside pressure sensor is outside nor- sor
range (KX) mal range • Disconnection or short circuit with chas-
wiring harness
harness
harness
DK10KX Throttle angle sensor: Input Throttle angle signal from accel- • Defective accelerator pedal
(ENG-38) signal outside range (KX) erator pedal is outside normal • Disconnection or short circuit with chas-
range sis ground in sensor power source circuit
wiring harness
harness
harness
DLE3LC Engine Ne speed sensor: Signal from engine Ne speed • Defective engine Ne speed sensor
(ENG-39) * See Contents (LC) sensor does not match signal • Disconnection or short circuit with chas-
from engine G speed sensor sis ground in sensor signal circuit wiring
harness
harness
DLH1LE Engine G speed sensor: Signal from engine G speed • Defective engine G speed sensor
(ENG-40) * See Contents (LC) sensor does not match signal • Disconnection or short circuit with chas-
from engine Ne speed sensor sis ground in sensor signal circuit wiring
harness
harness
20-318 HM300-1
c 1 c
(9)
TROUBLESHOOTING
• Sensor power source voltage Carries out operation under nor- • No great effect on machine E03
PIM (1) – (3): 4.6 – 5.4 V mal control
• Sensor signal voltage
PIM (2) – (3): 0.3 – 4.7 V
• Sensor power source voltage • Limits output with open control • Engine output is reduced E03
PFUEL (1) – (3): 4.6 – 5.4 V
PFUEL (2) – (3): 0.3 – 4.7 V
• Sensor power source voltage • Controls at low idle or high idle • Engine speed is fixed at low idle E03
AS1 (3) – (1): 4.6 – 5.4 V according to signal from idle or high idle, it is impossible to con-
• Sensor signal voltage validation switch trol acceleration at medium range
AS1 (2) – (1): 0.3 – 4.5 V
• Sensor resistance value • Carries out operation with lim- • Engine output is reduced E03
NE (male) (1) – (2): 85 – 210Ω ited output
• Sensor resistance value • Carries out operation with lim- • Engine output is reduced E03
G (male) (1) – (2): 1.4 – 3.5 kΩ ited output
HM300-1 20-319
1 c
(9) c
TROUBLESHOOTING ENG-1
ENG-1 FAILURE CODE [A000N1] (ENGINE: OVERRUN N1))
★ Nature of failure: The engine speed went above the operating range
Cause Remedy
1
• Turn starting switch ON.
Is another failure code also NO
• Operate machine monitor.
displayed or recorded at same
time?
YES Go to
troubleshooting
for displayed
code
2
Was machine operated in way NO
that would cause engine to
overrun?
YES Check cause of
failure and
repair damage
to engine
3 Go to
NO troubleshoot-
• Start engine. Can engine speed be read ing for failure
• Operate machine monitor. normally? code
[DEL3LC]
YES [DLH1LC]
Defective engine controller Replace
20-320 HM300-1
c 1 c
ENG-2 FAILURE CODE [A570NX] (ENGINE OIL FILTER: CLOGGED (NX))
★ Nature of failure:The signal circuit of the engine oil filter clogging switch became open (shut off from GND)
while the engine was running
Cause Remedy
1
NO
• Stop engine Is engine oil filter clogged?
YES
Clogged engine oil filter Clean or
replace
2
• Turn starting switch Is resistance between terminal NO
OFF. OF (switch end) and ground less Defective engine oil filter clogging Replace
• Disconnect OF. than 1Ω? switch
YES
3
• Turn starting switch Is resistance between terminal NO Defective contact or disconnection
OFF. CN6 (female) (5) and ground less in wiring harness between CN6 Repair or
• Disconnect CN6. than 1Ω? (female) (5) and OF replace
YES
ENG-2 Related electrical circuit diagram
HM300-1 20-321
1 c
(9) c
TROUBLESHOOTING
ENG-3, ENG-4
ENG-3 FAILURE CODE [AD00L2] (COMMON RAIL: * SEE CONTENTS (L2))
★ Nature of failure:The common rail fuel pressure has risen to high pressure (level 1)
Cause Remedy
• Turn starting switch ON. Is another failure code also NO

• Operate machine monitor. displayed or recorded at same
time? Go to trouble-
YES shooting for
displayed
code
Is suitable fuel for ambient NO

temperature being used? Unsuitable fuel being used Replace
YES
• Loosen joint of fuel Does fuel leak out from joint NO

supply pump overflow
valve. when priming pump is operated?
YES
• Disassemble fuel supply In overflow valve, is spring NO

pump overflow valve. damaged, seat worn, or ball Go to trouble-
stuck? shooting No.
7.
YES
Defective overflow valve Replace
Does fuel leak out from joint NO

• Loosen joint of common
rail pressure limiter
when priming pump is operated?
YES
When troubleshooting is carried out NO

for failure code [DH40KX], does Defective pressure limiter Replace
problem occur in electrical system?
YES Defective electric system of
common rail fuel pressure Repair or
sensor replace
NO Defective mechanical system of

Is overflow piping clogged? common rail fuel pressure Replace
sensor
YES
Clogged overflow piping Repair or
replace
ENG-4 FAILURE CODE [AD00MA] (COMMON RAIL: FUNCTION IMPOSSIBLE (MA))
★ Nature of failure:The common rail fuel pressure has risen to high pressure (level 2)
★ Carry out troubleshooting for Troubleshooting No. ENG-3 (failure code [AD00L2].
20-322 HM300-1
c 1 c
(9)
ENG-5 FAILURE CODE [AD10L3] (FUEL SUPPLY PUMP: * SEE CONTENTS (L3))
★ Nature of failure:Non-force feed (level 1) has occurred in the fuel supply pump
Cause Remedy
1
• Turn starting switch ON. Is another failure code also NO
time?
Go to trouble-
YES shooting for
displayed
code
2
Is suitable fuel for ambient NO
temperature being used? Unsuitable fuel being used Replace
YES
3
Is filter or strainer clogged? NO
(See Note 1)
YES Clean or
Clogged filter, strainer replace
4
• Measure fuel pressure (see
Is fuel low-pressure circuit NO
pressure 0.15 - 0.3 MPa {1.5 - 3 Defective low-pressure circuit Repair or
TESTING AND ADJUSTING). equipment (see Note 2) replace
kg/cm2}?
YES
5
• Disconnect outlet piping of
common rail pressure Is fuel drain amount from NO
limiter. pressure limiter less than 10 Defective pressure limiter Replace
• Start engine. cc/min?
YES
6
• Disconnect PCV connector Does engine stop if PCV connector on NO
on one side. one side is disconnected from fuel pump
• Start engine. and engine is operated on one lung?
YES
7
• Disconnect spill centralized
hose from injector. Is spill flow from injector normal? NO Defective fuel injector Replace
• Start engine. (See Note 3)
YES Defective common rail fuel Replace
pressure sensor
8
When troubleshooting is carried out for failure NO
codes [AD11KA], [AD11KB], [AD51KA], [AD51KB], Defective fuel supply pump Replace
does problem occur in electrical system?
YES Defective electric system of fuel Repair or
supply pump PCV replace
HM300-1 20-323
(7)
(9)
1 ! !
Note 1: Carry out inspection, maintenance, and replacement of the filter and strainer as follows.
1) Gauze filter : Disassemble and inspect. If it is clogged, clean it.
2) Gauze filter upstream strainer : If the gauze filter is clogged, clean the upstream strainer also.
3) Fuel filter : If the problem is not solved even when Steps 1) and 2) above have been carried out, replace
the fuel filter.
Note 2: If the equipment in the low-pressure circuit is defective, inspect the following points.
1) Remaining amount of fuel
2) Stuck, worn feed pump
3) Leakage, clogged low-pressure fuel piping
4) Defective operation of bypass valve, mistaken assembly of other parts
5) Clogged fuel filter
6) Fuel entering oil pan (fuel leakage inside head cover)
Fig. 1 Mounting positions of overflow valve (1), bypass valve (2), and fuel inlet port joint (with gauze filter) (3)
• Overflow valve (1) : Spring is seen through both holes.
• Bypass valve (2) : Spring is seen through one hole (on nut side).
• Fuel inlet joint (3) : Gauze filter is seen through both holes.
20-324 HM300-1
c 1 c
(7)
TROUBLESHOOTING
ENG-5, ENG-6, ENG-7
Note 3: Method of measuring amount of fuel spill flow

¤ The fuel in the spill line is at high tempera- Limits for fuel spill amount (total for 6 cylinders)
ture (up to 90°C), so be careful not to burn
Stall speed (rpm) Spill limit (cc/min)
yourself during the operation.
1) Disconnect the hose connected to the spill 1,600 960
tube return collection portion (rear of en- 1,700 1,020
gine).
2) Connect another hose to the tip of the spill 1,800 1,080
tube and collect the spill fuel in a container. 1,900 1,140
3) Start the engine, stall the engine at each
2,000 1,200
speed, and measure the spill fuel amount for
1 minute.
ENG-6 FAILURE CODE [AD10MA] (FUEL SUPPLY PUMP: FUNCTION IMPOSSIBLE (MA))
★ Nature of failure:Abnormal pressure has occurred in the common rail fuel pressure
ENG-7 FAILURE CODE [AD10MB] (FUEL SUPPLY PUMP: DROP IN FUNCTION (MB))
★ Nature of failure: Non-force feed (level 2) has occurred in the fuel supply pump
HM300-1 20-325
1 c
(9) c
ENG-8 FAILURE CODE [AD11KA] (FUEL SUPPLY PUMP SOLENOID VALVE 1:

DISCONNECTION (KA))
★ Nature of failure:A disconnection has occurred in the PCV1 circuit of the fuel supply pump
Cause Remedy
• Turn starting switch OFF.

Is resistance between PCV1 NO
(male) (1) - (2), and between (2) Defective fuel supply pump Replace
• Disconnect PCV1. PCV1
- ground as shown in Table 1?
YES
Defective contact or disconnection

NO in wiring harness between CN7
• Turn starting switch OFF. Is resistance between CN7 (female) (10) - PCV1 (female) (1) Repair or
• Disconnect CN7. (female) (10) and (11) 2.3 - 5.3Ω? replace
or between CN7 (female) (11) -
PCV1 (female) (2)
YES
Is resistance between CN7 Short circuit with chassis ground

• Turn starting switch OFF. NO in wiring harness between CN7 Repair or
• Disconnect CN7, PCV1. (female) (11) and ground more
than 1 MΩ? (female) (11) and PCV1 (female) replace
(2)
YES
Table 1
PCV1 (male) Resistance
Between (1) and (2) 2.3 – 5.3Ω
Between (2) and ground Min. 1 MΩ
20-326 HM300-1
c 1 c
ENG-9 FAILURE CODE [AD11KB] (FUEL SUPPLY PUMP SOLENOID VALVE 1:

SHORT CIRCUIT (KB))
★ Nature of failure:Excessive current has flowed in the PCV1 circuit of the fuel supply pump
Cause Remedy

YES
Short circuit with chassis ground

• Disconnect CN7, PCV1.
Is resistance between CN7 (female) NO or hot short in wiring harness
(10) and ground more than 1 MΩ Repair or
• Turn starting switch ON. between CN7 (female) (10) and replace
and is voltage less than 1 V? PCV1 (female) (1)
YES
Hot short in wiring harness

• Disconnect CN7, PCV1. Is voltage between CN7 (female) NO between CN7 (female) (11) and Repair or
• Turn starting switch ON. (11) and ground less than 1 V? replace
PCV1 (female) (2)
YES
Table 1
Between (1) and (2) 2.3 – 5.3Ω
HM300-1 20-327
1 c
(9) c
ENG-10 FAILURE CODE [AD51KA] (FUEL SUPPLY PUMP SOLENOID VALVE 2:

DISCONNECTION (KA))
★ Nature of failure:A disconnection has occurred in the PCV2 circuit of the fuel supply pump
Cause Remedy

YES

in wiring harness between CN7
• Turn starting switch OFF. Is resistance between CN7 (female) NO (female) (4) - PCV2 (female) (1) or Repair or
• Disconnect CN7. (4) and (12) 2.3 - 5.3Ω? replace
between CN7 (female) (12) -
PCV2 (female) (2)
YES

• Turn starting switch OFF. NO in wiring harness between CN7 Repair or
• Disconnect CN7, PCV2. (female) (12) and ground more
than 1 MΩ? (female) (12) and PCV2 (female) replace
(2)
YES
Table 1
Between (1) and (2) 2.3 – 5.3Ω
20-328 HM300-1
c 1 c
ENG-11 FAILURE CODE [AD51KB] (FUEL SUPPLY PUMP SOLENOID VALVE 2:

SHORT CIRCUIT (KB))
★ Nature of failure:Excessive current has flowed in the PCV2 circuit of the fuel supply pump
Cause Remedy

YES
Is resistance between CN7 (female) NO Short circuit with chassis ground

• Disconnect CN7 and PCV2. or hot short in wiring harness Repair or
• Turn starting switch ON. (4) and ground more than 1 MΩ
and is voltage less than 1 V? between CN7 (female) (4) and replace
PCV2 (female) (1)
YES
• Disconnect CN7 and PCV2. Is voltage between CN7 (female) NO Hot short in wiring harness Repair or
• Turn starting switch ON. (12) and ground less than 1 V? between CN7 (female) (12) and replace
PCV2 (female) (2)
YES
Table 1
Between (1) and (2) 2.3 – 5.3Ω
HM300-1 20-329
1 c
(9) c
ENG-12 FAILURE CODE [ADA1KA] (NO. 1 INJECTOR SOLENOID VALVE:

DISCONNECTION (KA))
★ Nature of failure:A disconnection has occurred in the No. 1 injector solenoid circuit
¤ High voltage (110 – 130V) is used for the electrical circuit of the fuel injector, so be careful of electrocution
and electrical leakage. For details, see TESTING AND ADJUSTING, Handling high-voltage circuit of engine
controller.
Cause Remedy
• Turn starting switch OFF. Is resistance between CN1 NO Defective No. 1 injector
• Disconnect CN1 (solenoid). Replace
(male) (1) and (2) 0.4 - 1.1Ω? solenoid
YES

• Turn starting switch OFF. Is resistance between CN6 (female) (7) - CN1 (female) (1) or Repair or
• Disconnect CN6 (controller). (female) (7) and (8) 0.4 - 1.1Ω? between CN6 (female) (8) - CN1 replace
(female) (2)
YES
20-330 HM300-1
c 1 c
ENG-13 FAILURE CODE [ADAZKB] (NO. 1, 2, 3 INJECTOR SOLENOID VALVE:

SHORT CIRCUIT (KB))
★ Nature of failure:Excessive current has flowed in the No. 1 injector solenoid circuit, No. 2 injector solenoid
circuit, or No. 3 injector solenoid circuit
controller.
a) Determining location of problem

Cause Remedy
Is resistance between CN6 (female) NO Abnormality in No. 1 injector Go to

(7) - (8), and between (7)(8) - solenoid system troubleshooting
• Disconnect CN6 (controller).
ground as shown in Table 1? procedure b)
YES
Go to
• Disconnect CN6 (controller). Is voltage between CN6 (female) NO Abnormality in No. 1 injector troubleshooting
• Turn starting switch ON. (7)(8) - ground less than 1 V? solenoid system procedure b)
YES
Is resistance between CN6 (female) NO Go to

• Turn starting switch OFF. Abnormality in No. 2 injector troubleshooting
• Disconnect CN6 (controller).
(4) - (10), and between (4)(10) -
ground as shown in Table 1? solenoid system procedure c)
YES
• Disconnect CN6 (controller).• Is voltage between CN6 (female) NO Abnormality in No. 2 injector Go to
• Turn starting switch ON. (4)(10) - ground less than 1 V? solenoid system troubleshooting
procedure c)
YES

(3) - (9), and between (3)(9) - ground Abnormality in No. 3 injector
• Disconnect CN6 (controller). solenoid system troubleshooting
as shown in Table 1? procedure d)
YES
• Disconnect CN6 (controller). Is voltage between CN6 (female) NO Abnormality in No. 3 injector Go to
• Turn starting switch ON. (3)(9) - ground less than 1 V? solenoid system troubleshooting
procedure d)
YES
Table 1
CN6 (female) CN6 (female) CN6 (female) Resistance
Between (7) and (8) Between (4) and (10) Between (3) and (9) 0.4 – 1.1Ω
Between (7)(8) and ground Between (4)(10) and ground Between (3)(9) and ground Min. 1 MΩ
HM300-1 20-331
1 c c
b) Troubleshooting No. 1 fuel injector system

Cause Remedy

Is resistance between CN1 (male) NO
(1) - (2), and between (1)(2) - Defective No. 1 injector Replace
• Disconnect CN1 (solenoid). solenoid
ground as shown in Table 2?
YES

• Disconnect CN6 and CN1. NO or hot short in wiring harness Repair or
(female) (7) and ground more than
1 MΩ and is voltage less than 1 V? between CN6 (female) (7) and replace
CN1 (female) (1)
YES Short circuit with chassis ground
or hot short in wiring harness Repair or
between CN6 (female) (8) and replace
CN1 (female) (2)
Table 2
CN1 (male) Resistance
Between (1) and (2) 0.4 – 1.1Ω
Between (1)(2) and ground Min. 1 MΩ
ENG-13 a) b) Related electrical circuit diagram
20-332 HM300-1
c 1 c
(9)
c) Troubleshooting No. 2 fuel injector system

Cause Remedy

YES
Is resistance between CN6 Short circuit with chassis ground or

• Disconnect CN6 and CN2. NO hot short in wiring harness Repair or
CN2 (female) (1)
CN2 (female) (2)
Table 3
Between (1) and (2) 0.4 – 1.1Ω
ENG-13 a) c) Related electrical circuit diagram
HM300-1 20-333
1 c
(9) c
d) Troubleshooting No. 3 fuel injector system

Cause Remedy

YES
Is resistance between CN6 Short circuit with chassis ground or

• Disconnect CN6 and CN3. NO hot short in wiring harness Repair or
CN3 (female) (1)
CN3 (female) (2)
Table 4
Between (1) and (2) 0.4 – 1.1Ω
ENG-13 a) d) Related electrical circuit diagram
20-334 HM300-1
c 1 c
(9)
ENG-14 FAILURE CODE [ADB1KA] (NO. 2 INJECTOR SOLENOID VALVE:

DISCONNECTION (KA))
controller.
Cause Remedy
• Turn starting switch OFF. Is resistance between CN2 (male) NO Defective No. 2 injector
• Disconnect CN2 (solenoid). (1) and (2) 0.4 - 1.1Ω? Replace
solenoid
YES

• Turn starting switch OFF. Is resistance between CN6 NO in wiring harness between CN6 Repair or
• Disconnect CN6 (controller). (female) (4) and (10) 0.4 - 1.1Ω? (female) (4) - CN2 (female) (1) or replace
between CN6 (female) (10) - CN2
(female) (2)
YES
HM300-1 20-335
1 c
(9) c
ENG-15 FAILURE CODE [ADC1KA] (NO. 3 INJECTOR SOLENOID VALVE:

DISCONNECTION (KA))
controller.
Cause Remedy
solenoid
YES

(female) (2)
YES
20-336 HM300-1
c 1 c
ENG-16 FAILURE CODE [ADD1KA] (NO. 4 INJECTOR SOLENOID VALVE:

DISCONNECTION (KA))
controller.
Cause Remedy
solenoid
YES

(female) (2)
YES
HM300-1 20-337
1 ! !
ENG-17 FAILURE CODE [ADDZKB] (NO. 4, 5, 6 INJECTOR SOLENOID VALVE:

SHORT CIRCUIT (KB))
★ Nature of failure:Excessive current has flowed in the No. 4 injector solenoid circuit, No. 5 injector solenoid
circuit, or No. 6 injector solenoid circuit
controller.
a) Determining location of problem Cause Remedy

• Turn starting switch OFF. Abnormality in No. 4 injector troubleshooting
• Disconnect CN7 (controller). (3) - (9), and between (3)(9) - solenoid system
ground as shown in Table 1? procedure b)
YES
NO Go to
• Disconnect CN7 (controller). Is voltage between CN7 (female) Abnormality in No. 4 injector troubleshooting
• Turn starting switch ON. (3)(9) - ground less than 1 V? solenoid system procedure b)
YES
• Turn starting switch OFF. Is resistance between CN7 (female) NO Go to

(1) - (7), and between (1)(7) - ground Abnormality in No. 5 injector troubleshooting
• Disconnect CN7 (controller). solenoid system
as shown in Table 1? procedure c)
YES
• Disconnect CN7 (controller). NO Go to

Is voltage between CN7 (female) Abnormality in No. 5 injector troubleshooting
• Turn starting switch ON. (1)(7) - ground less than 1 V? solenoid system procedure c)
YES

• Turn starting switch OFF. Abnormality in No. 6 injector
(2) - (8), and between (2)(8) - ground troubleshooting
• Disconnect CN7 (controller). solenoid system
as shown in Table 1? procedure d)
YES
NO Go to
• Disconnect CN7 (controller). Is voltage between CN7 (female) Abnormality in No. 6 injector troubleshooting
• Turn starting switch ON. (2)(8) - ground less than 1 V? solenoid system procedure d)
YES
Table 1
CN7 (female) CN7 (female) CN7 (female) Resistance
Between (3) and (9) Between (1) and (13) Between (2) and (8) 0.4 – 1.1Ω
Between (3)(9) and ground Between (1)(13) and ground Between (2)(8) and ground Min. 1 MΩ
20-338 HM300-1
! 1 !
b) Troubleshooting No. 4 fuel injector system

Cause Remedy

Is resistance between CN4 (male) (1) NO
- (2), and between (1)(2) - ground as Defective No. 4 injector Replace
shown in Table 2?
YES

Is resistance between CN7 NO or hot short in wiring harness Repair or
• Disconnect CN7 and CN4.
(female) (3) and ground more than between CN7 (female) (3) and replace
1 MΩ and is voltage less than 1 V? CN4 (female) (1)
CN4 (female) (2)
Table 2
Between (1) and (2) 0.4 – 1.1Ω
ENG-17 a) b) Related electrical circuit diagram
HM300-1 20-339
1 c
(9) c
c) Troubleshooting No. 5 fuel injector system

Cause Remedy

shown in Table 3?
YES

CN5 (female) (2)
Table 3
Between (1) and (2) 0.4 – 1.1Ω
ENG-17 a) c) Related electrical circuit diagram
20-340 HM300-1
c 1 c
(9)
d) Troubleshooting No. 6 fuel injector system

Cause Remedy

shown in Table 4?
YES

CN6 (female) (2)
Table 4
Between (1) and (2) 0.4 – 1.1Ω
ENG-17 a) d) Related electrical circuit diagram
HM300-1 20-341
1 c
(9) c
ENG-18 FAILURE CODE [ADE1KA] (NO. 5 INJECTOR SOLENOID VALVE:

DISCONNECTION (KA))
controller.
Cause Remedy
• Turn starting switch OFF. Is resistance between CN5 (male) (1) NO Defective No. 5 injector
• Disconnect CN5 (solenoid). and (2) 0.4 - 1.1Ω? Replace
solenoid
YES

(female) (2)
YES
20-342 HM300-1
c 1 c
ENG-19 FAILURE CODE [ADF1KA] (NO. 6 INJECTOR SOLENOID VALVE:

DISCONNECTION (KA))
controller.
Cause Remedy
• Turn starting switch OFF. Is resistance between CN6 (male) (1) NO Defective No. 6 injector
• Disconnect CN6 (solenoid). and (2) 0.4 - 1.1Ω? Replace
solenoid
YES

(female) (2)
YES
HM300-1 20-343
1 c c
ENG-20 FAILURE CODE [B@BAZG] (ENGINE OIL: DROP IN OIL PRESSURE (ZG))
★ Nature of failure:When running at low idle, the signal circuit of the engine oil pressure low-pressure switch
became closed (connected to GND), or when the engine speed was more than 1300 rpm,
the signal circuit of the oil pressure high-pressure
Cause Remedy
Check
• See TESTING AND NO cause of
Is engine oil pressure normal? Drop in engine oil pressure
ADJUSTING. failure and
repair
YES damage to
engine
• Insert T-adapter to CN4. Is voltage between CN4 (5) and NO

• Engine at low idle ground 20 - 30 V?
YES
Short circuit with chassis

• Turn starting switch OFF. Is resistance between CN4 (female) NO ground in wiring harness be- Repair or
• Disconnect CN4 and PSL. (5) and ground more than 1 MΩ? tween CN4 (female) (5) and replace
PSL
YES Defective engine oil low-pressure
switch Replace
• Insert T-adapter to CN4. NO

• Engine at midrange speed
Is voltage between CN4 (6) and
(Min. 1300 rpm)
ground 20 - 30 V?
YES
NO Short circuit with chassis ground Repair or

• Turn starting switch OFF. Is resistance between CN4 (female) in wiring harness between CN4
• Disconnect CN4, PSH. (6) and ground more than 1 MΩ? replace
(female) (6) and PSH
YES
Defective engine oil high-pressure
switch Replace
20-344 HM300-1
c 1 c
(9)
ENG-21 FAILURE CODE [B@BAZK] (ENGINE OIL: DROP IN LEVEL (ZK))
★ Nature of failure:The signal circuit of the engine oil pressure switch became open (shut off from GND)
Cause Remedy
1
NO
• Stop engine. Is engine oil level low?
YES
Drop in engine oil level Add
2
• Turn starting switch OFF. Is resistance between OL (male) NO
• Disconnect OL. (1) and ground less than 1Ω? Defective engine oil level switch Replace
YES
3
• Turn starting switch OFF. Is resistance between CN6 (female) NO Defective contact or disconnection
• Disconnect CN6. (1) and ground less than 1Ω? in wiring harness between CN6 Repair or
(female) (1) and OL (female) (1) replace
YES
HM300-1 20-345
(9)
1 ! !
ENG-22 FAILURE CODE [B@BCNS] (RADIATOR COOLANT: OVERHEAT (NS))
★ Nature of failure:The engine coolant temperature went above the operating range
Cause Remedy
NO
Stop engine. Is engine overheated? Defective engine controller Replace
YES Check cause

of failure and
Engine is overheated repair damage
to engine
20-346 HM300-1
! (9)
1 !
ENG-23 FAILURE CODE [D181KZ] (PREHEATING RELAY CONTACT:

DISCONNECTION OR SHORT CIRCUIT (KZ))
★ Nature of failure:A disconnection, short circuit with the ground, or short circuit with the power source has
occurred in the signal circuit of the heater relay
★ Before starting troubleshooting, check that fuse BT4-4 is normal (if the fuse is blown, there has probably been a surge
of current caused by a short circuit, so check the related circuits).
Cause Remedy
Does condition become normal NO

• Turn starting switch ON. when preheater relay (R37) is
interchanged with other relay?
YES
Defective preheater relay (R37) Replace
• Disconnect R37 and heater Hot short in wiring harness

relay (3). Is voltage between R37 (female) NO between R37 (female) (5) and Repair or
• Turn starting switch ON. (5) and ground less than 1 V? heater relay (3) replace
YES
• Turn starting switch OFF. Is resistance between R37 NO Short circuit with chassis
• Disconnect R37 and heater (female) (5) and ground more ground in wiring harness Repair or
relay (3). than 1 MΩ? between R37 (female) (5) and replace
heater relay (3)
YES
• Turn starting switch OFF. Is resistance between R37 NO Defective contact or disconnection
• Disconnect R37 and heater (female) (5) and heater relay (3) in wiring harness between R37 Repair or
relay (3). less than 1Ω? (female) (5) and heater relay (3) replace
YES
• Disconnect CN4 and heater Is voltage between CN4 (female) NO Hot short in wiring harness
relay (2). between CN4 (female) (5) and Repair or
heater relay (2)
YES
• Turn starting switch OFF. Is resistance between CN4 NO Short circuit with chassis ground in
• Disconnect CN4 and heater (female) (3) and ground more wiring harness between CN4 Repair or
relay (2). than 1 MΩ? (female) (3) and heater relay (2) replace
YES
• Turn starting switch OFF. Is resistance between CN4 NO Defective contact or disconnection
• Disconnect CN4 and heater (female) (3) and heater relay (2) in wiring harness between CN4 Repair or
relay (2). less than 1Ω? (female) (3) and heater relay (2) replace
YES
• Turn starting switch ON. Does condition become normal NO

when heater relay is replaced? Defective transmission controller Replace
YES
Defective heater relay Replace
HM300-1 20-347
1 c
(9) c
20-348 HM300-1
c 1 c
ENG-24 FAILURE CODE [D182KZ] (PREHEATING RELAY COIL: DISCONNECTION OR

SHORT CIRCUIT (KZ))
★ Nature of failure: A disconnection or short circuit with the ground has occurred in the drive circuit of the pre-
heater relay
★ Before starting troubleshooting, check that fuse BT4-4 is normal (if the fuse is blown, there has probably been a surge
of current caused by a short circuit, so check the related circuits).
Cause Remedy

• Turn starting switch ON. when preheater relay (R37) is
YES
Defective preheater relay (R37) Replace

• Disconnect R37. Is voltage between R37 (female) NO in wiring harness between fuse Repair or
• Turn starting switch ON. (1)(3) - ground 20 - 30 V? BT4-4 outlet and R37 (female) replace
(1)(3)
YES
Defective contact, disconnection, or

• Disconnect CN2. Is voltage between CN2 (female) (5) NO short circuit with chassis ground in Repair or
• Turn starting switch ON. and ground 20 - 30 V? wiring harness between CN2 replace
(female) (5) and R37 (female) (2)
YES
HM300-1 20-349
1 c c
ENG-25 FAILURE CODE [D1D0KB] (ENGINE CONTROLLER LOAD POWER SOURCE

RELAY: SHORT CIRCUIT (KB))
★ Nature of failure:Voltage was generated in the power supply circuit of the controller when the starting switch
was OFF
Cause Remedy
Does condition become normal when NO

• Turn starting switch OFF. engine power source relay (R36) is
YES
Defective engine power source Replace
relay (R36)

• Turn starting switch OFF. Is voltage between CN7 (6)(14) - NO between CN7 (female) (6) (14) Repair or
• Insert T-adapter to CN7. (5)(13) less than 8 V? and R36 (female) (5) replace
YES
20-350 HM300-1
c 1 c
(9)
TRO UBLESHOO TING ENG-25
HM300-1 20-351
1 !
(6) !
ENG-26 FAILURE CODE [D5ZAKX] (ENGINE THROTTLE MODIFY 1 SIGNAL:

INPUT SIGNAL OUTSIDE RANGE (KX))
★ Nature of failure:The voltage in the throttle modify signal circuit went outside the normal range (6 - 15 V)
Cause Remedy
• Insert T-adapter to CN4. Is voltage between CN4 (female) (16) NO

• Turn starting switch ON. and ground 6 - 15 V?
YES
Defective contact,
• Disconnect ATC3A. Is voltage between ATC3A (female) NO disconnection, or short circuit
with chassis ground in wiring Repair or
harness between CN4 (female)
(16) and ATC3A (female) (5)
YES
Defective transmission controller Replace
20-352 HM300-1
! 1 !
ENG-27 FAILURE CODE [DB20KT] (ENGINE CONTROLLER:

ABNORMALITY INSIDE CONTROLLER (KT))
★ Nature of failure:An abnormality has occurred inside the controller
Cause Remedy
Defective contact or
Turn starting switch OFF. Is resistance between CN7 (female) NO disconnection in wiring harness Repair or
Disconnect CN7. (5)(13) - ground less than 1Ω? between CN7 (female) (5)(13) - replace
ground
YES
HM300-1 20-353
1 ! !
20-354 HM300-1
! 1 !
(6)
ENG-28 FAILURE CODE [DB22KK] (ENGINE CONTROLLER LOAD POWER SOURCE

RELAY: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK))
★ Nature of failure:The voltage in the controller power supply voltage circuit dropped when the starting switch
was ON
★ Before starting troubleshooting, check that fuse BT2-4 and fuse BT4-4 are normal (if either fuse is blown,
there has probably been a surge of current caused by a short circuit, so check the related circuits).
Cause Remedy

• Turn starting switch ON. engine power source relay (R36) is
YES Defective engine power source
relay (R36) Replace
Defective contact or disconnec-

• Disconnect R36. Is voltage between R36 (female) (1) NO tion in wiring harness between Repair or
• Turn starting switch ON. and ground 20 - 30 V? R36 (female) (1) - fuse BT2-4 - replace
starting switch ACC
YES
• Turn starting switch OFF. Is resistance between R36 (female) NO Defective contact or disconnection
in wiring harness between R36 Repair or
• Disconnect R36. (2) and ground less than 1Ω? replace
(female) (2) and ground
YES
Is voltage between R36 (female) (3) NO Defective contact or disconnection

• Disconnect R36. Repair or
and ground 20 - 30 V? in wiring harness between R36
• Turn starting switch ON. replace
(female) (3) and fuse BT4-4
YES
• Insert T-adapter to CN7. Is voltage between CN7 (female) NO Defective contact or disconnection
in wiring harness between CN7 Repair or
• Turn starting switch ON. (6)(14) - ground 20 - 30 V? replace
(female) (6)(14) - R36 (female) (5)
YES
Defective engine controller. Replace
HM300-1 20-355
1 c
(9) c
20-356 HM300-1
c 1 c
(6)
ENG-29 FAILURE CODE [DB29KQ] (ENGINE CONTROLLER CONNECTION WIRING

HARNESS: MODEL SELECTION SIGNAL MISMATCH (KQ))
★ Nature of failure:The model selection signal does not match the setting inside the controller
Cause Remedy
• Turn starting switch OFF. Is resistance between MS (male) NO Defective model selection
• Disconnect MS. (1)(2)(3) - (4) as shown in Table 1? connector Replace
YES
• Turn starting switch OFF. Is resistance between MS (female) NO Defective contact or disconnec-
• Disconnect MS. (1) and ground less than 1Ω? tion in wiring harness between Repair or
MS (female) (1) and ground replace
YES
• Turn starting switch OFF. Is resistance between CN4 (female) NO Defective contact or disconnection
in wiring harness between CN4 Repair or
• Disconnect CN4. (13) and ground less than 1Ω? replace
(female) (13) and MS (female) (2)
YES
• Turn starting switch OFF. Is resistance between CN4 (female) NO Short circuit with chassis ground Repair or
• Disconnect CN4. (14) and ground more than 1 MΩ? in wiring harness between CN4 replace
YES
Is resistance between CN4 (female) NO Defective contact or disconnection

• Turn starting switch OFF. in wiring harness between CN4 Repair or
• Disconnect CN4. (15) and ground less than 1Ω? replace
YES
Table 1
MS (male) Resistance value
Between (3) and (4) Min. 1 MΩ
HM300-1 20-357
1 ! !
TROUBLESHOOTING
ENG-29, ENG-30
ENG-30 FAILURE CODE [DB2AMA] (ENGINE CONTROLLER FUEL INJECTION QUANTITY

CONTROL SWITCH: FUNCTION IMPOSSIBLE (MA))
★ Nature of failure:The fuel injection quantity control set switch inside the controller is not set at the correct
position
Cause Remedy
Are both fuel injection quantity NO

control switches 1 and 2 set to [F]? Defective engine controller Replace
YES
Defective setting of fuel injection Adjust
quantity control switch again
20-358 HM300-1
c 1 c
(9)
ENG-31 FAILURE CODE [DD11KB] (STARTING SWITCH: SHORT CIRCUIT (KB))
★ Nature of failure:The terminal C signal from the starting switch came ON when the engine was running
Cause Remedy
• Connect T-adapter to CN4. Is voltage between CN4 (2) and NO

• Turn starting switch ON. ground less than 1 V?
YES
• Disconnect starting switch Is voltage between starting switch NO

terminal C. terminal C and ground less than 1 V? Defective starting switch Replace
YES Hot short in wiring harness

between CN4 (female) (2) and Repair or
starting switch terminal C replace
HM300-1 20-359
1 c
(9) c
ENG-32 FAILURE CODE [DDA1L5] (ACCELERATION SWITCH: * SEE CONTENTS (L5))
★ Nature of failure:The idle validation switch of the accelerator pedal does not match the throttle angle signal
Cause Remedy
• Insert T-adapter to AS1. Does voltage (signal 2) between NO

• Turn starting switch ON. AS1 (5) and (4) change as Defective accelerator pedal Repair or
shown in Fig. 1? (switch) replace
YES
• Insert T-adapter to AS1. Does voltage (signal 3) between NO Defective accelerator pedal Repair or
• Turn starting switch ON. AS1 (6) and (4) change as (switch)
shown in Fig. 1? replace
YES
• Turn starting switch OFF. Is resistance between AS1 NO

• Disconnect AS1. (female) (4) and ground less
than 1Ω?
YES
Is resistance between CN4 NO Defective contact or disconnection

• Turn starting switch OFF. in wiring harness between CN4 Repair or
• Disconnect CN4 and AS1. (female) (8) and AS1 (female) (4)
less than 1Ω? (female) (8), (19) and AS1 (female) replace
(4)
YES
Defective contact, disconnection,

Does voltage (signal 2) between NO short circuit with chassis ground,
• Insert T-adapter to CN4.
CN4 (11) and (8) change as or hot short in wiring harness Repair or
shown in Fig 1? between CN4 (female) (11) and replace
AS1 (female) (5)
YES

• Insert T-adapter to CN4. Does voltage (signal 3) between NO short circuit with chassis ground, or
• Turn starting switch ON. CN4 (12) and (8) change as hot short in wiring harness between Repair or
shown in Fig. 1? CN4 (female) (12) and AS1 (female) replace
(6)
YES
20-360 HM300-1
c 1 c
(9)
Fig. 1
HM300-1 20-361
1 ! !
ENG-33 FAILURE CODE [DDE2L6] (ENGINE OIL PRESSURE SWITCH:

* SEE CONTENTS (L6))
★ Nature of failure:The engine oil pressure switch signal does not match the condition of the engine
Cause Remedy
Is voltage between CN4 (5) and NO

• Insert T-adapter to CN4.
YES
Is resistance between PSL NO Defective engine oil low-pres-

• Disconnect PSL. (switch) and ground as shown in sure switch Replace
Table 2?
YES Defective contact, disconnection,
or short circuit with chassis ground Repair or
in wiring harness between CN4 replace
(female) (5) and PSL
Is voltage between CN4 (6) and NO

• Insert T-adapter to CN4. ground as shown in Table 3?
YES
Is resistance between PSH NO Defective engine oil high-pressure

• Disconnect PSH. (switch) and ground as shown in Replace
switch
Table 4?
YES
Defective contact or disconnection Repair or
in wiring harness between CN4 replace
(female) (5) and PSH
Table 1 Table 3
CN4 Engine Voltage CN4 Engine Voltage

When stopped Max. 1 V When stopped Max. 1 V
Between (5) and Between (6) and
ground When more than ground When more than
20 – 30V 20 – 30V
600 rpm 1,300 rpm
Table 2 Table 4
PSL (switch) Engine Resistance value PSL (switch) Engine Resistance value
When stopped Max. 1Ω When stopped Max. 1Ω
Between PSL and Between PSH and
ground When more than ground When more than
Min. 1 MΩ Min. 1 MΩ
600 rpm 1,300 rpm
20-362 HM300-1
! 1 !
HM300-1 20-363
1 c c
ENG-34 FAILURE CODE [DGE2KX] (ENGINE COOLANT TEMPERATURE SENSOR

(FOR HIGH-TEMPERATURE): INPUT SIGNAL OUTSIDE RANGE (KX))
★ Nature of failure:The signal from the engine coolant high-temperature sensor is outside the normal range
Cause Remedy
• Turn starting switch OFF. Is resistance between TWH (male) NO

• Disconnect TWH. (1) and (2), and between (1) and Defective engine coolant high- Replace
• Coolant temperature:10 - 100°C ground as shown in Table 1? temperature sensor
YES

• Turn starting switch OFF. in wiring harness between CN2
• Disconnect CN2. Is resistance between CN2 (female) NO (female) (4) and TWH (female) (1) Repair or
• Coolant temperature:10 - 100°C (4) and (10) 90k - 3.5 kΩ? or between CN2 (female) (10) and replace
TWH (female) (2)
YES

• Turn starting switch OFF. Is resistance between CN2 (female) NO in wiring harness between CN2 Repair or
• Disconnect CN2 and TWH. (4) and ground more than 1 MΩ? (female) (4) and TWH (female) replace
(1)
YES
Table 1
TWH (male) Resistance
Between (1) and (2) 90k – 3.5kΩ
20-364 HM300-1
! (9)
1 !
ENG-35 FAILURE CODE [DGE3L6] (ENGINE COOLANT TEMPERATURE SENSOR

(FOR LOW-TEMPERATURE): * SEE CONTENTS (L6))
★ Nature of failure:The signal from the engine coolant low-temperature sensor has not been input
Cause Remedy
• Turn starting switch OFF. Is resistance between TWL (male) NO

• Disconnect TWL. (1) and (2), and between (1) and Defective engine coolant low- Replace
• Coolant temperature:10 - 100°C ground as shown in Table 1? temperature sensor
YES

• Turn starting switch OFF. in wiring harness between CN2
• Disconnect CN2. Is resistance between CN2 (female) NO (female) (3) and TWL (female) (1) Repair or
• Coolant temperature:10 - 100°C (3) and (10) 9 k - 0.3 kΩ? or between CN2 (female) (10) and replace
TWL (female) (2)
YES

• Turn starting switch OFF. Is resistance between CN2 (female) NO in wiring harness between CN2 Repair or
• Disconnect CN2 and TWL. (3) and ground more than 1 MΩ? (female) (3) and TWL (female) replace
(1)
YES
Table 1
TWL (male) Resistance
Between (1) and (2) 9k – 0.3kΩ
HM300-1 20-365
(9)
1 ! !
ENG-36 FAILURE CODE [DH30KX] (BOOST PRESSURE SENSOR: INPUT SIGNAL OUTSIDE
RANGE (KX))
★ Nature of failure:The signal from the boost sensor is outside the normal range
Cause Remedy
• Insert T-adapter to CN1

Is voltage between CN1 (3) and CN2 NO
and CN2.
(10) 0.3 - 4.7 V?
YES
• Disconnect PIM. Is voltage between PIM (female) (1) NO

• Turn starting switch ON. and ground 4.6 - 5.4 V?
YES

• Disconnect CN2 and PIM. Is resistance between CN2 (female) NO ground in wiring harness be- Repair or
• Turn starting switch OFF. (2) and ground more than 1 MΩ? tween CN2 (female) (2) and replace
PIM (female) (1)
YES

ground 4.6 - 5.4 V?

YES tion in wiring harness between Repair or
CN2 (female) (2) and PIM (fe- replace
male) (1)
• Turn starting switch OFF. Is resistance between PIM (female)

• Disconnect PIM. (3) and ground less than 1Ω?
YES
Is resistance between CN2 Defective contact or disconnec-

• Turn starting switch OFF. NO tion in wiring harness between Repair or
• Disconnect CN2 and PIM. (female) (10) and PIM (female)
(3) less than 1Ω? CN2 (female) (10) and PIM (fe- replace
male) (3)
YES

• Turn starting switch OFF. Is resistance between CN2 NO ground in wiring harness be-
(female) (10) and ground more Repair or
• Disconnect CN2 and PIM. tween CN2 (female) (10) and replace
than 1 MΩ? PIM (female) (3)
YES
• Insert T-adapter to PIM. Is voltage between PIM (2) and NO

• Turn starting switch ON. ground 0.3 - 4.7 V?
YES Defective contact or disconnec-

tion in wiring harness between Repair or
CN1 (female) (3) and PIM (fe- replace
male) (2)
Is resistance between CN1 Short circuit with chassis

• Turn starting switch OFF. NO ground in wiring harness be-
• Disconnect CN1 and PIM. than 1 MΩ? tween CN1 (female) (3) and replace
PIM (female) (2)
YES
Defective boost pressure sensor Replace
20-366 HM300-1
c 1 c
HM300-1 20-367
1 c c
ENG-37 FAILURE CODE [DH40KX] (COMMON RAIL PRESSURE SENSOR:

★ Nature of failure:The signal from the common rail fuel pressure sensor is outside the normal range
Cause Remedy
• Insert T-adapter to CN1

Is voltage between CN1 (1) and CN2 NO
and CN2.
(10) 0.3 - 4.7 V?
YES
• Disconnect PFUEL. Is voltage between PFUEL (female) NO

• Turn starting switch ON. (1) and ground 4.6 - 5.4 V?
YES

• Disconnect CN2 and PFUEL. Is resistance between CN2 (female) NO ground in wiring harness be- Repair or
PFUEL (female) (1)
YES

ground 4.6 - 5.4 V?

CN2 (female) (2) and PFUEL replace
(female) (1)
• Turn starting switch OFF. Is resistance between PFUEL NO

• Disconnect PFUEL. (female) (3) and ground less than 1Ω?
YES

• Disconnect CN2 and PFUEL. (female) (10) and PFUEL
(female) (3) less than 1Ω? CN2 (female) (10) and PFUEL replace
(female) (3)
YES

• Disconnect CN2 and PFUEL. (female) (10) and ground more (female) (10) and PFUEL (fe- replace
than 1 MΩ? male) (3)
YES
• Insert T-adapter to PFUEL. Is voltage between PFUEL (2) NO


CN1 (female) (1) and PFUEL replace
(female) (2)

• Disconnect CN1 and PFUEL. than 1 MΩ? tween CN1 (female) (1) and replace
PFUEL (female) (2)
YES
Defective common rail fuel pres- Replace
sure sensor
20-368 HM300-1
c 1 c
(9)
HM300-1 20-369
1 c c
ENG-38 FAILURE CODE [DK10KX] (THROTTLE ANGLE SENSOR: INPUT SIGNAL OUTSIDE
RANGE (KX))
★ Nature of failure:The throttle angle signal from the accelerator pedal is outside the normal range
Cause Remedy
• Insert T-adapter to CN1. Is voltage between CN1 (6) and (11) NO

• Turn starting switch ON. 0.3 - 4.7 V?
YES
• Disconnect AS1. Is voltage between AS1 (female) (3) NO

YES

• Disconnect CN1 and AS1. Is resistance between CN1 (female) NO ground in wiring harness be- Repair or
AS1 (female) (3)
YES

ground 4.6 - 5.4 V?

CN1 (female) (4) and AS1 (fe- replace
male) (3)
• Turn starting switch OFF. Is resistance between AS1 (female)

• Disconnect AS1. (1) and ground less than 1Ω?
YES

• Disconnect CN1 and AS1. (female) (11) and AS1 (female)
(1) less than 1Ω? CN1 (female) (11) and AS1 (fe- replace
male) (1)
YES

. Disconnect CN1 and AS1 than 1 MΩ? tween CN1 (female) (11) and replace
AS1 (female) (1)
YES
• Insert T-adapter to AS1. Is voltage between AS1 (2) and NO


CN1 (female) (6) and AS1 (fe- replace
male) (2)

• Disconnect CN1 and AS1. than 1 MΩ? tween CN1 (female) (6) and replace
AS1 (female) (2)
YES
Defective accelerator pedal (po- Replace
tentiometer)
20-370 HM300-1
c 1 c
(9)
HM300-1 20-371
1 ! !
ENG-39 FAILURE CODE [DLE3LC] (ENGINE NE SPEED SENSOR: * SEE CONTENTS (LC))
★ Nature of failure:The signal from the engine Ne speed sensor does not match the signal from the engine G
speed sensor
Cause Remedy
• Turn starting switch OFF. Is resistance between NE (male) (1) - NO Defective engine Ne speed
• Disconnect NE. (2), and between (1)(2) - ground as sensor Replace
shown in Table 1?
YES

• Turn starting switch OFF. Is resistance between CN1 (female) NO tion in wiring harness between Repair or
• Disconnect CN1. (5) and (12) 85 - 210 Ω? CN1 (female) (5) and NE (fe- replace
male) (1) or between CN1 (fe-
male) (12) and NE (female) (2)
YES
• Turn starting switch OFF. Is resistance between CN1 (male) (5) NO Short circuit with chassis ground in
wiring harness between CN1 Repair or
• Disconnect CN1 and NE. and ground more than 1 MΩ? replace
(female) (5) and NE (female) (1)
YES
NO Short circuit with chassis ground

• Turn starting switch OFF. Is resistance between CN1 (male) Repair or
in wiring harness between CN1
• Disconnect CN1 and NE. (12) and ground more than 1 MΩ? replace
(female) (5) and NE (female) (2)
YES
Table 1
NE (male) Resistance
Between (1) and (2) 85 – 210Ω
20-372 HM300-1
! 1 !
ENG-40 FAILURE CODE [DLH1LC] (ENGINE G SPEED SENSOR: * SEE CONTENTS (LC))
★ Nature of failure:The signal from the engine Ne speed sensor does not match the signal from the engine G
speed sensor
Cause Remedy
• Turn starting switch OFF. Is resistance between G (male) (1) - NO Defective engine G speed
• Disconnect G. (2), and between (1)(2) - ground as sensor Replace
shown in Table 1?
YES

• Turn starting switch OFF. Is resistance between CN2 (female) NO tion in wiring harness between Repair or
• Disconnect CN2. (1) and (9) 1.4 k - 3.5 kΩ? CN2 (female) (1) and G (fe- replace
male) (1) or between CN2 (fe-
male) (9) and G (female) (2)
YES
• Turn starting switch OFF. Is resistance between CN2 (female) NO Short circuit with chassis ground in
wiring harness between CN2 Repair or
• Disconnect CN2 and G. (1) and ground more than 1 MΩ? replace
(female) (1) and G (female) (1)
YES
• Turn starting switch OFF. NO Short circuit with chassis ground Repair or
Is resistance between CN2 (female) in wiring harness between CN2
• Disconnect CN2 and G. (9) and ground more than 1 MΩ? replace
(female) (12) and G (female) (2)
YES
Table 1
G (male) Resistance
Between (1) and (2) 1.4k – 3.5kΩ
HM300-1 20-373
1 c
(9) c
ENG-41 ENGINE DOES NOT START (STARTING MOTOR DOES NOT TURN)
★ Nature of failure:Even when the starting switch is turned to the START position, the starting motor does not
turn (no failure code is displayed)
★ If the engine does not start even when it is cranked, there is probably a problem in the engine mechanical
system, so see the Shop Manual for the 140-3 Engine.
★ Before starting troubleshooting, check that the circuit breaker is not OFF, and that the fusible link, fuse BT2-
20, and fuse BT3-10 are normal (if the circuit breaker is OFF or any fuse is blown, there has probably been
a surge of current caused by a short circuit, so check the related circuits).
Cause Remedy
• Disconnect CN78. Is voltage between CN78 (female) (2) NO

• Turn starting switch ON. and ground less than 1 V?
YES
Is voltage between CN78 (female) (2) and NO

• Disconnect CN78 and CN80. ground less than 1 V when alternator
• Turn starting switch ON. terminal R (CN80) is disconnected?
YES
Defective alternator Replace
• Disconnect CN78 and D01. Is voltage between CN78 (female) (2) NO Hot short in wiring harness between
and ground less than 1 V when diode CN78 (female) (2) - alternator Repair or
(D01) is disconnected? terminal R (CN80) - D01 (female) (2)
YES
Defective diode (D01) Replace
• Disconnect CN78. Is voltage between CN78 (female) (1) NO

• Turn starting switch to START. and ground 20 - 30 V?
YES
• Turn starting switch to Does condition become normal when engine NO

START. starting relay (R01) or transmission neutral
relay (R02) is interchanged with other relay?
YES Defective engine starting relay
(R01) or defective transmission Replace
neutral relay (R02)
• Disconnect R01. Is voltage between R01 (female) (1) NO Defective contact or disconnection
• Turn starting switch ON. and ground 20 - 30 V? in wiring harness between fuse Repair or
BT3-10 outlet and R01 (female) (1) replace
YES
To 12 To 7
20-374 HM300-1
c 1 c
(9)
From 4 From 6
Cause Remedy

• Disconnect R02. Is voltage between R02 (female) (6) NO in wiring harness between R01 Repair or
• Turn starting switch ON. and ground 20 - 30 V? (female) (2) and R02 (female) (6) replace
YES
NO Defective contact or disconnection

• Turn starting switch OFF. Is resistance between R02 (female) (3) in wiring harness between R02 Repair or
• Disconnect R02. and ground less than 1Ω? (female) (3) and ground replace
YES
• Disconnect R02. NO Defective contact or disconnection

Is voltage between R02 (female) (1) in wiring harness between R02 Repair or
• Turn starting switch ON. and ground 20 - 30 V? replace
(female) (1) and wiring harness
dividing point
YES
• Turn starting switch OFF. NO Defective contact or disconnection Repair or

Is resistance between R02 (female) in wiring harness between R02
• Disconnect R02. (2) and ground less than 1Ω? replace
(female) (2) and ground
YES
Defective starting switch or defective

• Disconnect R01. Is voltage between R01 (female) (3) NO contact or disconnection in wiring Repair or
• Turn starting switch START. and ground 20 - 30 V? harness between starting switch replace
terminal C and R01 (female) (3)
YES Defective contact or disconnection Repair or
in wiring harness between R01 replace
(female) (6) and CN78 (female) (1)
NO Defective contact or disconnection Repair or

• Turn starting switch OFF. Is voltage between starting motor in wiring harness between battery -
terminal B and ground 20 - 30 V? replace
battery relay - starting motor
terminal B
YES
Defective starting motor Replace
HM300-1 20-375
1 ! !
20-376 HM300-1
! 1 !
TROUBLESHOOTING OF
TRANSMISSION CONTROLLER
SYSTEM (TM MODE)
TM mode related electrical circuit diagram .............................................................................................. 20-404

Content of display and problem that appears on machine for each failure code ..................................... 20-410
TM-1 Failure code [1380MW] (Lock-up clutch: Slipping (MW)) ......................................................... 20-436
TM-2 Failure code [1500LO] (Transmission clutch: * See the table in Contents. (LO)) ..................... 20-437
TM-3 Failure code [15B0NX] (Transmission oil filter: Clogged (NX)) ................................................ 20-438
TM-4 Failure code [15G0MW] (R clutch: Slipping (MW)) .................................................................. 20-439
TM-5 Failure code [15H0MW] (Hi clutch: Slipping (MW)) .................................................................. 20-440
TM-6 Failure code [15J0MW] (Lo clutch: Slipping (MW)) .................................................................. 20-441
TM-7 Failure code [15K0MW] (1st clutch: Slipping (MW)) ................................................................. 20-442
TM-8 Failure code [15L0MW] (2nd clutch: Slipping (MW)) ................................................................ 20-443
TM-9 Failure code [15M0MW] (3rd clutch: Slipping (MW)) ................................................................ 20-444
TM-10 Failure code [15SBL1] (ECMV for R clutch: * See the table in Contents. (L1)) ........................ 20-445
TM-11 Failure code [15SBMA] (ECMV for R clutch: Function impossible (MA)) ................................. 20-446
TM-12 Failure code [15SCL1] (ECMV for Hi clutch: * See the table in Contents. (L1)) ....................... 20-447
TM-13 Failure code [15SCMA] (ECMV for Hi clutch: Function impossible (MA)) ................................ 20-448
TM-14 Failure code [15SDL1] (ECMV for Lo clutch: * See the table in Contents. (L1)) ...................... 20-449
TM-15 Failure code [15SDMA] (ECMV for Lo clutch: Function impossible (MA)) ............................... 20-450
TM-16 Failure code [15SEL1] (ECMV for 1st clutch: * See the table in Contents. (L1)) ..................... 20-451
TM-17 Failure code [15SEMA] (ECMV for 1st clutch: Function impossible (MA)) ............................... 20-452
TM-18 Failure code [15SFL1] (ECMV for 2nd clutch: * See the table in Contents. (L1)) .................... 20-453
TM-19 Failure code [15SFMA] (ECMV for 2nd clutch: Function impossible (MA)) .............................. 20-454
TM-20 Failure code [15SGL1] (ECMV for 3rd clutch: * See the table in Contents. (L1)) ..................... 20-455
TM-21 Failure code [15SGMA] (ECMV for 3rd clutch: Function impossible (MA)) .............................. 20-456
TM-22 Failure code [15SJL1] (ECMV for lock-up clutch: * See the table in Contents. (L1)) ............... 20-457
TM-23 Failure code [15SJMA] (ECMV for lock-up clutch: Function impossible (MA)) ........................ 20-458
TM-24 Failure code [15SKL1] (ECMV for inter-axle differential lock clutch:
* See the table in Contents. (L1)) ....................................................... 20-459
TM-25 Failure code [15SKMA] (ECMV for inter-axle differential lock clutch:
Function impossible (MA)) .................................................................. 20-460
TM-26 Failure code [2B61MW] (Inter-axle differential lock clutch: Slipping (MW)) ............................. 20-461
TM-27 Failure code [2F00KM] (Parking brake: Mistaken operation or mistaken setting (KM)) ........... 20-462
TM-28 Failure code [989A00] (Engine overrun prevention command signal: Actuated (00)) .............. 20-464
TM-29 Failure code [989AKZ] (Engine overrun prevention command signal:
Disconnection or short circuit (KZ)) .................................................... 20-465
TM-30 Failure code [989D00] (Rear overturn signal: Actuated (00)) ................................................... 20-466
TM-31 Failure code [AA10NX] (Air cleaner element: Clogged (NX)) ................................................... 20-468
TM-32 Failure code [AB00MA] (Alternator: Function impossible (MA)) ............................................... 20-470
TM-33 Failure code [B@BCZK] (Radiator coolant: Drop in level (ZK)) ............................................... 20-471
TM-34 Failure code [B@HAZK] (Hydraulic tank oil: Drop in level (ZK)) .............................................. 20-472
TM-35 Failure code [B@JANS] (Steering oil: Overheat (NS)) ............................................................. 20-473
TM-36 Failure code [D1B0KZ] (Transmission cut relay: Disconnection or short circuit (KZ)) ............. 20-474
TM-37 Failure code [D5ZBKX] (Inter-axle differential lock command signal:
Input signal outside range (KX)) ......................................................... 20-476
TM-38 Failure code [D5ZCKZ] (Exhaust brake command signal: Disconnection or short circuit (KZ)) . 20-478
TM-39 Failure code [D5ZDL4] (Forced neutral demand signal: * See the table in Contents. (L4)) ..... 20-479
TM-40 Failure code [D5ZEKX] (Engine load signal: Input signal outside range (KX)) ........................ 20-481
TM-41 Failure code [DAQ0KK] (Transmission controller: Drop in power source voltage, input (KK)) . 20-482
TM-42 Failure code [DAQ1KK] (Transmission controller main power supply line:
Drop in power source voltage, input (KK)) ......................................... 20-484
HM300-1 20-401
1 c
(9) c
TROUBLESHOOTING
TM-43 Failure code [DAQ2KK] (Transmission controller load power supply line:
Drop in power source voltage, input (KK)) .......................................... 20-485
TM-44 Failure code [DAQ3KK] (Transmission controller battery direct power supply line:
Drop in power source voltage, input (KK)) .......................................... 20-486
TM-45 Failure code [DAQ5KP] (Transmission controller power supply output 1:
Drop in output voltage (KP)) ............................................................... 20-487
TM-46 Failure code [DAQ9KM] (Transmission controller wiring harness:
Mistaken operation or mistaken setting (KM)) .................................... 20-488
TM-47 Failure code [DAQ9KQ] (Transmission controller wiring harness:
Non match in model selection signal (KQ)) ........................................ 20-489
TM-48 Failure code [DAQAKQ] (Transmission controller rotary switch:
Non match in model selection signal (KQ)) ........................................ 20-490
TM-49 Failure code [DAQSMA] (Transmission controller: Function impossible (MA) .......................... 20-490
TM-50 Failure code [DDTFKA] (Fill switch for inter-axle differential lock clutch: Disconnection (KA)) . 20-491
TM-51 Failure code [DDTGKA] (Fill switch for lock-up clutch: Disconnection (KA)) ............................ 20-492
TM-52 Failure code [DDTHKA] (Fill switch for Hi clutch: Disconnection (KA)) .................................... 20-493
TM-53 Failure code [DDTJKA] (Fill switch for Lo clutch: Disconnection (KA)) ..................................... 20-494
TM-54 Failure code [DDTKKA] (Fill switch for 1st clutch: Disconnection (KA)) ................................... 20-495
TM-55 Failure code [DDTLKA] (Fill switch for 2nd clutch: Disconnection (KA)) .................................. 20-496
TM-56 Failure code [DDTMKA] (Fill switch for 3rd clutch: Disconnection (KA)) .................................. 20-497
TM-57 Failure code [DDTNKA] (Fill switch for R clutch: Disconnection (KA)) ..................................... 20-498
TM-58 Failure code [DF10KA] (Gearshift lever: Disconnection (KA)) .................................................. 20-499
TM-59 Failure code [DF10KB] (Gearshift lever: Short circuit (KB)) ..................................................... 20-501
TM-60 Failure code [DGF1KX] (Transmission valve oil temperature sensor:
TM-61 Failure code [DGR3L8] (Brake oil temperature sensor (center):
TM-62 Failure code [DGR4L8] (Brake oil temperature sensor (front):
TM-63 Failure code [DGT1LX] (Torque converter oil temperature sensor:
TM-64 Failure code [DHT5KX] (Torque converter oil pressure sensor:
Input signal outside range (KX)) ......................................................... 20- 511
TM-65 Failure code [DHT5L6] (Torque converter oil pressure sensor:
TM-66 Failure code [DJF1KA] (Fuel level sensor: Disconnection (KA)) .............................................. 20-514
TM-67 Failure code [DK11KX] (Throttle angle sensor: Input signal outside range (KX)) ..................... 20-515
TM-68 Failure code [DLE2KA] (Engine speed sensor: Disconnection (KA)) ....................................... 20-517
TM-69 Failure code [DLE2LC] (Engine speed sensor: * See the table in Contents. (LC)) ................... 20-518
TM-70 Failure code [DLF1KA] (Transmission input shaft speed sensor:
Disconnection (KA)) ............................................................................ 20-519
TM-71 Failure code [DLF1LC] (Transmission input shaft speed sensor:
* See the table in Contents. (LC)) ....................................................... 20-520
TM-72 Failure code [DLF2KA] (Transmission intermediate shaft speed sensor:
Disconnection (KA)) ............................................................................ 20-521
TM-73 Failure code [DLF2LC] (Transmission intermediate shaft speed sensor:
TM-74 Failure code [DLT3KA] (Transmission output shaft R speed sensor: Disconnection (KA)) ...... 20-523
TM-75 Failure code [DLT3LC] (Transmission output shaft R speed sensor:
TM-76 Failure code [DXH0KA] (Solenoid for inter-axle differential lock: Disconnection (KA)) ............ 20-526
TM-77 Failure code [DXH0KB] (Solenoid for inter-axle differential lock: Short circuit (KB)) ................ 20-527
TM-78 Failure code [DXH1KA] (Solenoid for lock-up clutch: Disconnection (KA)) .............................. 20-528
TM-79 Failure code [DXH1KB] (Solenoid for lock-up clutch: Short circuit (KB)) .................................. 20-529
TM-80 Failure code [DXH2KA] (Solenoid for Hi clutch: Disconnection (KA)) ...................................... 20-530
TM-81 Failure code [DXH2KB] (Solenoid for Hi clutch: Short circuit (KB)) .......................................... 20-531
TM-82 Failure code [DXH3KA] (Solenoid for Lo clutch: Disconnection (KA)) ...................................... 20-532
TM-83 Failure code [DXH3KB] (Solenoid for Lo clutch: Short circuit (KB)) ......................................... 20-533
TM-84 Failure code [DXH4KA] (Solenoid for 1st clutch: Disconnection (KA)) ..................................... 20-534
20-402 HM300-1
c 1 c
(9)
TROUBLESHOOTING
TM-85 Failure code [DXH4KB] (Solenoid for 1st clutch: Short circuit (KB)) ........................................ 20-535
TM-86 Failure code [DXH5KA] (Solenoid for 2nd clutch: Disconnection (KA)) ................................... 20-536
TM-87 Failure code [DXH5KB] (Solenoid for 2nd clutch: Short circuit (KB)) ....................................... 20-537
TM-88 Failure code [DXH6KA] (Solenoid for 3rd clutch: Disconnection (KA)) .................................... 20-538
TM-89 Failure code [DXH6KB] (Solenoid for 3rd clutch: Short circuit (KB)) ........................................ 20-539
TM-90 Failure code [DXH7KA] (Solenoid for R clutch: Disconnection (KA)) ....................................... 20-540
TM-91 Failure code [DXH7KB] (Solenoid for R clutch: Short circuit (KB)) .......................................... 20-541
TM-92 Backup lamp, backup buzzer do not work properly .................................................................. 20-542
TM-93 Emergency steering does not operate ..................................................................................... 20-545
Appendix: Table for Failure Phenomenon Code
Failure Failure
Phenomenon Summary of Failure Phenomenon Summary of Failure
Code Code
An impossible combination of clutch fill signals turn on more
KA Disconnection L0
than 2 channels simultaneously.
KB Short-circuiting L1 While the order current to ECMV is off, the fill signal is on.
Power source voltage and
KK L2 The fuel pressure exceeds the specified max. value.
input lowered
Model selection signal
KQ L3 The intended unit is out of control.
wrong
ON and OFF signals in two systems do not concur with each
KR Communication ineffective L4
other.
Signals from engine revolution, C terminal, hydraulic pressure
Controller internally abnor-
KT L6 switch and coolant temperature sensor do not match up with
mal
the respective actual condition.
KX Input signal out of range L8 Analog signals in two systems do not concur with each other.
Disconnection or short-cir- Signals of revolution speed in two systems do not concur with
KZ LC
cuiting each other.
MA Function ineffective LD The switch is kept depressed for an unusually long time.
MB Function lowered LH While the order current to ECMV is on, the fill signal is off.
MW Sliding
HM300-1 20-403
(10)
1 Å Å
TROUBLESHOOTING
TROUBLESHOOTING TM MODE RELATED ELECTRICAL CIRCUIT DIAGRAM
TM MODE RELATED ELECTRICAL CIRCUIT DIAGRAM
20-404 HM300-1
c 1 c
TROUBLESHOOTING
★ This circuit diagram has been made by extracting the transmission controller related circuits and emergency
steering related circuits from the overall electrical circuit diagram.
HM300-1 20-405
1 ! !
TROUBLESHOOTING
20-406 HM300-1
! 1 !
TROUBLESHOOTING
HM300-1 20-407
1 ! !
TROUBLESHOOTING
20-408 HM300-1
! 1 !
TROUBLESHOOTING
HM300-1 20-409
1 c c
TROUBLESHOOTING

1380MW Lock-up clutch: When there is output to the lock- • Defective lock-up clutch solenoid
(TM-1) Slipping (MW) up clutch solenoid, there is an • Excessive resistance in solenoid (+) cir-
abnormality in the value calcu- cuit wiring harness
lated from the signals from the • Excessive resistance in solenoid (–) cir-
engine speed sensor, transmis- cuit wiring harness
sion input shaft speed sensor, • Defective lock-up clutch, pressure con-
transmission intermediate shaft trol valve hydraulic, mechanical system
speed sensor, and transmission • Defective transmission controller
output shaft R speed sensor.
1500L0 Transmission clutch: Fill switch signals have been in- • Other problem occurs at same time (fail-
(TM-2) * See Contents (LO) put from 2 clutches that do not ure code [15S*L1] is displayed)
form a normal combination. • Defective pressure control valve hydrau-
lic, mechanical system
• Defective transmission controller
15B0NX Transmission oil filter: When the torque converter oil • Clogged transmission oil filter (when ac-
(TM-3) Clogged (NX) temperature is more than 50°C, tuating system normally)
the signal circuit of the transmis- • Defective transmission oil filter clogging
sion filter clogging switch is switch
open (shut off from the ground). • Disconnection in switch signal circuit wir-
ing harness
ing harness
15G0MW R clutch: Slipping (MW) When there is output to the R • Defective R clutch solenoid
(TM-4) clutch solenoid, there is an ab- • Excessive resistance in solenoid (+) cir-
normality in the value calculated cuit wiring harness
from the signals from the trans- • Excessive resistance in solenoid (–) cir-
mission input shaft speed sen- cuit wiring harness
sor, intermediate shaft speed • Defective R clutch, pressure control
sensor, and output shaft R valve hydraulic, mechanical system
speed sensor. • Defective transmission controller
15H0MW Hi clutch: Slipping (MW) When there is output to the Hi • Defective Hi clutch solenoid
sor, intermediate shaft speed • Defective Hi clutch, pressure control
15J0MW Lo clutch: Slipping (MW) When there is output to the Lo • Defective Lo clutch solenoid
sor, intermediate shaft speed • Defective Lo clutch, pressure control
20-410 HM300-1
c 1 c
(9)
TROUBLESHOOTING
★ The code (TM-**) given below the failure code is the troubleshooting number.
• Solenoid resistance value • Holds speed range during trav- • Lock-up is canceled and trans- E03
L/C-PS (male) (1) – (2): 5 – 15 Ω el, turns lock-up actuation mission cannot be shifted
OFF. • If gearshift lever is operated to N,
• Holds at Neutral if gearshift le- machine cannot move off again
ver is operated to N. until it is stopped
• Turns transmission cut relay • Suddenly shifts to Neutral when E03

OFF. traveling and cannot move off
• Sets transmission to Neutral. again
• Switch resistance value • Takes no action • If machine continues to be used E01

T03 (male) (1) – (2): as it is, there is danger that dirt will
• When normal: Max. 1 Ω circulate in transmission circuit
• Solenoid resistance value • Sets transmission to Neutral. • Suddenly shifts to Neutral when E03
R-PS (male) (1) – (2): 5 – 15 Ω traveling
H-PS (male) (1) – (2): 5 – 15 Ω traveling
• Cannot move off again unless ma-
chine is stopped
L-PS (male) (1) – (2): 5 – 15 Ω traveling
chine is stopped
HM300-1 20-411
1 c
(9) c
TROUBLESHOOTING
15K0MW 1st clutch: Slipping (MW) When there is output to the 1st • Defective 1st clutch solenoid
sor, intermediate shaft speed • Defective 1st clutch, pressure control
15L0MW 2nd clutch: Slipping (MW) When there is output to the 2nd • Defective 2nd clutch solenoid
sor, intermediate shaft speed • Defective 2nd clutch, pressure control
15M0MW 3rd clutch: Slipping (MW) When there is output to the 3rd • Defective 3rd clutch solenoid
sor, intermediate shaft speed • Defective 3rd clutch, pressure control
15SBL1 ECMV for R clutch: Even when the output to the R • Defective R clutch fill switch
(TM-10) * See Contents (L1) clutch solenoid is turned OFF, • Short circuit with chassis ground in
the signal from the fill switch switch circuit wiring harness
stays ON and the clutch is not • Defective R clutch pressure control valve
disengaged. hydraulic, mechanical system
15SBMA ECMV for R clutch: Function Even when there is output to the • Defective R clutch solenoid
(TM-11) impossible (MA) R clutch solenoid, the signal • Excessive resistance in solenoid (+) cir-
from the fill switch stays OFF cuit wiring harness
and the clutch is not engaged. • Excessive resistance in solenoid (–) cir-
cuit wiring harness
• Defective R clutch or pressure control
valve hydraulic, mechanical system
15SCL1 ECMV for Hi clutch: Even when the output to the Hi • Defective Hi clutch fill switch
stays ON and the clutch is not • Defective Hi clutch or pressure control
disengaged. valve hydraulic, mechanical system
15SCMA ECMV for Hi clutch: Function Even when there is output to the • Defective Hi clutch solenoid
(TM-13) impossible (MA) Hi clutch solenoid, the signal • Excessive resistance in solenoid (+) cir-
cuit wiring harness
• Defective Hi clutch pressure control
20-412 HM300-1
c 1 c
(9)
TROUBLESHOOTING
1-PS (male) (1) – (2): 5 – 15 Ω traveling
Switch resistance value • Sets transmission to Neutral. • Suddenly shifts to Neutral when E03
R-SW (male) (1) – ground: traveling
• When clutch is released: • Cannot move off again unless ma-
Min. 1 MΩ chine is stopped
• When clutch is engaged:
Max. 1 Ω
R-PS (male) (1) – (2): 5 – 15 Ω traveling
chine is stopped
• Switch resistance value • Sets transmission to Neutral. • Suddenly shifts to Neutral when E03
H-SW (male) (1) – ground: traveling
Max. 1 Ω
H-PS (male) (1) – (2): 5 – 15 Ω traveling
chine is stopped
HM300-1 20-413
1 c
(9) c
TROUBLESHOOTING
15SDL1 ECMV for Lo clutch: Even when the output to the Lo • Defective Lo clutch fill switch
stays ON and the clutch is not • Defective Lo clutch pressure control
15SDMA ECMV for Lo clutch: Even when there is output to the • Defective Lo clutch solenoid
(TM-15) Function impossible (MA) Lo clutch solenoid, the signal • Excessive resistance in solenoid (+) cir-
cuit wiring harness
• Defective Lo clutch or pressure control
15SEL1 ECMV for 1st clutch: Even when the output to the 1st • Defective 1st clutch fill switch
stays ON and the clutch is not • Defective 1st clutch pressure control
15SEMA ECMV for 1st clutch: Even when there is output to the • Defective 1st clutch solenoid
(TM-17) Function impossible (MA) 1st clutch solenoid, the signal • Excessive resistance in solenoid (+) cir-
cuit wiring harness
• Defective 1st clutch or pressure control
15SFL1 ECMV for 2nd clutch: Even when the output to the 2nd • Defective 2nd clutch fill switch
stays ON and the clutch is not • Defective 2nd clutch pressure control
15SFMA ECMV for 2nd clutch: Even when there is output to the • Defective 2nd clutch solenoid
(TM-19) Function impossible (MA) 2nd clutch solenoid, the signal • Excessive resistance in solenoid (+) cir-
cuit wiring harness
• Defective 2nd clutch or pressure control
15SGL1 ECMV for 3rd clutch: Even when the output to the 3rd • Defective 3rd clutch fill switch
stays ON and the clutch is not • Defective 3rd clutch pressure control
20-414 HM300-1
c 1 c
(9)
TROUBLESHOOTING
L-SW (male) (1) – ground: traveling
Max. 1 Ω
L-PS (male) (1) – (2): 5 – 15 Ω traveling
chine is stopped
1-SW (male) (1) – ground: traveling
Max. 1 Ω
chine is stopped
Max. 1 Ω
chine is stopped
Max. 1 Ω
HM300-1 20-415
1 c
(9) c
TROUBLESHOOTING
15SGMA ECMV for 3rd clutch: Even when there is output to the • Defective 3rd clutch solenoid
(TM-21) Function impossible (MA) 3rd clutch solenoid, the signal • Excessive resistance in solenoid (+) cir-
cuit wiring harness
• Defective 3rd clutch or pressure control
15SJL1 ECMV for lock-up clutch: Even when the output to the • Defective lock-up clutch fill switch
(TM-22) * See Contents (L1) lock-up clutch solenoid is turned • Short circuit with chassis ground in
OFF, the signal from the fill switch circuit wiring harness
switch stays ON and the clutch • Defective lock-up clutch pressure control
is not disengaged. valve hydraulic, mechanical system
15SJMA ECMV for lock-up clutch: Even when there is output to the • Defective lock-up clutch solenoid
(TM-23) Function impossible (MA) lock-up clutch solenoid, the sig- • Excessive resistance in solenoid (+) cir-
nal from the fill switch stays OFF cuit wiring harness
cuit wiring harness
• Defective lock-up clutch or pressure con-
trol valve hydraulic, mechanical system
15SKL1 ECMV for inter-axle differen- Even when the output to the dif- • Defective differential lock clutch fill
(TM-24) tial lock clutch: ferential lock clutch solenoid is switch
* See Contents (L1) turned OFF, the signal from the • Short circuit with chassis ground in
fill switch stays ON and the switch circuit wiring harness
clutch is not disengaged. • Defective differential lock clutch pres-
sure control valve hydraulic, mechanical
system
15SKMA ECMV for inter-axle differen- Even when there is output to the • Defective differential lock clutch solenoid
(TM-25) tial lock clutch: Function im- differential lock clutch solenoid, • Excessive resistance in solenoid (+) cir-
possible (MA) the signal from the fill switch cuit wiring harness
stays OFF and the clutch is not • Excessive resistance in solenoid (–) cir-
engaged. cuit wiring harness
• Defective differential lock clutch or pres-
sure control valve hydraulic, mechanical
system
2B61MW Inter-axle differential lock When there is output to the dif- • Defective differential lock clutch solenoid
(TM-26) clutch: Slipping (MW) ferential lock clutch solenoid, • Excessive resistance in solenoid (+) cir-
there is an abnormality in the cuit wiring harness
value calculated from the sig- • Excessive resistance in solenoid (–) cir-
nals from the transmission out- cuit wiring harness
put shaft F speed sensor and • Defective differential lock clutch or pres-
output shaft R speed sensor (re- sure control valve hydraulic, mechanical
tarder controller is responsible system
for calculating value). • Defective transmission controller
20-416 HM300-1
c 1 c
(9)
TROUBLESHOOTING
chine is stopped
• Switch resistance value • Holds speed range when trav- • Lock-up is canceled and it be- E03
L/C-SW (male) (1) – ground: eling and turns lock-up actua- comes impossible to shift gear
• When clutch is released: tion OFF • If gearshift lever is returned to N,
Min. 1 MΩ • When gearshift lever is re- machine cannot move off again
• When clutch is engaged: turned to N, holds in Neutral until it is stopped
Max. 1 Ω • Lock-up pilot lamp does not give
display normally
• Solenoid resistance value • Holds speed range when trav- • Lock-up is canceled and it be- E03
L/C-PS (male) (1) – (2): eling and turns lock-up actua- comes impossible to shift gear
5 – 15 Ω tion OFF • If gearshift lever is returned to N,
• When gearshift lever is re- machine cannot move off again
turned to N, holds in Neutral until it is stopped
• Switch resistance value • Turns inter-axle differential • Inter-axle differential lock does E01
D/L-SW (male) (1) – ground: lock command OFF not work
• When clutch is released:
Min. 1 MΩ
Max. 1 Ω
• Solenoid resistance value • Turns inter-axle differential • Inter-axle differential lock does E02
D/L-PS (male) (1) – (2) : lock command OFF not work
5 – 15 Ω
D/L-PS (male) (1) – (2) : lock command OFF not work
5 – 15 Ω
HM300-1 20-417
1 c
(9) c
TROUBLESHOOTING
2F00KM Parking brake: Mistaken op- Travel operation was carried out • Forgot to release parking brake (when
(TM-27) eration or mistaken setting when parking brake signal cir- system is working normally)
(KM) cuit was closed (connected with • Defective fuse
ground) • Defective parking brake oil pressure
switch
• Defective parking brake relay
sis ground in switch power source circuit
wiring harness
sis ground in switch signal circuit wiring
harness
• Disconnection in relay GND circuit wiring
harness
• Defective retarder controller(q1)
989A00 Engine overrun prevention The transmission input shaft • Engine overrun
(TM-28) command signal: Actuated speed became more than 2450 • Defective transmission controller
(00) rpm when the speed range was
other than Neutral.
989AKZ Engine overrun prevention Disconnection, short circuit with • Defective retarder controller(q1)
(TM-29) command signal: Disconnec- ground, hot short occurred in • Disconnection, short circuit with chassis
tion or short circuit (KZ) overrun prevention command ground, or hot short in signal circuit wir-
circuit, or did not match commu- ing harness
nications data (S-NET) • Defective transmission controller
989D00 Rear overturn signal: Actuat- Dump body was operated to • Dump operated when machine is in-
(TM-30) ed (00) RAISE when machine was inclined (when system is working normally)
clined more than 15° • Defective inclination sensor
• Disconnection or hot short in sensor
power source circuit wiring harness
ing harness
ground, or hot short in sensor signal cir-
cuit wiring harness
AA10NX Air cleaner element: Clogged Air cleaner clogging signal cir- • Clogged air cleaner element (when sys-
(TM-31) (NX) cuit became open (shut off from tem is working normally)
ground) when engine was run- • Defective air cleaner clogging sensor
ning • Defective dust indicator relay
• Short circuit with chassis ground in sen-
sor signal circuit wiring harness
• Disconnection in relay signal circuit wir-
ing harness
• Disconnection in relay GND circuit wiring
harness
AB00MA Alternator: Function impossi- Electricity generation signal was • Defective alternator
(TM-32) ble (MA) not input from alternator when • Disconnection or short circuit with chas-
engine was running. sis ground in alternator signal circuit
20-418 HM300-1
c 1 c
(9)
TROUBLESHOOTING
• Switch resistance value • Takes no action • If the machine is used as it is, None
B17 (male) (1) – (2) : • User code is not displayed there is danger that the parking
• Brake released: Min. 1 MΩ brake may be damaged
• Brake applied: Max. 1 Ω
• Relay resistance value
R32 (male) (1) – (2) : 100 – 500 Ω
• Issues order to retarder con- • Brake is applied, travel speed is E02

troller(q1) to apply brake (re- reduced
tarder)
• Signal voltage • Continues control with signal • No great effect on machine E01
ATC1 (13) – (8)(16) on S-NET
• When command is ON:
20 – 30 V
• When command is OFF:
Max. 1 V
• A. Sensor power source voltage • Takes no action • If the dump RAISE operation is None
T10 (1) – (3): 11 – 13 V • User code is not displayed continued in this condition, the
• Sensor signal voltage machine may tip over
T10 (2) – (3):
• When machine is horizontal:
2.9 – 3.1 V
• When machine is inclined 15°
to left: 1.4 – 1.6 V
• When machine is inclined 15°
to right: 4.4 – 4.6 V
• Sensor resistance value • Takes no action • If the machine is used as it is, the E01
T11 (male) (1) – (2) engine air intake capacity may
• When normal: Min. 1 MΩ drop
• When clogged: Max. 1 Ω
• Relay resistance value
R32 (male) (3) – (6): Max. 1 Ω
• Alternator generating voltage • Takes no action • If the machine is used as it is, the E03
Alternator R – E: 27.5 – 29.5 V power supply voltage will drop
and it may become impossible for
the machine to travel
• Dump body cannot be controlled
(Dump body does not move)
HM300-1 20-419
1 c
(9) c
TROUBLESHOOTING
B@BCZK Radiator coolant: Drop in lev- Radiator coolant level switch • Drop in radiator coolant level (when sys-
(TM-33) el (ZK) signal circuit became open (shut tem is working normally)
off from ground) when engine • Defective radiator coolant level switch
was running • Disconnection in switch signal circuit wir-
ing harness
ing harness
B@HAZK Hydraulic tank oil: Drop in lev- When the engine was stopped, • Drop in hydraulic tank oil level (when
(TM-34) el (ZK) the signal circuit of the hydraulic system is working normally)
tank level switch became open • Defective hydraulic tank level switch
(shut off from GND) • Disconnection in switch circuit wiring
harness
B@JANS Steering oil: Overheat (NS) The signal circuit of the steering • Steering oil temperature overheating
(TM-35) oil temperature switch became (when system is working normally)
open (shut off from GND) • Defective steering oil temperature switch
• Disconnection in switch circuit wiring
harness
D1B0KZ Transmission cut relay: Dis- Abnormal voltage was generat- • Defective transmission cut relay
(TM-36) connection or short circuit ed in the transmission cut relay • Disconnection or short circuit with chas-
(KZ) circuit sis ground in relay power source circuit
• When relay is actuated: 10 V wiring harness
or more • Disconnection, short circuit with chassis
• When relay is stopped: Less ground, or hot short in relay output circuit
than 4 V wiring harness
D5ZBKX Inter-axle differential lock The voltage in the differential • Defective retarder controller(q1)
(TM-37) command signal: Input signal lock signal circuit became less • Disconnection, short circuit with chassis
outside range (KX) than 0.5 V or more than 4.5 V ground, or hot short in signal circuit wir-
ing harness
D5ZCKZ Exhaust brake command sig- A disconnection, short circuit • Defective retarder controller(q1)
(TM-38) nal: Disconnection or short with ground, or hot short was • Disconnection, short circuit with chassis
circuit (KZ) generated in the exhaust brake ground, or hot short in signal circuit wir-
command circuit, or there was a ing harness
mismatch with the communica- • Defective transmission controller
tion (S-NET) data
D5ZDL4 Forced neutral demand sig- There was a mismatch between • Defective retarder controller(q1)
(TM-39) nal: * See Contents (L4) forced neutral demand signal 1 • Disconnection, short circuit with chassis
and signal 2 ground, or hot short in signal 1 circuit wir-
ing harness
ground, or hot short in signal 2 circuit wir-
ing harness
D5ZEKX Engine load signal: Input sig- The engine load signal circuit • Defective engine controller
(TM-40) nal outside range (KX) was outside the correct range • Disconnection, short circuit with chassis
ground, or hot short in signal circuit wir-
ing harness
20-420 HM300-1
c 4 c
1
(9)
TROUBLESHOOTING
• Sensor resistance value • Takes no action • If the machine is used as it is, the E01
T01 (male) (1) – (2): engine may overheat
• When normal: Max. 1 Ω
• Sensor resistance value • Takes no action • If the machine is used as it is, it E01
T06 (male) (1) – ground: may become impossible to carry
• When oil level is normal: out dump operations
Max. 1 Ω
• When oil level has dropped:
Min. 1 MΩ
• Sensor resistance value • Takes no action • If the machine is used as it is, oil E02
T04 (male) (1) – ground: leakage may occur
• When oil temperature is 25°C:
Max 1 Ω
• When oil temperature is
123°C: Min. 1 MΩ
• Controller inlet voltage • Turns transmission cut relay • Suddenly shifts to Neutral when E03
ATC1 (15) – (8)(16): OFF. traveling and machine cannot
• When relay actuated: Max. 1 V • Sets transmission to Neutral. move off again
• When relay stopped: 20 – 30 V
• Signal voltage • Turns inter-axle differential • Inter-axle differential lock does E01
ATC3A (8) – (18): 0.7 – 4.3 V lock command OFF not work
• Signal voltage • Continues control with signal • No great effect on machine E01
ATC1 (14) – (8)(16): on S-NET
• When command is OFF:
Max. 1 V
• When command is ON:
20 – 30 V
• Continues control with signal • No great effect on machine E01

on S-NET
• Signal voltage • Carries out control with load • Gearshift feeling may change E01
ATC3A (4) – (16): 0 – 15 V taken as heavy load slightly
HM300-1 20-421
1 c
(9) c
TROUBLESHOOTING
DAQ0KK Transmission controller: Drop When the engine was running, • Another problem is occurring at the
(TM-41) in power source voltage, in- both the main power supply volt- same time (failure code AB00MA is dis-
put (KK) age circuit and the direct power played)
supply voltage circuit became • Battery tends to lose power
less than 18 V • Disconnection or short circuit with chas-
sis ground in power source circuit wiring
harness
ness
DAQ1KK Transmission controller main The voltage difference between • Disconnection or short circuit with chas-
(TM-42) power supply line: Drop in the main power supply voltage sis ground in main power source circuit
power source voltage, input circuit and the direct power sup- wiring harness
(KK) ply voltage circuit became more • Defective transmission controller
than 5 V
DAQ2KK Transmission controller load When the controller power sup- • Defective transmission cut relay
(TM-43) power supply line: Drop in ply voltage circuit was normal, • Disconnection or short circuit with chas-
power source voltage, input the solenoid power supply volt- sis ground in relay power source circuit
(KK) age circuit became less than wiring harness
18 V • Disconnection or short circuit with chas-
sis ground in relay output circuit wiring
harness
DAQ3KK Transmission controller bat- The voltage in the direct power • Disconnection or short circuit with chas-
(TM-44) tery direct power supply line: supply voltage circuit became sis ground in direct power source circuit
Drop in power source volt- less than 5 V wiring harness
age, input (KK) • Defective transmission controller
DAQ5KP Transmission controller pow- The voltage in the 12V power • Defective inclination sensor
(TM-45) er supply output 1: Drop in supply circuit for the sensor be- • Short circuit with chassis ground in sen-
output voltage (KP) came less than 6 V sor power source circuit wiring harness
DAQ9KM Transmission controller wir- When the starting switch is ON, • Mistaken connection of connector ATC3
(TM-46) ing harness: Mistaken opera- the input connector check signal (A, B) and connector ATC5 (A, B) (when
tion or mistaken setting (KM) does not match the setting in- system is working normally)
side the controller • Disconnection in signal 1 circuit wiring
harness
DAQ9KQ Transmission controller wir- When the starting switch is ON, • Disconnection in model selection signal
(TM-47) ing harness: Non match in the input model selection signal circuit wiring harness
model selection signal (KQ) is different from the setting of the • Defective transmission controller
controller
DAQAKQ Transmission controller rota- The model setting of the rotary • Defective setting of rotary switch
(TM-48) ry switch: Non match in mod- switch does not match the set- • Defective transmission controller
el selection signal (KQ) ting inside the controller
DAQSMA Transmission controller: The communication (S-NET) • Another problem is occurring at the
(TM-49) Function impossible (MA) with the machine monitor is de- same time (failure code DAQSKR is dis-
fective and the option setting played)
cannot be made • Defective machine monitor
20-422 HM300-1
c 1 c
(9)
TROUBLESHOOTING
• Main power source voltage • Sets transmission to Neutral. • Suddenly shifts to Neutral when E03
ATC1 (9)(17) – (8)(16): 20 – 30 V traveling and machine cannot
• Direct power source voltage move off again
ATC1 (7) – (8)(16): 20 – 30 V
• Main power source voltage • Does not allow updating of in- • Condition before problem oc- E03
ATC1 (9)(17) – (8)(16): 20 – 30 V put related data curred is maintained
• Solenoid power source voltage • Turns transmission cut relay • Suddenly shifts to Neutral when E03
ATC2 (1)(12) – ATC1 (8)(16): OFF. traveling and machine cannot
20 – 30 V • Sets transmission to Neutral. move off again
• Direct power source voltage • Sets transmission to Neutral. • Suddenly shifts to Neutral when E03
ATC1 (7) – (8)(16): 20 – 30 V traveling and machine cannot
move off again
• Controller output voltage • Shuts off output of sensor 12V • Does not judge rear overturn E03
ATC2 (14) – ATC3A (16): power supply alarm
11 – 13 V
• Wiring harness resistance value • Turns transmission cut relay • Machine does not move off even E03
ATC5A (female) (1) – ground: OFF. when operation is carried out to
Max. 1 Ω • Holds transmission in Neutral. move machine off
• Does not record in trouble da-
ta.
• Wiring harness resistance value • Turns transmission cut relay • Machine does not move off even E03
ATC5B (female) (14)(15)(16) – OFF. when operation is carried out to
ground: Max. 1 Ω • Holds transmission in Neutral. move machine off
ta.
• Rotary switch setting position • Turns transmission cut relay • Machine does not move off even E03
See TESTING AND ADJUST- OFF. when operation is carried out to
ING. • Holds transmission in Neutral. move machine off
ta.
• Sets transmission to Neutral. • Machine does not move off even E03
when operation is carried out to
move machine off
HM300-1 20-423
1 c
(9) c
TROUBLESHOOTING
DDTFKA Fill switch for inter-axle differ- When the output is made to the • Defective differential clutch fill switch
(TM-50) ential lock clutch: Disconnec- differential lock clutch solenoid, • Disconnection or hot short in switch cir-
tion (KA) the clutch engages, but the sig- cuit wiring harness
nal from the fill switch does not • Defective transmission controller
come ON
DDTGKA Fill switch for lock-up clutch: When the output is made to the • Defective lock-up clutch fill switch
(TM-51) Disconnection (KA) lock-up clutch solenoid, the • Disconnection or hot short in switch cir-
clutch engages, but the signal cuit wiring harness
from the fill switch does not • Defective transmission controller
come ON
DDTHKA Fill switch for Hi clutch: When the output is made to the • Defective Hi clutch fill switch
(TM-52) Disconnection (KA) Hi clutch solenoid, the clutch en- • Disconnection or hot short in switch cir-
gages, but the signal from the fill cuit wiring harness
switch does not come ON • Defective transmission controller
DDTJKA Fill switch for Lo clutch: When the output is made to the • Defective Lo clutch fill switch
(TM-53) Disconnection (KA) Lo clutch solenoid, the clutch • Disconnection or hot short in switch cir-
engages, but the signal from the cuit wiring harness
fill switch does not come ON • Defective transmission controller
DDTKKA Fill switch for 1st clutch: When the output is made to the • Defective 1st clutch fill switch
(TM-54) Disconnection (KA) 1st clutch solenoid, the clutch • Disconnection or hot short in switch cir-
DDTLKA Fill switch for 2nd clutch: When the output is made to the • Defective 2nd clutch fill switch
(TM-55) Disconnection (KA) 2nd clutch solenoid, the clutch • Disconnection or hot short in switch cir-
DDTMKA Fill switch for 3rd clutch: When the output is made to the • Defective 3rd clutch fill switch
(TM-56) Disconnection (KA) 3rd clutch solenoid, the clutch • Disconnection or hot short in switch cir-
DDTNKA Fill switch for R clutch: When the output is made to the • Defective R clutch fill switch
(TM-57) Disconnection (KA) R clutch solenoid, the clutch en- • Disconnection or hot short in switch cir-
gages, but the signal from the fill cuit wiring harness
switch does not come ON • Defective transmission controller
20-424 HM300-1
c 1 c
(9)
TROUBLESHOOTING
• Fill switch resistance value • Takes no action • Inter-axle differential lock is actu- E01
ATC5A (male) (17) – ground: ated, but pilot lamp does not light
• When clutch is released: up
Min. 1 MΩ
Max. 1 Ω
• Fill switch resistance value • Holds speed range during trav- • Cannot shift gear E03
ATC5A (male) (11) – ground: el • If gearshift lever is returned to N,
• When clutch is released: • When gearshift lever is re- machine cannot move off again
Min. 1 MΩ turned to N, holds in Neutral until it is stopped
• When clutch is engaged: • Lock-up pilot lamp does not light
Max. 1 Ω up
Max. 1 Ω
Max. 1 Ω
Max. 1 Ω
Max. 1 Ω
Max. 1 Ω
Max. 1 Ω
HM300-1 20-425
1 c
(9) c
TROUBLESHOOTING
DF10KA Gearshift lever: Disconnec- Nothing is input for the gearshift • Defective gearshift lever
(TM-58) tion (KA) lever signal • Disconnection or short circuit with chas-
sis ground in lever power source circuit
wiring harness
• Disconnection in lever GND circuit wiring
harness
sis ground in lever signal circuit wiring
harness
DF10KB Gearshift lever: Short circuit The gearshift lever signal was • Defective shift lever
(TM-59) (KB) input at the same time from 2 or • Hot short in lever signal circuit wiring har-
more systems ness
DGF1KX Transmission valve oil tem- The voltage of the signal circuit • Defective transmission valve oil temper-
(TM-60) perature sensor: Input signal for the transmission valve oil ature sensor
outside range (KX) temperature sensor became • Disconnection, short circuit with chassis
less than 0.97 V, or there was a ground, or hot short in sensor signal cir-
big difference from the torque cuit wiring harness
converter oil temperature • Disconnection in sensor GND circuit wir-
ing harness
DGR3L8 Brake oil temperature sensor When the front brake oil temper- • Defective center brake oil temperature
(TM-61) (center): * See Contents (L8) ature sensor signal and rear sensor
brake oil temperature sensor • Disconnection or hot short in sensor sig-
signal were more than 60°C, the nal circuit wiring harness
center brake oil temperature • Disconnection in sensor GND circuit wir-
sensor was less than 10°C ing harness
DGR4L8 Brake oil temperature sensor When the center brake oil tem- • Defective front brake oil temperature
(TM-62) (front): * See Contents (L8) perature sensor signal and rear sensor
brake oil temperature sensor • Disconnection or hot short in sensor sig-
signal were more than 60°C, the nal circuit wiring harness
front brake oil temperature sen- • Disconnection in sensor GND circuit wir-
sor was less than 10°C ing harness
DGT1KX Torque converter oil tempera- The voltage of the signal circuit • Defective torque converter oil tempera-
(TM-63) ture sensor: Input signal out- for the torque converter oil tem- ture sensor
side range (KX) perature sensor became less • Disconnection, short circuit with chassis
than 0.97 V, or there was a big ground, or hot short in sensor signal cir-
difference from the transmission cuit wiring harness
valve oil temperature sensor sig- • Disconnection in sensor GND circuit
nal • Defective transmission controller
20-426 HM300-1
! (9)
1 !
TROUBLESHOOTING
• Gearshift lever power source • Condition before abnormality • Shifts to higher speed range than E03
voltage occurred is maintained speed range set by gearshift lever
SF1 (1) – (2): 20 – 24 V • Stays in Neutral and machine can-
• Gearshift lever signal voltage not move off
SF1 (3)(4)(5)(6)(7)(8)(9)(10) • Impossible to change direction of
(11) – (2): travel between FORWARD and
Selected circuit: 20 – 24 V REVERSE
Not selected circuit: Max. 1 V • All gearshift lever position lamps
go out
• Gearshift lever power source • Controls using signal in order • Shifts to higher speed range than E03
voltage of high priority speed range set by gearshift lever
SF1 (1) – (2): 20 – 24V (1): N > D > 5 > 4 > 3 > 2 > 1 • Stays in Neutral and machine can-
Gearshift lever signal voltage (2): N > R2 > R1 not move off
SF1 (3)(4)(5)(6)(7)(8)(9)(10) • If the signal for both system (1) • Gearshift lever position lamps are
(11) – (2): and system (2) are input at the different from position of lever
Selected circuit: 20 – 24 V same time, shifts transmission
Not selected circuit: Max. 1 V to Neutral
• Sensor resistance value • Controls clutch oil pressure • Transmission shock becomes ex- E03
LUB-T (male) (1) – (2): with clutch oil temperature be- cessive
• When oil temperature is 25°C: fore abnormality occurred
37 – 50 kΩ
3.5 – 4.0 kΩ
• Sensor resistance value • Takes no action • Retarder oil temperature gauge E01
T14 (male) (1) – (2): does not give correct display
• When oil temperature is 25°C: • If it is used as it is, the braking ef-
37 – 50 kΩ fect may become weaker
3.5 – 4.0 kΩ
• Sensor resistance value • Takes no action • Retarder oil temperature gauge E01
T15 (male) (1) – (2): does not give correct display
• When oil temperature is 25°C: • If it is used as it is, the braking ef-
37 – 50 kΩ fect may become weaker
3.5 – 4.0 kΩ
• Sensor resistance value • Takes no action • Torque converter oil temperature E01
TC-SE (male) (1) – (2): gauge does not give correct dis-
• When oil temperature is 25°C: play
37 – 50 kΩ
3.5 – 4.0 kΩ
HM300-1 20-427
1 c
(9) c
TROUBLESHOOTING
DHT5KX Torque converter oil pressure The voltage in the signal circuit • Defective torque converter oil pressure
(TM-64) sensor: Input signal outside of the torque converter oil pres- sensor
range (KX) sure sensor became less than • Disconnection or short circuit with chas-
0.5 V or more than 4.5 V sis ground in sensor power source circuit
wiring harness
ing harness
cuit wiring harness
DHT5L6 Torque converter oil pressure When the engine is stopped, the • Defective torque converter oil pressure
(TM-65) sensor: * See Contents (L6) torque converter oil pressure circuit (when actuating system normally)
sensor signal circuit inputs the • Defective torque converter oil pressure
oil pressure sensor
• Hot short in sensor signal circuit wiring
harness
DJF1KA Fuel level sensor: The voltage of the signal circuit • Defective fuel level sensor
(TM-66) Disconnection (KA) of the fuel level sensor became • Disconnection or hot short in sensor sig-
more than 4.0 V nal circuit wiring harness
ing harness
DK11KX Throttle angle sensor: The voltage in the signal circuit • Defective accelerator sensor or defective
(TM-67) Input signal outside range of the acceleration sensor be- accelerator pedal
(KX) came less than 0.6 V or more • Disconnection, short circuit with chassis
than 4.7 V ground, or hot short in sensor power
source circuit wiring harness
ing harness
cuit wiring harness
DLE2KA Engine speed sensor: There is a disconnection in the • Defective engine speed sensor or defec-
(TM-68) Disconnection (KA) signal circuit of the engine tive adjustment
speed sensor and the signal is • Disconnection in sensor signal circuit
not input wiring harness
ing harness
DLE2LC Engine speed sensor: When the signal of the engine • Defective engine speed sensor
(TM-69) * See Contents (LC) speed sensor is less than 350 • Short circuit with chassis ground or hot
rpm, the signal of the transmis- short in sensor signal circuit wiring har-
sion input shaft speed sensor in- ness
puts more than 500 rpm • Defective transmission controller
20-428 HM300-1
! (9)
1 !
TROUBLESHOOTING
• Sensor power source voltage • Fixes torque converter oil pres- • Excessive shock when lock-up is E01
TC-INT (2) – (1): 20 – 30 V sure to oil pressure set inside actuated
• Sensor signal voltage controller and carries out con-
TC-INT (3) – (1): 0.8 – 2.0 V trol
• Sensor power source voltage • Fixes torque converter oil pres- • Excessive shock when lock-up is E01
TC-INT (2) – (1): 20 – 30 V sure to oil pressure set inside actuated
• Sensor signal voltage controller and carries out con-
TC-INT (3) – (1): 0.8 – 2.0 V trol
• Sensor resistance value • Takes no action • Fuel gauge does not give correct E01
T08 (male) (1) – (2): display
• When full: Max. 12 Ω
• When empty: 74 – 100 Ω
• Sensor power source voltage • Carries out automatic shifting • Transmission shock becomes ex- E03
AS2 (1) – (3): 4.6 – 5.4 V in normal mode (but controls cessive
• Sensor signal voltage with clutch oil pressure taken • Immediately shifts up when travel-
AS3 (2) – (3): as engine at full throttle) ing downhill
• Lo position: 1.0 – 1.4 V
• Hi position: 3.6 – 4.0 V
• Sensor resistance value • Holds speed range during trav- • Cannot shift gear E03
EREV (male) (1) – (2): el • If gearshift lever is returned to N,
500 – 1000 Ω • When gearshift lever is re- machine cannot move off again
• Tachometer does not work (dis-
plays 0 rpm)
EREV (male) (1) – (2): el • If gearshift lever is returned to N,
500 – 1000 Ω • When gearshift lever is re- machine cannot move off again
• Tachometer does not go above
350 rpm
HM300-1 20-429
1 c
(9) c
TROUBLESHOOTING
DLF1KA Transmission input shaft There is a disconnection in the • Defective transmission input shaft speed
(TM-70) speed sensor: signal circuit of the transmission sensor or defective adjustment
Disconnection (KA) input shaft speed sensor and the • Disconnection in sensor signal circuit
signal is not input wiring harness
ing harness
DLF1LC Transmission input shaft There is an abnormality in the • Defective transmission input shaft speed
(TM-71) speed sensor: speed calculated from the en- sensor
* See Contents (LC) gine speed sensor signal, trans- • Short circuit with chassis ground or hot
mission intermediate shaft short in sensor signal circuit wiring har-
speed sensor signal, and output ness
shaft R speed sensor signal, • Defective transmission controller
and the speed of the transmis-
sion input shaft sensor signal
DLF2KA Transmission intermediate There is a disconnection in the • Defective transmission intermediate

(TM-72) shaft speed sensor: signal circuit of the transmission shaft speed sensor or defective adjust-
Disconnection (KA) intermediate shaft speed sensor ment
and the signal is not input • Disconnection in sensor signal circuit
wiring harness
ing harness
DLF2LC Transmission intermediate There is an abnormality in the • Defective transmission intermediate

(TM-73) shaft speed sensor: speed calculated from the en- shaft speed sensor
mission input shaft speed short in sensor signal circuit wiring har-
sensor signal, and output shaft ness
R speed sensor signal, and the • Defective transmission controller
speed of the transmission inter-
mediate shaft sensor signal
DLT3KA Transmission output shaft R There is a disconnection in the • Defective transmission output shaft R
(TM-74) speed sensor: signal circuit of the transmission speed sensor or defective adjustment
Disconnection (KA) output shaft R speed sensor and • Disconnection in sensor signal circuit
the signal is not input wiring harness
ing harness
DLT3LC Transmission output shaft R There is an abnormality in the • Defective transmission output shaft R
(TM-75) speed sensor: speed calculated from the en- speed sensor or defective adjustment
mission input shaft speed short in sensor signal circuit wiring har-
sensor signal, and intermediate ness
shaft speed sensor signal, and • Defective transmission controller
the speed of the transmission • Eefective retarder controller(q1)
output shaft R sensor signal
DXH0KA Solenoid for inter-axle differ- No electric current flows when • Defective differential lock clutch solenoid
(TM-76) ential lock: there is output to the differential • Disconnection in solenoid (+) circuit wir-
Disconnection (KA) lock clutch solenoid ing harness
ing harness
20-430 HM300-1
c 4 c
1
(9)
TROUBLESHOOTING
• Sensor resistance value • Holds speed range during trav- • Lock-up is canceled and trans- E03
N1 (male) (1) – (2): 500 – 1000 Ω el and turns actuation of lock- mission cannot be shifted
up OFF • If gearshift lever is returned to N,
• Sensor resistance value • Holds speed range during trav- • Lock-up is canceled and trans- E03
N1 (male) (1) – (2): 500 – 1000 Ω el and turns actuation of lock- mission cannot be shifted
up OFF • If gearshift lever is returned to N,
N2 (male) (1) – (2): 500 – 1000 Ω el • If gearshift lever is returned to N,
• Sensor resistance value • Holds speed range during trav- • Speedometer displays 0 km/h E03
N3 (male) (1) – (2): 500 – 1000 Ω el • Cannot shift gear
• When gearshift lever is re- • If gearshift lever is returned to N,
turned to N, holds in Neutral machine cannot move off again
until it is stopped
• Speedometer displays abnormal
speed
• Solenoid resistance value • Continues output as it is • Inter-axle differential lock does E01
D/L-PS (male) (1) – (2): 5 – 15 Ω not work
HM300-1 20-431
1 c
(9) c
TROUBLESHOOTING
DXH0KB Solenoid for inter-axle differ- An extremely large electric cur- • Defective differential lock clutch solenoid
(TM-77) ential lock: Short circuit (KB) rent flows when there is output • Short circuit, short circuit with chassis
to the differential lock clutch so- ground, or hot short in solenoid (+) circuit
lenoid or electric current flows wiring harness
when it is OFF • Hot short in solenoid (–) circuit wiring
harness
DXH1KA Solenoid for lock-up clutch: No electric current flows when • Defective lock-up clutch solenoid
(TM-78) Disconnection (KA) there is output to the lock-up • Disconnection in solenoid (+) circuit
clutch solenoid • Disconnection in solenoid (–) circuit
DXH1KB Solenoid for lock-up clutch: An extremely large electric cur- • Defective lock-up clutch solenoid
(TM-79) Short circuit (KB) rent flows when there is output • Short circuit, short circuit with chassis
to the lock-up clutch solenoid or ground, or hot short in solenoid (+) circuit
electric current flows when it is wiring harness
OFF • Hot short in solenoid (–) circuit wiring
harness
DXH2KA Solenoid for Hi clutch: No electric current flows when • Defective Hi clutch solenoid
(TM-80) Disconnection (KA) there is output to the Hi clutch • Disconnection in solenoid (+) circuit
solenoid • Disconnection in solenoid (–) circuit
DXH2KB Solenoid for Hi clutch: An extremely large electric cur- • Defective Hi clutch solenoid
to the Hi clutch solenoid or elec- ground, or hot short in solenoid (+) circuit
tric current flows when it is OFF wiring harness
• Hot short in solenoid (–) circuit wiring
harness
DXH3KA Solenoid for Lo clutch: No electric current flows when • Defective Lo clutch solenoid
(TM-82) Disconnection (KA) there is output to the Lo clutch • Disconnection in solenoid (+) circuit
DXH3KB Solenoid for Lo clutch: An extremely large electric cur- • Defective Lo clutch solenoid
to the Lo clutch solenoid or elec- ground, or hot short in solenoid (+) circuit
harness
DXH4KA Solenoid for 1st clutch: No electric current flows when • Defective 1st clutch solenoid
(TM-84) Disconnection (KA) there is output to the 1st clutch • Disconnection in solenoid (+) circuit
20-432 HM300-1
c 1 c
(9)
TROUBLESHOOTING
D/L-PS (male) (1) – (2): 5 – 15 Ω lock command OFF not work or is not canceled
• Solenoid resistance value • Turns lock-up actuation OFF • Lock-up is not actuated E03
L/C-PS (male) (1) – (2): 5 – 15 Ω
• Solenoid resistance value • Holds speed range during trav- • Lock-up is always canceled or al- E03
L/C-PS (male) (1) – (2): 5 – 15 Ω el and turns actuation of lock- ways actuated and transmission
up OFF cannot be shifted
• When gearshift lever is re- • If gearshift lever is operated to N,
turned to N, holds in Neutral machine cannot move off again
until it is stopped (depending on
condition of failure, machine may
not be able to move off again)
• Solenoid resistance value • Shifts to Neutral during travel E03

H-PS (male) (1) – (2): 5 – 15 Ω • If travel is not stopped, machine
cannot move off again
• Solenoid resistance value • Sets transmission to Neutral. • Shifts to Neutral during travel E03
H-PS (male) (1) – (2): 5 – 15 Ω • If travel is not stopped, machine
cannot move off again (depending
on condition of failure, machine
may not be able to move off
again)
L-PS (male) (1) – (2): 5 – 15 Ω • If travel is not stopped, machine
L-PS (male) (1) – (2): 5 – 15 Ω • If travel is not stopped, machine
again)
1-PS (male) (1) – (2): 5 – 15 Ω • If travel is not stopped, machine
HM300-1 20-433
1 c
(9) c
TROUBLESHOOTING
DXH4KB Solenoid for 1st clutch: An extremely large electric cur- • Defective 1st clutch solenoid
to the 1st clutch solenoid or ground, or hot short in solenoid (+) circuit
harness
DXH5KA Solenoid for 2nd clutch: No electric current flows when • Defective 2nd clutch solenoid
(TM-86) Disconnection (KA) there is output to the 2nd clutch • Disconnection in solenoid (+) circuit
DXH5KB Solenoid for 2nd clutch: An extremely large electric cur- • Defective 2nd clutch solenoid
to the 2nd clutch solenoid or ground, or hot short in solenoid (+) circuit
harness
DXH6KA Solenoid for 3rd clutch: Dis- No electric current flows when • Defective 3rd clutch solenoid
(TM-88) connection (KA) there is output to the 3rd clutch • Disconnection in solenoid (+) circuit
DXH6KB Solenoid for 3rd clutch: Short An extremely large electric cur- • Defective 3rd clutch solenoid
(TM-89) circuit (KB) rent flows when there is output • Short circuit, short circuit with chassis
to the 3rd clutch solenoid or ground, or hot short in solenoid (+) circuit
harness
DXH7KA Solenoid for R clutch: Discon- No electric current flows when • Defective R clutch solenoid
(TM-90) nection (KA) there is output to the R clutch so- • Disconnection in solenoid (+) circuit
lenoid • Disconnection in solenoid (–) circuit
DXH7KB Solenoid for R clutch: Short An extremely large electric cur- • Defective R clutch solenoid
(TM-91) circuit (KB) rent flows when there is output • Short circuit, short circuit with chassis
to the R clutch solenoid or elec- ground, or hot short in solenoid (+) circuit
harness
20-434 HM300-1
c 1 c
(9)
TROUBLESHOOTING
again)
again)
again)
R-PS (male) (1) – (2): 5 – 15 Ω • If travel is not stopped, machine
R-PS (male) (1) – (2): 5 – 15 Ω • If travel is not stopped, machine
again)
HM300-1 20-435
1 c
(9) c
TROUBLESHOOTING TM-1
TM-1 FAILURE CODE [1380MW] (LOCK-UP CLUTCH: SLIPPING (MW))
★ Nature of failure:When there is output to the lock-up clutch solenoid, there is an abnormality in the value cal-
culated from the signals from the engine speed sensor, transmission input shaft speed sen-
sor, transmission intermediate shaft speed sensor, and transmission output shaft R speed
sensor.
Cause Remedy
1
• Turn starting switch OFF. Is resistance between L/C-PS NO Defective lock-up clutch
(male) (1) and (2) 5 – 15 Ω? Replace
• Disconnect L/C-PS. solenoid
YES
2 Excessive resistance in wiring

NO harness between ATC2 (female) Repair or
• Turn starting switch OFF. Is resistance between ATC2 (10) and L/C-PS (female) (1) or replace
• Disconnect ATC2. (female) (10) and (20) 5 – 15Ω? ATC2 (female) (20) and L/C-PS
(female) (2)
YES
Carry out
3 troubleshoot-
Does condition become normal NO Defective hydraulic, mechanical ing for
• Turn starting switch ON. when transmission controller is system of lock-up clutch or mechanical
replaced? pressure control valve system
YES
Defective transmission Replace
controller
TM-1 Related electrical circuit diagram
20-436 HM300-1
c 1 c
TM-2 FAILURE CODE [1500LO] (TRANSMISSION CLUTCH:

* SEE THE TABLE IN CONTENTS. (LO))
★ Nature of failure:Fill switch signals have been input from 2 clutches that do not form a normal combination.
Cause Remedy
1
Is other failure code [15S*L1] also NO
time? Go to
troubleshooting
YES of displayed
Other problem occurring at
same time code
Carry out
2 troubleshoot-
Does condition become normal Defective hydraulic, mechanical ing for
NO system of clutch pressure mechanical
when transmission controller is
replaced? control valve system
YES
controller
HM300-1 20-437
1 c c
TM-3 FAILURE CODE [15B0NX] (TRANSMISSION OIL FILTER: CLOGGED (NX))
★ Nature of failure:When the torque converter oil temperature is more than 50°C, the signal circuit of the trans-
mission filter clogging switch is open (shut off from the ground).
★ After remedy and comfirming that the machine is normal, carry out intial input to transmission controller in
accordance with the SPECIAL FUNCTION OF MACHINE MONITOR in TESTING AND ADJUSTING.
Cause Remedy
1
• Stop engine. Is transmission oil filter clogged?
NO
YES Clean or
Clogged transmission oil filter
replace
2
• Turn starting switch OFF. Is resistance between T03 (male) NO Defective transmission oil filter Replace
• Disconnect T03. (1) and (2) less than 1 Ω? clogging sensor
YES
3
Is resistance between T03 NO Defective contact or disconnection Repair or
in wiring harness between T03
(female) (2) and ground less than replace
• Disconnect T03. 1 Ω? (female) (2) and ground
YES
4
Is resistance between ATC5A NO Defective contact or disconnection Repair or
(female) (6) and ground less than in wiring harness between ATC5A replace
• Disconnect ATC5A. 1 Ω? (female) (6) and T03 (female) (1)
YES
controller
20-438 HM300-1
c 1 c
(9)
TM-4 FAILURE CODE [15G0MW] (R CLUTCH: SLIPPING (MW))
★ Nature of failure:When there is output to the R clutch solenoid, there is an abnormality in the value calculat-
ed from the signals from the transmission input shaft speed sensor, transmission interme-
diate shaft speed sensor, and transmission output shaft R speed sensor.
Cause Remedy
1
• Turn starting switch OFF. Is resistance between R-PS NO
Defective R clutch solenoid Replace
• Disconnect R-PS. (male) (1) and (2) 5 – 15 Ω?
YES

• Turn starting switch OFF. Is resistance between ATC2 (5) and R-PS (female) (1) or ATC2 replace
• Disconnect ATC2. (female) (5) and (15) 5 – 15Ω? (female) (15) and R-PS (female)
(2)
YES
Carry out
3 troubleshoot-
• Turn starting switch ON. when transmission controller is system of R clutch or pressure mechanical
YES
controller
HM300-1 20-439
1 c
(9) c
TM-5 FAILURE CODE [15H0MW] (HI CLUTCH: SLIPPING (MW))
★ Nature of failure:When there is output to the Hi clutch solenoid, there is an abnormality in the value calcu-
lated from the signals from the transmission input shaft speed sensor, transmission inter-
mediate shaft speed sensor, and transmission output shaft R speed sensor.
Cause Remedy
1
• Turn starting switch OFF. Is resistance between H-PS NO
Defective Hi clutch solenoid Replace
• Disconnect H-PS. (male) (1) and (2) 5 – 15 Ω?
YES

• Turn starting switch OFF. Is resistance between ATC2 (4) and H-PS (female) (1) or ATC2 replace
• Disconnect ATC2. (female) (4) and (15) 5 – 15Ω? (female) (15) and H-PS (female)
(2)
YES
Carry out
3 troubleshoot-
• Turn starting switch ON. when transmission controller is system of Hi clutch or pressure mechanical
YES
controller
20-440 HM300-1
c 1 c
(9)
TM-6 FAILURE CODE [15J0MW] (LO CLUTCH: SLIPPING (MW))
★ Nature of failure:When there is output to the Lo clutch solenoid, there is an abnormality in the value calcu-
Cause Remedy
1
• Turn starting switch OFF. Is resistance between L-PS NO
Defective Lo clutch solenoid Replace
• Disconnect L-PS. (male) (1) and (2) 5 – 15 Ω?
YES

• Turn starting switch OFF. Is resistance between ATC2 (7) and L-PS (female) (1) or ATC2 replace
• Disconnect ATC2. (female) (7) and (17) 5 – 15Ω? (female) (17) and L-PS (female)
(2)
YES
Carry out
3 troubleshoot-
• Turn starting switch ON. when transmission controller is system of Lo clutch or pressure mechanical
YES
controller
HM300-1 20-441
1 c
(9) c
TM-7 Failure code [15K0MW] (1st clutch: Slipping (MW))
★ Nature of failure:When there is output to the 1st clutch solenoid, there is an abnormality in the value calcu-
Cause Remedy
1
• Turn starting switch OFF. Is resistance between 1-PS NO
Defective 1st clutch solenoid Replace
• Disconnect 1-PS. (male) (1) and (2) 5 – 15 Ω?
YES

• Turn starting switch OFF. Is resistance between ATC2 (2) and 1-PS (female) (1) or ATC2 replace
• Disconnect ATC2. (female) (2) and (13) 5 – 15Ω? (female) (13) and 1-PS (female)
(2)
YES
Carry out
3 troubleshoot-
• Turn starting switch ON. when transmission controller is system of 1st clutch or pressure mechanical
YES
controller
20-442 HM300-1
c 1 c
(9)
TM-8 FAILURE CODE [15L0MW] (2ND CLUTCH: SLIPPING (MW))
★ Nature of failure:When there is output to the 2nd clutch solenoid, there is an abnormality in the value calcu-
Cause Remedy
1
Defective 2nd clutch solenoid Replace
YES

(2)
YES
Carry out
3 troubleshoot-
• Turn starting switch ON. when transmission controller is system of 2nd clutch or mechanical
YES
controller
HM300-1 20-443
1 c
(9) c
TM-9 FAILURE CODE [15M0MW] (3RD CLUTCH: SLIPPING (MW))
★ Nature of failure:When there is output to the 3rd clutch solenoid, there is an abnormality in the value calcu-
Cause Remedy
1
Defective 3rd clutch solenoid Replace
YES

(2)
YES
Carry out
3 troubleshoot-
• Turn starting switch ON. when transmission controller is system of 3rd clutch or pressure mechanical
YES
controller
20-444 HM300-1
c 1 c
(9)
TM-10 FAILURE CODE [15SBL1] (ECMV FOR R CLUTCH:

* SEE THE TABLE IN CONTENTS. (L1))
★ Nature of failure:Even when the output to the R clutch solenoid is turned OFF, the signal from the fill switch
stays ON and the clutch is not disengaged.
Cause Remedy
1
Is resistance between R-SW NO
• Turn starting switch OFF. (male) (1) and ground more than 1 Defective R clutch fill switch Replace
• Disconnect R-SW. MΩ?
YES
2
• Turn starting switch OFF. Is resistance between ATC5A NO in wiring harness between ATC5A Repair or
• Disconnect ATC5A. (female) (16) and ground more (female) (16) and R-SW (female) replace
than 1 MΩ? (1)
YES
Carry out
3 troubleshoot-
• Turn starting switch ON. when transmission controller is system of R clutch pressure mechanical
YES
controller
HM300-1 20-445
1 ! !
TM-11 FAILURE CODE [15SBMA] (ECMV FOR R CLUTCH: FUNCTION IMPOSSIBLE (MA))
★ Nature of failure:Even when there is output to the R clutch solenoid, the signal from the fill switch stays OFF
and the clutch is not engaged.
Cause Remedy
1
Is resistance between R-PS (male) NO
• Turn starting switch OFF. (1) and (2) 5 – 15 Ω? Defective R clutch solenoid Replace
• Disconnect R-PS.
YES

• Turn starting switch OFF. Is resistance between ATC2 NO harness between ATC2 (female) Repair or
• Disconnect ATC2. (female) (5) and (15) 5 – 15Ω? (5) and R-PS (female) (1) or ATC2 replace
(female) (15) and R-PS (female)
(2)
YES
Carry out
3 troubleshoot-
• Turn starting switch ON. when transmission controller is system of R clutch or pressure mechanical
YES
controller
20-446 HM300-1
! 1 !
TM-12 FAILURE CODE [15SCL1] (ECMV FOR HI CLUTCH:

★ Nature of failure:Even when the output to the Hi clutch solenoid is turned OFF, the signal from the fill switch
Cause Remedy
1
Is resistance between H-SW NO
• Turn starting switch OFF. (male) (1) and ground more than 1 Defective Hi clutch fill switch Replace
• Disconnect H-SW. MΩ?
YES
2
• Disconnect ATC5A. (female) (12) and ground more (female) (12) and H-SW (female) replace
than 1 MΩ? (1)
YES
Carry out
3 troubleshoot-
• Turn starting switch ON. when transmission controller is system of Hi clutch pressure mechanical
YES
controller
HM300-1 20-447
1 ! !
TM-13 FAILURE CODE [15SCMA] (ECMV FOR HI CLUTCH: FUNCTION IMPOSSIBLE (MA))
★ Nature of failure:Even when there is output to the Hi clutch solenoid, the signal from the fill switch stays OFF
Cause Remedy
1
• Turn starting switch OFF. Is resistance between H-PS (male) NO Defective Hi clutch solenoid Replace
• Disconnect H-PS. (1) and (2) 5 – 15Ω?
YES

harness between ATC2 (female) Repair or
• Turn starting switch OFF. Is resistance between ATC2 NO (4) and H-PS (female) (1) or ATC2 replace
• Disconnect ATC2. (female) (4) and (15) 5 – 15Ω? (female) (15) and H-PS (female)
(2)
YES
Carry out
3 troubleshoot-
• Turn starting switch ON. when transmission controller is system of Hi clutch or pressure mechanical
YES
controller
20-448 HM300-1
! 1 !
TM-14 FAILURE CODE [15SDL1] (ECMV FOR LO CLUTCH:

★ Nature of failure:Even when the output to the Lo clutch solenoid is turned OFF, the signal from the fill switch
Cause Remedy
1
Is resistance between L-SW NO
• Turn starting switch OFF. (male) (1) and ground more than 1 Defective Lo clutch fill switch Replace
• Disconnect L-SW. MΩ?
YES
2
• Disconnect ATC5A. (female) (10) and ground more (female) (10) and L-SW (female) replace
than 1 MΩ? (1)
YES
Carry out
3 troubleshoot-
• Turn starting switch ON. when transmission controller is system of Lo clutch pressure mechanical
YES
controller
HM300-1 20-449
1 ! !
TM-15 FAILURE CODE [15SDMA] (ECMV FOR LO CLUTCH: FUNCTION IMPOSSIBLE (MA))
★ Nature of failure:Even when there is output to the Lo clutch solenoid, the signal from the fill switch stays OFF
Cause Remedy
1
• Turn starting switch OFF. Is resistance between L-PS (male) NO
Defective Lo clutch solenoid Replace
• Disconnect L-PS. (1) and (2) 5 – 15Ω?
YES

• Turn starting switch OFF. Is resistance between ATC2 NO (7) and L-PS (female) (1) or ATC2 replace
• Disconnect ATC2. (female) (7) and (17) 5 – 15Ω? (female) (17) and L-PS (female)
(2)
YES
Carry out
3 troubleshoot-
• Turn starting switch ON. when transmission controller is system of Lo clutch or pressure mechanical
YES
controller
20-450 HM300-1
! 1 !
TM-16 FAILURE CODE [15SEL1] (ECMV FOR 1ST CLUTCH:

★ Nature of failure:Even when the output to the 1st clutch solenoid is turned OFF, the signal from the fill switch
Cause Remedy
1
Is resistance between 1-SW NO
• Turn starting switch OFF. (male) (1) and ground more than 1 Defective 1st clutch fill switch Replace
• Disconnect 1-SW. MΩ?
YES
2 Short circuit with chassis ground

in wiring harness between ATC5A Repair or
• Turn starting switch OFF. Is resistance between ATC5A NO replace
(female) (13) and ground more (female) (13) and 1-SW (female)
• Disconnect ATC5A. (1)
than 1 MΩ?
YES
Carry out
3 troubleshoot-
• Turn starting switch ON. when transmission controller is system of 1st clutch pressure mechanical
YES
controller
HM300-1 20-451
1 ! !
TM-17 FAILURE CODE [15SEMA] (ECMV FOR 1ST CLUTCH: FUNCTION IMPOSSIBLE (MA))
★ Nature of failure:Even when there is output to the 1st clutch solenoid, the signal from the fill switch stays OFF
Cause Remedy
1
• Turn starting switch OFF. Is resistance between 1-PS (male) NO
Defective 1st clutch solenoid Replace
• Disconnect 1-PS. (1) and (2) 5 – 15Ω?
YES

• Turn starting switch OFF. Is resistance between ATC2 NO (2) and 1-PS (female) (1) or ATC2
• Disconnect ATC2. replace
(female) (2) and (13) 5 – 15Ω? (female) (13) and 1-PS (female)
(2)
YES
Carry out
3 troubleshoot-
• Turn starting switch ON. when transmission controller is system of 1st clutch or pressure mechanical
YES
controller
20-452 HM300-1
! 1 !
TM-18 FAILURE CODE [15SFL1] (ECMV FOR 2ND CLUTCH:

★ Nature of failure:Even when the output to the 2nd clutch solenoid is turned OFF, the signal from the fill switch
Cause Remedy
1
• Turn starting switch OFF. (male) (1) and ground more than 1 Defective 2nd clutch fill switch Replace
YES

than 1 MΩ?
YES
Carry out
3 troubleshoot-
• Turn starting switch ON. when transmission controller is system of 2nd clutch pressure mechanical
YES
controller
HM300-1 20-453
1 ! !
TM-19 FAILURE CODE [15SFMA] (ECMV FOR 2ND CLUTCH: FUNCTION IMPOSSIBLE (MA))
★ Nature of failure:Even when there is output to the 2nd clutch solenoid, the signal from the fill switch stays
OFF and the clutch is not engaged.
Cause Remedy
1
Defective 2nd clutch solenoid Replace
YES

(2)
YES
Carry out
3 troubleshoot-
NO system of 2nd clutch or pressure mechanical
YES
controller
20-454 HM300-1
! 1 !
TM-20 FAILURE CODE [15SGL1] (ECMV FOR 3RD CLUTCH:

★ Nature of failure:Even when the output to the 3rd clutch solenoid is turned OFF, the signal from the fill switch
Cause Remedy
1
• Turn starting switch OFF. (male) (1) and ground more than 1 Defective 3rd clutch fill switch Replace
YES

than 1 MΩ?
YES
Carry out
3 troubleshoot-
• Turn starting switch ON. when transmission controller is system of 3rd clutch pressure mechanical
YES
controller
HM300-1 20-455
1 ! !
TM-21 FAILURE CODE [15SGMA] (ECMV FOR 3RD CLUTCH: FUNCTION IMPOSSIBLE (MA))
★ Nature of failure:Even when there is output to the 3rd clutch solenoid, the signal from the fill switch stays
Cause Remedy
1
Defective 3rd clutch solenoid Replace
YES

(2)
YES
Carry out
3 troubleshoot-
NO system of 3rd clutch or pressure mechanical
YES
controller
20-456 HM300-1
! 1 !
TM-22 FAILURE CODE [15SJL1] (ECMV FOR LOCK-UP CLUTCH:

★ Nature of failure:Even when the output to the lock-up clutch solenoid is turned OFF, the signal from the fill
switch stays ON and the clutch is not disengaged.
Cause Remedy
1
Is resistance between L/C-SW NO
• Turn starting switch OFF. (male) (1) and ground more than Defective lock-up clutch fill Replace
• Disconnect L/C-SW. 1 MΩ? switch
YES
2 Short circuit with chassis ground in

• Turn starting switch OFF. Is resistance between ATC5A NO wiring harness between ATC5A Repair or
• Disconnect ATC5A. (female) (15) and ground more (female) (11) and L/C-SW (female) replace
than 1 MΩ? (1)
YES
Carry out
3 troubleshoot-
NO system of lock-up clutch pressure mechanical
YES
controller
HM300-1 20-457
1 ! !
TM-23 FAILURE CODE [15SJMA] (ECMV FOR LOCK-UP CLUTCH:

FUNCTION IMPOSSIBLE (MA))
★ Nature of failure:Even when there is output to the lock-up clutch solenoid, the signal from the fill switch stays
Cause Remedy
1
• Turn starting switch OFF. Is resistance between L/C-PS NO
Defective lock-up clutch Replace
• Disconnect L/C-PS. (male) (1) and (2) 5 – 15Ω? solenoid
YES

• Turn starting switch OFF. Is resistance between ATC2 (10) and L/C-PS (female) (1) or replace
• Disconnect ATC2. (female) (10) and (20) 5 – 15Ω? ATC2 (female) (20) and L/C-PS
(female) (2)
YES
Carry out
3 troubleshoot-
NO system of lock-up clutch or mechanical
YES
controller
20-458 HM300-1
! 1 !
TM-24 FAILURE CODE [15SKL1] (ECMV FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH:
★ Nature of failure:Even when the output to the differential lock clutch solenoid is turned OFF, the signal from
the fill switch stays ON and the clutch is not disengaged.
Cause Remedy
1
Is resistance between D/L-SW NO
• Turn starting switch OFF. (male) (1) and ground more than 1 Defective differential lock Replace
• Disconnect D/L-SW. MΩ? clutch fill switch
YES

• Turn starting switch OFF. Is resistance between ATC5A NO wiring harness between ATC5A Repair or
• Disconnect ATC5A. (female) (17) and ground more (female) (17) and D/L-SW (female) replace
than 1 MΩ? (1)
YES
Carry out
3 troubleshoot-
NO system of differential lock clutch mechanical
YES
controller
HM300-1 20-459
1 c
(9) c
TM-25 FAILURE CODE [15SKMA] (ECMV FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH:
FUNCTION IMPOSSIBLE (MA))
★ Nature of failure:Even when there is output to the differential lock clutch solenoid, the signal from the fill
switch stays OFF and the clutch is not engaged.
Cause Remedy
1
• Turn starting switch OFF. Is resistance between D/L-PS NO
Defective differential lock Replace
• Disconnect D/L-PS. (male) (1) and (2) 5 – 15Ω? clutch solenoid
YES

• Turn starting switch OFF. Is resistance between ATC2 NO (8) and D/L-PS (female) (1) or
(female) (8) and (18) 5 – 15Ω? ATC2 (female) (18) and D/L-PS
(female) (2)
YES
Carry out
3 troubleshoot-
replaced? or pressure control valve system
YES
controller
20-460 HM300-1
c 1 c
TM-26 FAILURE CODE [2B61MW] (INTER-AXLE DIFFERENTIAL LOCK CLUTCH:

SLIPPING (MW))
★ Nature of failure:When the power is output to the differential lock clutch solenoid, the value calculated from
the signals of the transmission output shaft forward speed sensor and transmission output
shaft reverse speed sensor is abnormal. (The value is calculated by the retarder control-
ler.)
Cause Remedy
1
• Turn starting switch OFF. Is resistance between D/L-PS NO Defective differential lock Replace
• Disconnect D/L-PS. (male) (1) and (2) 5 – 15Ω? clutch solenoid
YES

• Turn starting switch OFF. Is resistance between ATC2 (8) and D/L-PS (female) (1) or
• Disconnect ATC2. (female) (8) and (18) 5 – 15Ω? replace
ATC2 (female) (18) and D/L-PS
(female) (2)
YES
Carry out
3 troubleshoot-
replaced? or pressure control valve system
YES
controller
HM300-1 20-461
1 c
(9) c
TM-27 FAILURE CODE [2F00KM] (PARKING BRAKE: MISTAKEN OPERATION OR

MISTAKEN SETTING (KM))
★ Nature of failure:Travel operation was carried out when parking brake signal circuit was closed (connected
with ground)
★ Before starting troubleshooting, check that fuse BT3-16 is normal (if the fuse is blown, there has probably
been a surge of current caused by a short circuit, so check the related circuits).
Cause Remedy
1
Did machine travel with parking NO
brake switch at PARKING position?
YES Mistaken operation of parking

brake switch —
2
• Start engine. Does condition become normal when NO
• Operate gearshift lever. parking brake relay (R03) is
YES Defective parking brake relay Replace
(R03)
3
• Disconnect R03.
Is voltage between R03 (female) NO
• Start engine.
• Parking brake switch: RELEASED (1) and ground 20 – 30 V?
YES
4
Is resistance between R03 Defective contact or
• Turn starting switch OFF. NO disconnection in wiring harness Repair or
• Disconnect R03.
(female) (2) and ground less than
1 Ω? between R03 (female) (2) and replace
ground
YES

• Turn starting switch OFF. Is resistance between BRC5A NO in wiring harness between Repair or
• Disconnect R03 and (female) (5) and ground more than BRC5A (female) (5) and R03
BRC5A. 1 MΩ? replace
(female) (3)
YES
Defective retarder controller(q1) Replace
6
• Disconnect B17. Is resistance between B17 (male) NO Defective parking brake
• Start engine. (1) and (2) less than 1Ω? Replace
• Parking brake switch: RELEASED pressure switch
YES
7
NO Defective contact or disconnection Repair or
• Disconnect B17. Is voltage between B17 (female) in wiring harness between fuse
(1) and ground 20 – 30 V? BT3-16 outlet – B17 (female) (1)
YES Defective contact or

disconnection in wiring harness Repair or
between B17 (female) (2) and replace
R03 (female) (1)
20-462 HM300-1
! 1 !
4
HM300-1 20-463
1 ! !
TM-28 FAILURE CODE [989A00] (ENGINE OVERRUN PREVENTION COMMAND SIGNAL:

ACTUATED (00))
★ Nature of failure:The transmission input shaft speed became more than 2450 rpm when the speed range
was other than Neutral.
Cause Remedy
1
Did machine travel with Operate for
NO Defective transmission a short time
transmission input shaft speed at
more than 2450 rpm? controller and watch
condition
YES
Engine overrun —
20-464 HM300-1
! 1 !
TM-29 FAILURE CODE [989AKZ] (ENGINE OVERRUN PREVENTION COMMAND SIGNAL:

★ Nature of failure:Disconnection, short circuit with ground, hot short occurred in overrun prevention com-
mand circuit, or did not match communications data (S-NET)
Cause Remedy
1
• Disconnect ATC1 and Is voltage between ATC1 (female) NO between ATC1 (female) (13) and Repair or
BRC5B. (13) and ground less than 1 V?
• Turn starting switch ON. BRC5B (female) (5) replace
YES
2
Is resistance between ATC1 Defective contact or disconnection
• Turn starting switch OFF. NO in wiring harness between ATC1 Repair or
• Disconnect ATC1 and (female) (13) and BRC5B (female)
BRC5A. (5) less than 1 Ω? (female) (13) and BRC5B replace
(female) (5)
YES
3
• Turn starting switch OFF. Short circuit with chassis ground
Is resistance between ATC1 NO Repair or
• Disconnect ATC1 and (female) (13) and ground more in wiring harness between ATC1
BRC5A. than 1 MΩ? (female) (13) and BRC5B replace
(female) (5)
YES
4
• Turn starting switch ON. when transmission controller is Defective retarder controller(q1) Replace
replaced?
YES
controller
HM300-1 20-465
(9)
1 !
4 !
From 7
Cause Remedy
8
• Insert T-adapter to T10. Is voltage between T10 (2) and NO
• Turn starting switch ON. ground 2.9 – 3.1 V?

between ATC3B (female) (16) replace
and T10 (female) (2)
9
• Disconnect ATC3B and Is voltage between T10 (female) NO Hot short in wiring harness
T10. between ATC3B (female) (16) Repair or
YES
10
• Turn starting switch OFF. Is resistance between T10 NO Short circuit with chassis ground
• Disconnect ATC3B and (female) (2) and ground more in wiring harness between ATC3B Repair or
T10. than 1 MΩ (female) (16) and T10 (female) (2) replace
YES
Defective inclination sensor Replace
HM300-1 20-467
(9)
1 ! !
TM-31 FAILURE CODE [AA10NX] (AIR CLEANER ELEMENT: CLOGGED (NX))
★ Nature of failure:Air cleaner clogging signal circuit became open (shut off from ground) when engine was
running
1
NO Cause Remedy
Is dust indicator red?
YES Clean or
Clogged air cleaner element
replace
2
• Start engine. when dust indicator relay (R32)
is interchanged with other relay?
YES Defective dust indicator relay
(R32) Replace
3
• Disconnect R32.
Is resistance between R32 NO
• Start engine. (female) (2) and ground more
than 1 MΩ?
YES
4
Is resistance between T11 NO
(female) and T12 (male) less than Defective air cleaner clogging Replace
• Disconnect T11. switch
1 Ω?
YES Short circuit with chassis
ground in wiring harness Repair or
between R32 (female) (2) and replace
T11 (female)
5 Defective contact or
Is resistance between ATC3A disconnection in wiring harness
• Turn starting switch OFF. NO between ATC3A (female) (19) Repair or
• Disconnect ATC3A. (female) (19) and (16) less than and R32 (female) (3) or
1 Ω? replace
between ATC3A (female) (16)
and R32 (female) (6)
YES
controller
20-468 HM300-1
c 1 c
HM300-1 20-469
1 c c
TM-32 FAILURE CODE [AB00MA] (ALTERNATOR: FUNCTION IMPOSSIBLE (MA))
★ Nature of failure : Electricity generation signal was not input from alternator when engine was running.
: Dump body cannot be controlled (Dump body does not move).
Cause Remedy
1
Disconnect ATC3B. Is voltage between ATC3B (female) NO
Start engine (mid-range
speed). (1) and ground 27.5 - 29.5 V?
YES

controller
2
Disconnect alternator
terminal R. Is voltage between alternator R and NO
Start engine (mid-range E 27.5 - 29.5 V?
speed).
YES
or short circuit with chassis ground Repair or
in wiring harness between ATC3B replace
(female) (1) and alternator terminal R
3
Turn starting switch ON Is voltage between alternator B and NO Defective contact, disconnection,
E 20 - 30 V? or short circuit with chassis ground Repair or
in wiring harness between alternator replace
YES terminal B and battery relay terminal M
Defective alternator Replace
20-470 HM300-1
c 1 c
4
TM-33 FAILURE CODE [B@BCZK] (RADIATOR COOLANT: DROP IN LEVEL (ZK))
★ Nature of failure:Radiator coolant level switch signal circuit became open (shut off from ground) when en-
gine was running
★ If the level of the coolant in the radiator has dropped, check around the engine and radiator for signs of cool-
ant leakage before adding coolant.
Cause Remedy
1
• Stop engine. NO
Has radiator coolant level dropped?
YES Check for

Drop in radiator coolant level coolant
leakage, add
coolant
2
• Turn starting switch OFF. Is resistance between T01 (male) NO Defective radiator coolant level Replace
• Disconnect T01. (1) and (2) less than 1 Ω? switch
YES
3
Is resistance between T01 NO Defective contact or disconnection Repair or
in wiring harness between T01
(female) (2) and ground less than replace
• Disconnect T01. 1 Ω? (female) (2) and ground
YES
4
Is resistance between ATC5A NO Defective contact or disconnection Repair or
(female) (3) and ground less than in wiring harness between ATC5A replace
• Disconnect ATC5A. 1 Ω? (female) (3) and T01 (female) (1)
YES
controller
HM300-1 20-471
(9)
1 ! !
TM-34 FAILURE CODE [B@HAZK] (HYDRAULIC TANK OIL: DROP IN LEVEL (ZK))
★ Nature of failure:When the engine was stopped, the signal circuit of the hydraulic tank level switch became
open (shut off from GND)
★ If the level of the oil in the hydraulic tank has dropped, check the hydraulic equipment and hydraulic piping
for signs of oil leakage before adding oil.
Cause Remedy
1
Has oil level in hydraulic tank NO
• Stop engine.
dropped?
YES Check for oil

Drop in hydraulic tank oil level leakage, add
oil
2
• Turn starting switch OFF. Is resistance between T06 (male) NO Defective hydraulic tank level Replace
• Disconnect T06. (1) and ground less than 1 Ω? switch
YES
3
Is resistance between ATC5A Defective contact or
(female) (2) and ground less
• Disconnect ATC5A. between ATC5A (female) (2) replace
than 1Ω?
YES
controller
20-472 HM300-1
c 1 c
TM-35 FAILURE CODE [B@JANS] (STEERING OIL: OVERHEAT (NS))
★ Nature of failure:The signal circuit of the steering oil temperature switch became open (shut off from GND)
Cause Remedy
1
Did steering oil temperature go NO
above 120fC?
YES Overheating of steering oil —
2
• Turn starting switch OFF. Is resistance between T04 (male) NO Defective steering oil Replace
• Disconnect T04. (1) and ground less than 1 Ω? temperature switch
YES
3
Is resistance between ATC3A Defective contact or
• Disconnect ATC3A. (female) (11) and ground less than
1 Ω? between ATC3A (female) (11) replace
YES
controller
HM300-1 20-473
1 ! !
TM-36 FAILURE CODE [D1B0KZ] (TRANSMISSION CUT RELAY:

★ Nature of failure:Abnormal voltage was generated in the transmission cut relay circuit (relay actuated: 10 V
or more; relay stopped: Less than 4 V)
Cause Remedy
1
• Turn starting switch ON. when transmission cut relay (R15)
YES Defective transmission cut relay Replace
(R15)
2
• Disconnect R15. Is voltage between R15 (female) NO disconnection in wiring harness Repair or
• Turn starting switch ON. (1) and ground 20 - 30 V? between fuse BT3 - 14 outlet - replace
R15 (female) (1)
YES
3
Is voltage between ATC1 NO
• Disconnect ATC1 and R15. (female) (15) and ground less
than 1 V?
YES
4 Short circuit between wiring

• Turn starting switch OFF. Is resistance between R15 NO harness at R15 (female) (1) end Repair or
• Disconnect ATC1 and (female) (1) and R15 (female) (2) and wiring harness at R15 replace
R15. more than 1 MΩ? (female) (2) end
YES Hot short in wiring harness Repair or
between ATC1 (female) (15) replace
• Turn starting switch OFF. Is resistance between ATC1 NO disconnection in wiring harness
• Disconnect ATC1 and (female) (15) and R15 (female) Repair or
R15. (2) less than 1 Ω? and R15 (female) (2)
YES
6 Short circuit with chassis

• Turn starting switch OFF. Is resistance between ATC1 NO ground in wiring harness
• Disconnect ATC1 and (female) (15) and ground more Repair or
R15. than 1 MΩ? and R15 (female) (2)
YES
controller
20-474 HM300-1
c 1 c
(9)
HM300-1 20-475
1 c c
TM-38 FAILURE CODE [D5ZCKZ] (EXHAUST BRAKE COMMAND SIGNAL:

★ Nature of failure:A disconnection, short circuit with ground, or hot short was generated in the exhaust brake
command circuit, or there was a mismatch with the communication (S-NET) data
Cause Remedy
1
• Disconnect ATC1 and Is voltage between ATC1 (female) NO between ATC1 (female) (14) and Repair or
BRC5B. (14) and ground less than 1 V?
• Turn starting switch ON. BRC5B (female) (4) replace
YES
2
Is resistance between ATC1 Defective contact or disconnection
• Turn starting switch OFF. NO in wiring harness between ATC1 Repair or
• Disconnect ATC1 and (female) (14) and BRC5B (female)
BRC5B. (4) less than 1 Ω? (female) (14) and BRC5B replace
(female) (4)
YES
3
Is resistance between ATC1 NO Repair or
• Disconnect ATC1 and (female) (14) and ground more in wiring harness between ATC1
BRC5B. than 1 MΩ? (female) (14) and BRC5B replace
(female) (4)
YES
4
replaced?
YES
controller
20-478 HM300-1
! (9)
1 !
4
TM-41 FAILURE CODE [DAQ0KK] (TRANSMISSION CONTROLLER:

DROP IN POWER SOURCE VOLTAGE, INPUT (KK))
★ Nature of failure:When the engine was running, both the main power supply voltage circuit and the direct
power supply voltage circuit became less than 18 V
Cause Remedy
1
• Turn starting switch ON. Is other failure code [AB00MA] NO
• Operate machine displayed or recorded at same
monitor. time? Go to
YES troubleshoot
Another problem is occurring at ing for
the same time displayed
code
2
• Insert T-adapter to ATC1. Is voltage between ATC1 (7) - NO
• Start engine (mid-range (8)(16) and between ATC1
speed). (9)(17) - (8)(16) 20 - 30 V?
YES Defective transmission Replace
controller
3
Is resistance between ATC1 Defective contact or
• Disconnect ATC1. (female) (8)(16) and ground less
than 1 Ω? between ATC1 (female) (8)(16) replace
and ground
YES
4
Is battery voltage more than 24 NO Defective battery or defective
• Turn starting switch OFF. V and specific gravity more than Charge or
1.26? charging replace

between battery - battery relay - replace
transmission controller
20-482 HM300-1
! 1 !
HM300-1 20-483
1 ! !
TM-43 FAILURE CODE [DAQ2KK] (TRANSMISSION CONTROLLER LOAD POWER SUPPLY

LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))
★ Nature of failure:When the controller power supply voltage circuit was normal, the solenoid power supply
voltage circuit became less than 18 V
Cause Remedy
1
• Insert T-adapter to ATC1 Is voltage between ATC2 (1)(12) NO
and ATC2.
• Turn starting switch ON. and ATC1 (8)(16) 20 - 30 V?
YES
controller
2
• Turn starting switch ON. when transmission cut relay (R15)
is replaced with other relay?
YES
Defective transmission cut relay Replace
(R15)
3
• Disconnect R15. Is voltage between R15 (3) and NO disconnection in wiring harness Repair or
• Turn starting switch ON. ground 20 - 30 V? between fuse BT3-14 outlet - replace
R15 (female) (3)
ATC2 (female) (1)(12)
HM300-1 20-485
1 ! !
TM-46 FAILURE CODE [DAQ9KM] (TRANSMISSION CONTROLLER WIRING HARNESS:

MISTAKEN OPERATION OR MISTAKEN SETTING (KM))
★ Nature of failure:When the starting switch is ON, the input connector check signal does not match the setting
inside the controller
Cause Remedy
1
Are connectors ATC3 (A, B) and NO
• Turn starting switch OFF. ATC5 (A, B) connected at correct Mistaken connection of Connect
place? controller connector again
YES
2
Is resistance between ATC5A NO disconnection in wiring harness
(female) (1) and ground less than Repair or
• Disconnect ATC5A. between ATC5A (female) (1) replace
1 Ω? and ground
YES
controller
20-488 HM300-1
! 1 !
TM-47 FAILURE CODE [DAQ9KQ] (TRANSMISSION CONTROLLER WIRING HARNESS:

NON MATCH IN MODEL SELECTION SIGNAL (KQ))
★ Nature of failure:When the starting switch is ON, the input model selection signal is different from the setting
of the controller
Cause Remedy
1
Is resistance between ATC5B NO Defective contact or disconnection
• Turn starting switch OFF. (female) (14) and ground less in wiring harness between ATC5B Repair or
• Disconnect ATC5B. than 1 Ω? (female) (14) and ground replace
YES
2
Is resistance between ATC5B NO Short circuit with chassis ground Repair or
• Turn starting switch OFF. in wiring harness between ATC5B replace
• Disconnect ATC5B. (female) (15) and ground more
than 1 MΩ? (female) (15) and ground
YES
3
Is resistance between ATC5B NO Defective contact or disconnection Repair or
• Turn starting switch OFF. (female) (16) and ground less in wiring harness between ATC5B replace
• Disconnect ATC5B. than 1Ω? (female) (16) and ground
YES
controller
HM300-1 20-489
1 ! !
TM-58 FAILURE CODE [DF10KA] (GEARSHIFT LEVER: DISCONNECTION (KA))
★ Nature of failure: Nothing is input for the gearshift lever signal

1
• Insert T-adapter to ATC1 Is voltage between each pin of NO Cause Remedy
and ATC5B. ATC5B and ATC1 (8) as shown
• Turn starting switch ON. in Table 1?
controller
2
• Insert T-adapter to SF1. Is voltage between SF1 (1) and NO
• Turn starting switch ON. (2) 20 - 30 V?
YES
• Insert T-adapter to SF1. Is voltage between SF1 (1) and NO disconnection in wiring harness Repair or
• Turn starting switch ON. ground 20 - 30 V? between fuse BT3-10 outlet and replace
SF1 (female) (1)
YES Defective contact or Repair or
disconnection in wiring harness replace
between SF1 (female) (2) and
ATC1 (female) (8)
• Turn starting switch OFF. Is resistance between each pin of NO disconnection in wiring harness
• Disconnect ATC5B and ATC5B (female) and each pin of between SF1 (female) and Repair or
SF1. SF1 (female) as shown in Table 2? ATC5B (female) where replace
resistance value is not normal
YES

• Turn starting switch OFF. Is resistance between each pin NO ground in wiring harness
• Disconnect ATC5B and of ATC5B (female) and ground between SF1 (female) and Repair or
SF1. as shown in Table 3? ATC5B (female) where replace
resistance value is not normal
YES
Defective gearshift lever Replace
Table 1 Table 2 Table 3
Shift ATC5B (female), Resistance Resistance

ATC5B, ATC1 Voltage ATC5B (female)
position SF1 (female) value value
ATC5B(2) - ATC1(8) R1 ATC5B(2) - SF1(4) (2) - and ground
ATC5B(3) - ATC1(8) R2 ATC5B(3) - SF1(3) (3) - and ground
ATC5B(4) - ATC1(8) N ATC5B(4) - SF1(5) (4) - and ground
ATC5B(5) - ATC1(8) D ATC5B(5) - SF1(6) (5) - and ground
ATC5B(6) - ATC1(8) 1 20 - 30 V ATC5B(6) - SF1(11) Max. 1 Ω (6) - and ground Min. 1 MΩ
ATC5B(7) - ATC1(8) 2 ATC5B(7) - SF1(10) (7) - and ground
HM300-1 20-499
1 ! !
20-500 HM300-1
! 1 !
TM-59 FAILURE CODE [DF10KB] (GEARSHIFT LEVER: SHORT CIRCUIT (KB))
★ Nature of failure: The gearshift lever signal was input at the same time from 2 or more systems
Cause Remedy
1
• Insert a T-adapter into Is the voltage between each pin of
ATC1 and ATC5B NO
ATC5B and ATC1 (8) as shown in
• Turn the engine starting
switch ON. the Table 1?
YES
Transmission controller Replace
defective
2
• Separate ATC5B and
SF1. Is the voltage between each pin of NO
• Turn the engine starting ATC5B (female) and grounding as A wiring harness between Repair or
switch ON. shown in the Table 2? ATC5B (female) and SF1 replace
(female) which shows abnormal
YES voltage is short-circuited
Gearshift lever defective Replace
Table 1 Table 2
Shift ATC5B (female) Voltage

ATC5B, ATC1 Voltage
position (2) - and ground
ATC5B(2) - ATC1(8) R1 (3) - and ground
ATC5B(3) - ATC1(8) R2 (4) - and ground
ATC5B(4) - ATC1(8) N (5) - and ground
ATC5B(5) - ATC1(8) D (6) - and ground Max. 1 V
ATC5B(6) - ATC1(8) 1 Max. 1 V (7) - and ground
ATC5B(7) - ATC1(8) 2 (8) - and ground
ATC5B(10) - ATC1(8) 5
HM300-1 20-501
1 c
(9) c
20-502 HM300-1
c 1 c
TM-60 FAILURE CODE [DGF1KX] (TRANSMISSION VALVE OIL TEMPERATURE SENSOR:

★ Nature of failure:The voltage of the signal circuit for the transmission valve oil temperature sensor became
less than 0.97 V, or there was a big difference from the torque converter oil temperature
★ Check that the sensor has returned to normalcy after taking corrective steps, and then implement initializing
the transmission controller, referring to “Special Functions of Machine Monitor” in TESTING and ADJUST-
ING.
Cause Remedy
1
• Disconnect ATC3A and Is voltage between ATC3B NO
ATC3B. (female) (9) and ground less than
• Turn starting switch ON. 1 V?
YES
2
• Disconnect ATC3B and Is voltage between ATC3B (female) NO
LUB-T.
(9) and ground less than 1 V?
between ATC3B (female) (9) Repair or
• Turn starting switch ON. and LUB-T (female) (1) replace
YES
Defective transmission valve oil Replace
temperature sensor
3
• Turn starting switch OFF. Is resistance between ATC3B (female) NO
• Disconnect ATC3A and (9) - ATC3A (female) (16) and between
ATC3B. (9) - ground as shown in Table 1?
YES
controller
4
Is resistance between LUB-T NO
. Turn starting switch OFF. (male) (1) - (2) and between (1) - Defective transmission valve oil
. Disconnect LUB-T. temperature sensor Replace
Defective contact,
YES disconnection, or short circuit
harness between ATC3B replace
(female) (9) and LUB-T (female)
(1), or defective contact or
disconnection in wiring harness
and LUB-T (female) (2)
Table 1 Table 2
Between ATC3B (female) Between ATC3B Between LUB-T
Oil Oil Between LUB-T (male) (1)
(9) and ATC3A (female) (female) (9) and (male) (1) and
temperature temperature and (2)
(16) ground ground
25°C 37 – 50 kΩ 25°C 37 – 50 kΩ
100°C 3.5 – 4.0 kΩ 100°C 3.5 – 4.0 kΩ
HM300-1 20-503
1 c
(9) c
20-504 HM300-1
c 1 c
TM-61 FAILURE CODE [DGR3L8] (BRAKE OIL TEMPERATURE SENSOR (CENTER):

★ Nature of failure:When the front brake oil temperature sensor signal were more than 60°C, the center brake
oil temperature sensor was less than 10°C
Cause Remedy
1
YES
2
• Disconnect ATC3B and Is voltage between ATC3B NO Hot short in wiring harness
T14. (female) (8) and ground less between ATC3B (female) (8) Repair or
• Turn starting switch ON. than 1 V? and T14 (female) (1) replace
YES Defective center brake oil

temperature sensor Replace
3
• Turn starting switch OFF. Is resistance between ATC3B NO
• Disconnect ATC3A and (female) (8) and ATC3A (female)
ATC3B. (16) as shown in Table 1?
YES
controller
4
• Turn starting switch OFF. Is resistance between T14 (male) NO Defective center brake oil
• Disconnect T14. (1) and (2) as shown in Table 2? temperature sensor Replace
YES disconnection in wiring harness
between ATC3B (female) (8) - Repair or
T14 (female) (1) or between replace
ATC3A (female) (16) - T14
(female) (2)
Table 1 Table 2
Oil Between ATC3B (female) (8) Oil
Between T14 (male) (1) and (2)
temperature and ATC3A (female) (16) temperature
25°C 37 – 50 kΩ 25°C 37 – 50 kΩ
100°C 3.5 – 4.0 kΩ 100°C 3.5 – 4.0 kΩ
HM300-1 20-505
1 c
(9) c
20-506 HM300-1
c 1 c
TM-62 FAILURE CODE [DGR4L8] (BRAKE OIL TEMPERATURE SENSOR (FRONT):

★ Nature of failure:When the center brake oil temperature sensor signal were more than 60°C, the front brake
oil temperature sensor was less than 10°C
Cause Remedy
1
YES
2
YES Defective front brake oil

3
YES
controller
4
• Turn starting switch OFF. Is resistance between T15 (male) NO Defective front brake oil
• Disconnect T15. (1) and (2) as shown in Table 2? temperature sensor Replace
between ATC3B (female) (3) - Repair or
T15 (female) (1) or between replace
ATC3A (female) (16) - T15
(female) (2)
Table 1 Table 2
Oil Between ATC3B (female) (3) Oil
Between T15 (male) (1) and (2)
temperature and ATC3A (female) (16) temperature
25°C 37 – 50 kΩ 25°C 37 – 50 kΩ
100°C 3.5 – 4.0 kΩ 100°C 3.5 – 4.0 kΩ
HM300-1 20-507
1 c
(9) c
20-508 HM300-1
c 1 c
TM-63 FAILURE CODE [DGT1LX] (TORQUE CONVERTER OIL TEMPERATURE SENSOR:

★ Nature of failure:The voltage of the signal circuit for the torque converter oil temperature sensor became
less than 0.97 V, or there was a big difference from the transmission valve oil temperature
sensor signal
Cause Remedy
1
YES
2
• Disconnect ATC3B and Is voltage between ATC3B NO Hot short in wiring harness Repair or
TC-SE. (female) (7) and ground less between ATC3B (female) (7) replace
• Turn starting switch ON. than 1 V? and TC-SE (female) (1)
YES Defective torque converter oil
3
• Turn starting switch OFF. Is resistance between ATC3B (female) (7) - NO
• Disconnect ATC3A and ATC3A (female) (16) and between(7) -
ATC3B. ground as shown in Table 1?
YES
controller
4
Is resistance between TC-SE NO
• Turn starting switch OFF. (male) (1) - (2) and between (1) - Defective torque converter oil
• Disconnect TC-SE. temperature sensor Replace
Defective contact,
harness between ATC3B replace
(female) (7) and TC-SE
(female) (1), or defective
contact or disconnection in
wiring harness between ATC3A
(female) (16) and TC-SE
(female) (2)
Table 1 Table 2
Between ATC3B (female) Between ATC3B Between TC-SE
Oil Oil Between TC-SE (male)
(7) and ATC3A (female) (female) (7) and (male) (1) and
temperature temperature (1) and (2)
(16) ground ground
25°C 37 – 50 kΩ 25°C 37 – 50 kΩ
100°C 3.5 – 4.0 kΩ 100°C 3.5 – 4.0 kΩ
HM300-1 20-509
1 c
(9) c
20-510 HM300-1
c 1 c
TM-64 FAILURE CODE [DHT5KX] (TORQUE CONVERTER OIL PRESSURE SENSOR:

★ Nature of failure:The voltage in the signal circuit of the torque converter oil pressure sensor became less
than 0.5 V or more than 4.5 V
Cause Remedy
1
• Insert T-adapter to Is voltage between ATC3A (7) NO
ATC3A.
• Turn starting switch ON. and (16)(17) 0.8 - 2.0 V?
YES
Defective transmission
controller Replace
2
Is voltage between TC-INT NO
• Disconnect TC-INT.
• Turn starting switch ON. (female) (2) and ground 20 - 30
V?
YES

• Disconnect ATC1 and Is resistance between TC-INT NO ground in wiring harness Repair or
TC-INT. (female) (2) and ground more between ATC1 (female) (3) and replace
• Turn starting switch ON. than 1 MΩ?
TC-INT (female) (2)
YES
4
• Insert T-adapter to ATC1. Is voltage between ATC1 (3) and NO Defective transmission Replace
• Disconnect TC-INT.
• Turn starting switch ON. ground 20 - 30 V? controller
YES disconnection in wiring harness Repair or
between ATC1 (female) (3) and replace
TC-INT (female) (2)
5
• Turn starting switch OFF. Is resistance between TC-INT NO
• Disconnect TC-INT. (female) (1) and ground less
than 1 Ω?
YES
• Turn starting switch OFF. Is resistance between ATC3A NO disconnection in wiring harness
• Disconnect ATC3A and (female) (16)(17) and TC-INT Repair or
between ATC3A (female) (16) replace
TC-INT. (female) (3) less than 1 Ω? (17) and TC-INT (female) (1)
YES Defective transmission
controller Replace
7
• Insert T-adapter to TC- Is voltage between TC-INT (3) NO
INT.

between ATC3A (female) (7) Repair or
and TC-INT (female) (3) replace
To 8
HM300-1 20-511
1 c
(9) c
From 7
Cause Remedy
8 Hot short in wiring harness
• Disconnect ATC3A and Is voltage between TC-INT NO
TC-INT. (female) (3) and ground less between ATC3A (female) (7) Repair or
• Turn starting switch ON. than 1 V? and TC-INT (female) (3) replace
YES
• Turn starting switch OFF. Is resistance between TC-INT NO ground in wiring harness Repair or
• Disconnect ATC3A and (female) (3) and ground more between ATC3A (female) (7) replace
TC-INT. than 1 MΩ? and TC-INT (female) (3)
YES Defective torque converter oil Replace
temperature sensor
20-512 HM300-1
c 1 c
(9)
TM-65 FAILURE CODE [DHT5L6] (TORQUE CONVERTER OIL PRESSURE SENSOR:

★ Nature of failure:When the engine is stopped, the torque converter oil pressure sensor signal circuit inputs
the oil pressure
Cause Remedy
1
• Insert T-adapter to NO
ATC3A. Is voltage between ATC3A (7) and
• Turn starting switch ON. (16) (17) 0.8 V?
YES
controller
2
• Disconnect ATC3A and Hot short in wiring harness
TC-INT. Is voltage between ATC3A (female) NO between ATC3A (female) (7) and Repair or
• Turn starting switch ON. (7) and ground less than 1 V? TC-INT (female) (3) replace
YES
Defective torque converter oil Replace
pressure sensor
HM300-1 20-513
1 c
(9) c
TM-66 FAILURE CODE [DJF1KA] (FUEL LEVEL SENSOR: DISCONNECTION (KA))
★ Nature of failure: The voltage of the signal circuit of the fuel level sensor became more than 4.0 V
Cause Remedy
1
YES
2
YES
Defective fuel level sensor Replace
3
• Disconnect ATC3A and (female) (4) - ATC3A (female)
YES
controller
4
• Turn starting switch OFF. Is resistance between T08 (male) NO Defective fuel level sensor
Replace
• Disconnect T08. (1) – (2) as shown in Table 2?
between ATC3B (female) (4) Repair or
and T08 (female) (1) or replace
Table 1 Table 2
Between ATC3B (female) (4) Between T08 (male)
Fuel tank Fuel tank
and ATC3A (female) (16) (1) and (2)
Full Max. 12 Ω Full Max. 12 Ω
Empty 74 – 100 Ω Empty 74 – 100 Ω
20-514 HM300-1
c 1 c
(9)
TM-67 FAILURE CODE [DK11KX] (THROTTLE ANGLE SENSOR: INPUT SIGNAL OUTSIDE
RANGE (KX))
★ Nature of failure:The voltage in the signal circuit of the acceleration sensor became less than 0.6 V or more
than 4.7 V
Cause Remedy
1
• Insert T-adapter to
Is voltage between ATC3B (11) NO
ATC3A and ATC3B.
• Turn starting switch ON. and ATC3A (16) 1.0 - 4.0 V?
YES Defective transmission

controller Replace
2
YES
3
• Disconnect ATC3A and Is voltage between AS2 (female) NO between ATC3A (female) (6) Repair or
AS2.
• Turn starting switch ON. (1) and ground less than 1 V? and AS2 (female) (1) replace
YES

• Disconnect ATC3A and (female) (1) and ground more ground in wiring harness Repair or
AS2. than 1 MΩ? between ATC3A (female) (6) replace
and AS2 (female) (1)
YES
5
ATC3A. Is voltage between ATC3A (6) NO Defective transmission
Replace
• Disconnect AS2. and ground 4.6 - 5.4 V? controller
6
• Disconnect AS2. (female) (3) and ground less
than 1 Ω?
YES
• Turn starting switch OFF. Is resistance between ATC3A Repair or
NO disconnection in wiring harness replace
• Disconnect ATC3A and (female) (16) and AS2 (female) between ATC3A (female) (16)
AS2. (3) less than 1 Ω? and AS2 (female) (3)
controller
To 8
HM300-1 20-515
1 c
(9) c
From 7
Cause Remedy
8
between ATC3B (female) (11) replace
9
• Disconnect ATC3B and NO Hot short in wiring harness
Is voltage between AS2 (female) between ATC3B (female) (11) Repair or
AS2.
• Turn starting switch ON. (2) and ground less than 1 V? and AS2 (female) (2) replace
YES
10
• Turn starting switch OFF. Is resistance between AS2 NO ground in wiring harness Repair or
• Disconnect ATC3B and (female) (2) and ground more between ATC3B (female) (11) replace
AS2. than 1 MΩ? and AS2 (female) (2)
YES
Defective accelerator sensor or
defective accelerator pedal Replace
20-516 HM300-1
c 1 c
(9)
TM-68 FAILURE CODE [DLE2KA] (ENGINE SPEED SENSOR: DISCONNECTION (KA))
★ Nature of failure:There is a disconnection in the signal circuit of the engine speed sensor and the signal is
not input
Cause Remedy
1
• Turn starting switch OFF. Is resistance between ATC3A NO
• Disconnect ATC3A. (female) (13) and (14) 500 - 1000
Ω?
YES
2
• Turn starting switch OFF. Is resistance between EREV NO
• Disconnect EREV. (male) (1) and (2) 500 - 1000 Ω? Defective engine speed sensor Replace
and EREV (female) (1) or
3 and EREV (female) (2)
• See TESTING AND Does condition become normal NO
ADJUSTING. when engine speed sensor is Defective transmission Replace
• Start engine. adjusted? controller
YES
Defective adjustment of engine Adjust
speed sensor
HM300-1 20-517
1 c c
TM-69 FAILURE CODE [DLE2LC] (ENGINE SPEED SENSOR:

* SEE THE TABLE IN CONTENTS. (LC))
★ Nature of failure:When the signal of the engine speed sensor is less than 350 rpm, the signal of the trans-
mission input shaft speed sensor inputs more than 500 rpm
Cause Remedy
1
• Disconnect ATC3A. Is voltage between ATC3A NO
• Turn starting switch ON. (female) (13) and ground less
than 1 V?
YES
2
• Disconnect ATC3A and Is voltage between ATC3A NO Hot short in wiring harness
EREV. (female) (13) and ground less between ATC3A (female) (13) Repair or
• Turn starting switch ON. than 1 V? and EREV (female) (1) replace
YES
Defective engine speed sensor Replace
3
Is resistance between ATC3A NO
• Turn starting switch OFF. (female) (13) and ground more
• Disconnect ATC3A. than 1 MΩ?
YES
controller
4
Is resistance between EREV NO
• Turn starting switch OFF. (male) (1) and ground more than
• Disconnect EREV Defective engine speed sensor Replace
1 MΩ?

and EREV (female) (1)
20-518 HM300-1
c 1 c
(9)
TM-70 FAILURE CODE [DLF1KA] (TRANSMISSION INPUT SHAFT SPEED SENSOR:

DISCONNECTION (KA))
★ Nature of failure:There is a disconnection in the signal circuit of the transmission input shaft speed sensor
and the signal is not input
ING.
Cause Remedy
1
Ω?
YES
2
• Turn starting switch OFF. Is resistance between N1 (male) NO Defective transmission input
• Disconnect N1. (1) and (2) 500 - 1000 Ω? shaft speed sensor Replace
and N1 (female) (1) or between
ATC3A (female) (14) and N1
3 (female) (2)
ADJUSTING. when transmission input shaft Defective transmission Replace
• Start engine. speed sensor is adjusted? controller
YES Defective adjustment of
transmission input shaft speed Adjust
sensor
HM300-1 20-519
1 c
(9) c
TM-71 FAILURE CODE [DLF1LC] (TRANSMISSION INPUT SHAFT SPEED SENSOR:

★ Nature of failure:There is a disconnection in the signal circuit of the transmission input shaft speed sensor
and the signal is not input
ING.
Cause Remedy
1
• Turn starting switch ON. (female) (2) and ground less than
1 V?
YES
2
N1. (female) (2) and ground less between ATC3A (female) (2) Repair or
• Turn starting switch ON. than 1 V? and N1 (female) (1) replace
YES Defective transmission input Replace

shaft speed sensor
3
• Disconnect ATC3A. (female) (2) and ground more
than 1 MΩ?
YES
controller
4
• Turn starting switch OFF. Is resistance between N1 (male) NO Defective transmission input
• Disconnect N1. (1) and ground more than 1 MΩ? shaft speed sensor Replace

and N1 (female) (1)
20-520 HM300-1
! (9)
1 !
TM-72 FAILURE CODE [DLF2KA] (TRANSMISSION INTERMEDIATE SHAFT SPEED

SENSOR: DISCONNECTION (KA))
★ Nature of failure:There is a disconnection in the signal circuit of the transmission intermediate shaft speed
sensor and the signal is not input
ING.
Cause Remedy
1
Ω?
YES
2
• Turn starting switch OFF. Is resistance between N2 (male) NO Defective transmission intermediate
• Disconnect N2. (1) and (2) 500 - 1000 Ω? shaft speed sensor Replace
3 (female) (2)
ADJUSTING. when transmission intermediate Defective transmission Replace
• Start engine. shaft speed sensor is adjusted? controller
transmission intermediate shaft Adjust
speed sensor
HM300-1 20-521
1 c
(9) c
TM-73 FAILURE CODE [DLF2LC] (TRANSMISSION INTERMEDIATE SHAFT SPEED

SENSOR: * SEE THE TABLE IN CONTENTS. (LC))
★ Nature of failure:There is an abnormality in the speed calculated from the engine speed sensor signal, trans-
mission input shaft speed sensor signal, and output shaft R speed sensor signal, and the
speed of the transmission intermediate shaft sensor signal
ING.
Cause Remedy
1
• Turn starting switch ON. (female) (12) and ground less
than 1 V?
YES
2
Repair or
N2. (female) (12) and ground less between ATC3A (female) (12)
than 1 V? and N2 (female) (1)
YES Defective transmission intermediate Replace
shaft speed sensor
3
• Turn starting switch OFF. (female) (12) and ground more
• Disconnect ATC3A. than 1 MΩ?
controller
4
• Turn starting switch OFF. Is resistance between N2 (male) NO Defective transmission intermediate
• Disconnect N2. (1) and ground more than 1 MΩ? shaft speed sensor Replace

and N2 (female) (1)
20-522 HM300-1
c 1 c
(9)
TM-74 FAILURE CODE [DLT3KA] (TRANSMISSION OUTPUT SHAFT R SPEED SENSOR:

DISCONNECTION (KA))
★ Nature of failure:There is a disconnection in the signal circuit of the transmission output shaft R speed sen-
sor and the signal is not input
ING.
Cause Remedy
1
• Disconnect ATC3A and (female) (3) and (14) 500 - 1000
BRC3A. Ω?
YES
2
• Turn starting switch OFF. Is resistance between N3 (male) NO Defective transmission output
• Disconnect N3. (1) and (2) 500 - 1000 Ω? shaft R speed sensor Replace
3 (female) (2)
ADJUSTING. when transmission output shaft R Defective transmission Replace
• Start engine. speed sensor is adjusted? controller
transmission output shaft R Adjust
speed sensor
HM300-1 20-523
1 c
(9) c
TM-75 FAILURE CODE [DLT3LC] (TRANSMISSION OUTPUT SHAFT R SPEED SENSOR:

★ Nature of failure:There is an abnormality in the speed calculated from the engine speed sensor signal, trans-
mission input shaft speed sensor signal, and intermediate shaft speed sensor signal, and
the speed of the transmission output shaft R sensor signal
ING.
Cause Remedy
1
• Disconnect ATC3A and Is voltage between ATC3A NO
BRC3A. (female) (12) and ground less
• Turn starting switch ON. than 1 V?
YES
2
• Disconnect ATC3A, Is voltage between ATC3A NO between ATC3A (female) (3) - Repair or
BRC3A, and N3. (female) (12) and ground less BRC3A (female) (13) - N3 replace
• Turn starting switch ON. than 1 V?
(female) (1)
YES Defective transmission output
shaft R speed sensor Replace
3
• Disconnect ATC3A and (female) (3) and ground more
BRC3A. than 1 MΩ?
YES
4
• Turn starting switch OFF. Is resistance between N3 (male) NO Defective transmission output
• Disconnect N3. (1) and ground more than 1 MΩ? shaft R speed sensor Replace
YES ground in wiring harness Repair or
between ATC3A (female) (3) - replace
BRC3A (female) (13) - N3
(female) (1)
5
replaced?
YES
controller
20-524 HM300-1
c 4 c
1
(9)
HM300-1 20-525
1 ! !
TM-76 FAILURE CODE [DXH0KA] (SOLENOID FOR INTER-AXLE DIFFERENTIAL LOCK:

DISCONNECTION (KA))
★ Nature of failure:No electric current flows when there is output to the differential lock clutch solenoid
Cause Remedy
1
• Turn starting switch OFF. Is resistance between ATC2 NO
• Disconnect ATC2. (female) (8) and (18) 5 – 15 Ω?
YES
controller
2
NO Defective differential lock clutch Replace
• Turn starting switch OFF. Is resistance between D/L-PS solenoid
• Disconnect D/L-PS. (male) (1) and (2) 5 – 15 Ω?

YES in wiring harness between ATC2
(female) (8) and D/L-PS (female) Repair or
(1) or between ATC2 (female) (18) replace
and D/L-PS (female) (2)
20-526 HM300-1
! 1 !
TM-77 FAILURE CODE [DXH0KB] (SOLENOID FOR INTER-AXLE DIFFERENTIAL LOCK:

SHORT CIRCUIT (KB))
★ Nature of failure:An extremely large electric current flows when there is output to the differential lock clutch
solenoid or electric current flows when it is OFF
Cause Remedy
1
• Disconnect ATC2. (female) (8) - (18) and between
(8) - ground as shown in Table 1?
YES
2
• Turn starting switch OFF. Is resistance between D/L-PS NO Defective differential lock clutch
• Disconnect D/L-PS. (male) (1) - (2) and between (1) - solenoid Replace
YES in wiring harness between ATC2 Repair or
(female) (8) and D/L-PS (female)
(1) or short circuit in wiring replace
harness between ATC2 (female)
(18) and D/L-PS (female) (2)
• Disconnect ATC2 and Is voltage between ATC2 NO between ATC2 (female) (8) and Repair or
D/L-PS. (female) (8) - (18) - ground less D/L-PS (female) (1) or between replace
• Turn starting switch ON. than 1 V? ATC2 (female) (18) and D/L-PS
(female) (2)
YES
controller
Table 1 Table 2
ATC2 (female) Resistance value D/L-PS (male) Resistance value

Between (8) and (18) 5 – 15 Ω Between (1) and (2) 5 – 15 Ω
Between (8) and ground Min. 1 MΩ Between (1) and ground Min. 1 MΩ
HM300-1 20-527
1 c
(9) c
TM-78 FAILURE CODE [DXH1KA] (SOLENOID FOR LOCK-UP CLUTCH:

DISCONNECTION (KA))
★ Nature of failure: No electric current flows when there is output to the lock-up clutch solenoid
Cause Remedy
1
YES
controller
2
NO Defective lock-up clutch Replace
• Turn starting switch OFF. Is resistance between L/C-PS
• Disconnect L/C-PS. (male) (1) and (2) 5 – 15 Ω? solenoid

(female) (10) and L/C-PS (female) Repair or
(1) or between ATC2 (female) (20) replace
and L/C-PS (female) (2)
20-528 HM300-1
c 1 c
TM-79 FAILURE CODE [DXH1KB] (SOLENOID FOR LOCK-UP CLUTCH:

SHORT CIRCUIT (KB))
★ Nature of failure:An extremely large electric current flows when there is output to the lock-up clutch solenoid
or electric current flows when it is OFF
Cause Remedy
1
• Disconnect ATC2. (female) (10) - (20) and between
(10) - ground as shown in Table 1?
YES
2
Is resistance between L/C-PS NO Defective lock-up clutch
• Disconnect L/C-PS. (male) (1) - (2) and between (1) - solenoid Replace
(female) (10) and L/C-PS (female)
(20) and L/C-PS (female) (2)
3
• Disconnect ATC2 and Is voltage between ATC2 NO between ATC2 (female) (10) and Repair or
L/C-PS. (female) (10)(20) - ground less L/C-PS (female) (1) or between replace
• Turn starting switch ON. than 1 V? ATC2 (female) (20) and L/C-PS
(female) (2)
YES
controller
Table 1 Table 2
ATC2 (female) Resistance value L/C-PS (male) Resistance value
HM300-1 20-529
1 c
(9) c
TM-80 FAILURE CODE [DXH2KA] (SOLENOID FOR HI CLUTCH: DISCONNECTION (KA))
★ Nature of failure: No electric current flows when there is output to the Hi clutch solenoid
Cause Remedy
1
YES
controller
2
Replace
• Turn starting switch OFF. Is resistance between H-PS (male) NO Defective Hi clutch solenoid
• Disconnect H-PS. (1) and (2) 5 – 15 Ω?

(female) (4) and H-PS (female) (1) Repair or
or between ATC2 (female) (15) replace
and H-PS (female) (2)
20-530 HM300-1
c 1 c
TM-81 FAILURE CODE [DXH2KB] (SOLENOID FOR HI CLUTCH: SHORT CIRCUIT (KB))
★ Nature of failure:An extremely large electric current flows when there is output to the Hi clutch solenoid or
electric current flows when it is OFF
Cause Remedy
1
• Disconnect ATC2. (female) (4) - (15) and between (4)
YES
2
Is resistance between H-PS NO Defective Hi clutch solenoid
• Disconnect H-PS. (male) (1) - (2) and between (1) - Replace
(female) (4) and H-PS (female)
(15) and H-PS (female) (2)
3
• Disconnect ATC2 and H- Is voltage between ATC2 NO between ATC2 (female) (4) and H- Repair or
PS. (female) (4)(15) - ground less PS (female) (1) or between ATC2 replace
• Turn starting switch ON. than 1 V? (female) (15) and H-PS (female)
(2)
YES
controller
Table 1 Table 2
ATC2 (female) Resistance value H-PS (male) Resistance value

HM300-1 20-531
1 c
(9) c
TM-82 FAILURE CODE [DXH3KA] (SOLENOID FOR LO CLUTCH: DISCONNECTION (KA))
★ Nature of failure: No electric current flows when there is output to the Lo clutch solenoid
Cause Remedy
1
YES
controller
2
NO Defective Lo clutch solenoid Replace
• Turn starting switch OFF. Is resistance between L-PS (male)
• Disconnect L-PS. (1) and (2) 5 – 15 Ω?

(female) (7) and L-PS (female) (1) Repair or
and L-PS (female) (2)
20-532 HM300-1
c 1 c
TM-83 FAILURE CODE [DXH3KB] (SOLENOID FOR LO CLUTCH: SHORT CIRCUIT (KB))
★ Nature of failure:An extremely large electric current flows when there is output to the Lo clutch solenoid or
Cause Remedy
1
YES
2
Is resistance between L-PS NO
• Disconnect L-PS. (male) (1) - (2) and between (1) - Defective Lo clutch solenoid Replace
(female) (7) and L-PS (female) (1)
or short circuit in wiring harness replace
between ATC2 (female) (17) and
L-PS (female) (2)
3
• Disconnect ATC2 and L- Is voltage between ATC2 NO between ATC2 (female) (7) and L- Repair or
• Turn starting switch ON. than 1 V? (female) (17) and L-PS (female)
(2)
YES
controller
Table 1 Table 2
ATC2 (female) Resistance value L-PS (male) Resistance value
HM300-1 20-533
1 c
(9) c
TM-84 FAILURE CODE [DXH4KA] (SOLENOID FOR 1ST CLUTCH: DISCONNECTION (KA))
★ Nature of failure: No electric current flows when there is output to the 1st clutch solenoid
Cause Remedy
1
YES
controller
2
NO Defective 1st clutch solenoid Replace
• Turn starting switch OFF. Is resistance between 1-PS (male)
• Disconnect 1-PS. (1) and (2) 5 – 15 Ω?

(female) (2) and 1-PS (female) (1) Repair or
and 1-PS (female) (2)
20-534 HM300-1
c 1 c
TM-85 FAILURE CODE [DXH4KB] (SOLENOID FOR 1ST CLUTCH: SHORT CIRCUIT (KB))
★ Nature of failure:An extremely large electric current flows when there is output to the 1st clutch solenoid or
Cause Remedy
1
YES
2
Is resistance between 1-PS NO
• Disconnect 1-PS. (male) (1) - (2) and between (1) - Defective 1st clutch solenoid Replace
(female) (2) and 1-PS (female) (1)
1-PS (female) (2)
3
• Disconnect ATC2 and 1- Is voltage between ATC2 NO between ATC2 (female) (2) and 1- Repair or
• Turn starting switch ON. than 1 V? (female) (13) and 1-PS (female)
(2)
YES
controller
Table 1 Table 2
ATC2 (female) Resistance value 1-PS (male) Resistance value

HM300-1 20-535
1 c
(9) c
TM-86 FAILURE CODE [DXH5KA] (SOLENOID FOR 2ND CLUTCH: DISCONNECTION (KA))
★ Nature of failure: No electric current flows when there is output to the 2nd clutch solenoid
Cause Remedy
1
YES
controller
2
NO Defective 2nd clutch solenoid Replace
• Turn starting switch OFF. Is resistance between 2-PS (male)
• Disconnect 2-PS. (1) and (2) 5 – 15 Ω?

20-536 HM300-1
c 1 c
TM-87 FAILURE CODE [DXH5KB] (SOLENOID FOR 2ND CLUTCH: SHORT CIRCUIT (KB))
★ Nature of failure:An extremely large electric current flows when there is output to the 2nd clutch solenoid or
Cause Remedy
1
YES
2
• Disconnect 2-PS. (male) (1) - (2) and between (1) - Defective 2nd clutch solenoid Replace
2-PS (female) (2)
3
(2)
YES
controller
Table 1 Table 2
HM300-1 20-537
1 c
(9) c
TM-88 FAILURE CODE [DXH6KA] (SOLENOID FOR 3RD CLUTCH: DISCONNECTION (KA))
★ Nature of failure: No electric current flows when there is output to the 3rd clutch solenoid
Cause Remedy
1

controller
2
• Disconnect 3-PS. (1) and (2) 5 – 15 Ω? Defective 3rd clutch solenoid Replace

20-538 HM300-1
c 1 c
TM-89 FAILURE CODE [DXH6KB] (SOLENOID FOR 3RD CLUTCH: SHORT CIRCUIT (KB))
★ Nature of failure:An extremely large electric current flows when there is output to the 3rd clutch solenoid or
Cause Remedy
1
YES
2
• Disconnect 3-PS. (male) (1) - (2) and between (1) - Defective 3rd clutch solenoid Replace
3-PS (female) (2)
3
(2)
YES
controller
Table 1 Table 2
HM300-1 20-539
1 c
(9) c
TM-90 FAILURE CODE [DXH7KA] (SOLENOID FOR R CLUTCH: DISCONNECTION (KA))
★ Nature of failure: No electric current flows when there is output to the R clutch solenoid
Cause Remedy
1
YES
controller
2
• Turn starting switch OFF. Is resistance between R-PS (male) NO
• Disconnect R-PS. (1) and (2) 5 – 15 Ω? Defective R clutch solenoid Replace

(female) (5) and R-PS (female) (1) Repair or
and R-PS (female) (2)
20-540 HM300-1
c 1 c
(9)
TM-91 FAILURE CODE [DXH7KB] (SOLENOID FOR R CLUTCH: SHORT CIRCUIT (KB))
★ Nature of failure:An extremely large electric current flows when there is output to the R clutch solenoid or
Cause Remedy
1
YES
2
Is resistance between R-PS NO
• Disconnect R-PS. (male) (1) - (2) and between (1) - Defective R clutch solenoid Replace
(female) (5) and R-PS (female) Repair or
(15) and R-PS (female) (2)
• Disconnect ATC2 and R- Is voltage between ATC2 NO between ATC2 (female) (5) and R- Repair or
• Turn starting switch ON. than 1 V? (female) (15) and R-PS (female)
(2)
YES
controller
Table 1 Table 2
ATC2 (female) Resistance value R-PS (male) Resistance value
Between (5) and (15) 5 - 15 Ω Between (1) and (2) 5 - 15 Ω
HM300-1 20-541
1 c
(9) c
TM-92 BACKUP LAMP, BACKUP BUZZER DO NOT WORK PROPERLY
★ Nature of failure: Backup lamp or backup buzzer do not work properly (no failure code is displayed)
a)Even when gearshift lever is operated to R1 or R2, backup lamp and backup buzzer do not work
★ The lamp and buzzer GND circuits are centralized at joint connector (CJK), so check that the continuity is
normal.
Cause Remedy
1
• Turn starting switch ON. backup lamp and buzzer relay (R05) is
YES
Defective backup lamp, buzzer Replace
relay (R05)
2
• Disconnect R05.
Is voltage between R05 (female) NO disconnection in wiring harness Repair or
• Gearshift lever: R1, R2 (5) and ground 20 - 30 V? between R05 (female) (5) and replace
wiring harness at dividing point
YES
3
Is resistance between R05 Defective contact or
NO
• Turn starting switch OFF. (female) (6) and ground less disconnection in wiring harness Repair or
• Disconnect R05. between R05 (female) (6) and
than 1 Ω? replace
ground
YES
• Disconnect R05. between BT1-16 outlet and R05
• Turn starting switch ON. (2)(4) - ground 20 - 30 V? replace
(female) (2) (4)

disconnection in wiring harness Repair
between CJK (female) (6) and replace
ground
b) Backup lamp and backup buzzer do not work when gearshift lever is operated to R1 (work normally
at R2)
Cause Remedy
between SF1 (female) (4) - D06 replace
- wiring harness at dividing point
c) Backup lamp and backup buzzer do not work when gearshift lever is operated to R2 (work normally
at R1)
Cause Remedy
between SF1 (female) (3) - D05 replace
- wiring harness at dividing point
20-542 HM300-1
c 1 c
(9)
d) Backup lamp do not work (Backup buzzer works normally)
Cause Remedy
1
Do back-up lamps light up normally, NO
• Turn starting switch ON. if the back-up lamp and alarm buzzer
relay (R05) is replaced with another?
YES
Back-up lamp and alarm buzzer Replace
relay (R05) faulty
2
• Turn starting switch ON. Is voltage between BL47 (1) and NO
• Gearshift lever: R1, R2 grounding 20 – 30 V? Wiring harness between R05 Repair or
(female) (1) and BL47 (female) (1) replace
either disconnected or connected
defectively
YES
3
• Turn starting switch OFF. Is resistance value of the wiring harness NO
• Disconnect BL47 and CJK. between BL47 (female) (2) and CJK Wiring harness between BL47 Repair or
(female) (5) less than 1Ω? (female) (2) and CJK (female) (5) replace
either disconnected or connected
YES defectively
Back-up lamps faulty Replace
e) Backup buzzer do not work (Backup lamp works normally)
Cause Remedy
1
Does back-up alarm buzzer sound normally, if NO
• Turn starting switch ON. the back-up lamp and alarm buzzer relay
(R05) is replaced with another?
YES
Back-up lamp and alarm buzzer Replace
relay (R05) faulty
2
• Turn starting switch ON. Is voltage between the back-up alarm NO
• Gearshift lever: R1, R2 buzzer terminal (49) and grounding 20
– 30 V?
YES
3
NO Wiring harness between R05 (female) Repair or
• Turn starting switch ON. Is voltage between CJK (8) and (3) and CJK (female) (8) either
• Gearshift lever: R1, R2 grounding 20 – 30 V? replace
disconnected or connected defectively
YES Wiring harness between back-up
alarm buzzer terminal 49 and CJK Repair or
(female) (1) either disconnected or replace
connected defectively
4
• Turn starting switch OFF. Is resistance value of the wiring harness NO Wiring harness between back-up
• Disconnect terminal 41 between back-up lamp and buzzer terminal 41 Repair or
alarm buzzer terminal 41 and CJK
and CJK. and CJK (female) (7) less than 1 Ω? replace
(female) (7) either disconnected or
YES
connected defectively
Back-up alarm buzzer faulty Replace
HM300-1 20-543
(9)
1 c c
f) Gearshift lever is not operated to R1 or R2, but backup lamp and backup buzzer are actuated
Cause Remedy
1
• Turn starting switch ON. backup lamp and buzzer relay (R05)
YES Defective backup lamp, buzzer Replace
relay (R05)
2
• Disconnect R05. Is voltage between R05 Hot short in wiring harness between
NO
• Gearshift lever: Other (female) (5) and ground less R05 (female) (5) - D05 (female) (1) Repair or
than 1 V? - D06 (female) (1) replace
than R1, R2
YES
3
Is voltage between R05 (female) NO Hot short in wiring harness between
R05 (female) (1) and BL47 (female) Repair or
• Disconnect R05.
(1)
YES
Hot short in wiring harness between Repair or
R05 (female) (3) and backup buzzer replace
20-544 HM300-1
! (9)
1 !
TM-93 EMERGENCY STEERING DOES NOT OPERATE
Failure content (1) When steering pump stops, automatic emergency steering does not operate.
General
Check that the parking brake is released.
information
Causes Standard values when normal and remarks for troubleshooting

If fuse (16) is broken, circuit probably has ground fault. (Check it in
1 Defective fuse (16)
item 8.)
a Prepare with starting switch OFF, then start engine and carry
out troubleshooting.
• Connect T-adapter to B17 (male).
Defective parking brake Resis-
2 B17 (male) Operation of parking brake
switch (Internal contact) tance
Released (Closed) Max. 1 z
Between (1) – (2)
Operated (Open) Min. 1 Mz
a Prepare with starting switch OFF, then start engine and carry
out troubleshooting.
• Connect T-adapter to E02 (male).
Defective flow switch Resis-
3 E02 (male) Steering pump
(Internal contact) tance
Operated (Open) Min. 1 Mz
Between (1) – (2)
Stopped (Closed) Max. 1 z
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
1) Between relay terminal (7) – ground Voltage 20 – 30V
Defective emergency 2) Between relay terminal (8) – ground Voltage 20 – 30V
Possible causes 4
steering timer 3) Between relay terminal (6) – ground Voltage 20 – 30V
and the
standard values • If voltage is normal in 1) above and abnormal 2) and 3), timer is
when normal defective.
• If voltage is abnormal in 1), carry out troubleshooting in item 7.
Defective emergency a Prepare with starting switch OFF, then carry out troubleshoot-
5
steering relay ing without turning starting switch ON.
Resis-
4) Between relay terminal (58) – ground Max. 1 z
tance
• If voltage is normal in 1), 3) and 4) above and abnormal 2), relay
is defective.
• If voltage is abnormal in 1), carry out troubleshooting in item 7
Between motor terminal M-2 – ground Voltage 20 – 30V
Defective emergency a Prepare with starting switch OFF, then carry out troubleshoot-
6
steering motor ing without turning starting switch ON.
Between motor terminal E-2 – ground Voltage 20 – 30V
• If result of above troubleshooting is normal, starting motor is
defective.
HM300-1 20-545
(10)
1 Å Å

a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.
Wiring harness between fuse (16) – B17 Resis-
Max. 1 z
(female) (1) tance
Wiring harness between B17 (female) (2) – Resis-
Max. 1 z
CJR (female) (1) tance
Wiring harness between CJR (female) (2) – Resis-
Max. 1 z
E02 (female) (2) tance
Wiring harness between E02 (female) (1) – Resis-
Max. 1 z
timer terminal (7) tance
Disconnection in wiring
Wiring harness between timer terminal (8) – Resis-
7 harness (Disconnection in Max. 1 z
relay terminal (61) tance
wiring or defective contact)
Wiring harness between relay terminal (77) Resis-
Max. 1 z
– motor terminal M-2 tance
Wiring harness between timer terminal (2) – Resis-
Max. 1 z
ground tance
Wiring harness between motor terminal e-2 Resis-
Possible causes Max. 1 z
– ground tance
and the
standard values Wiring harness between relay terminal (58) Resis-
Max. 1 z
when normal – ground tance
Wiring harness between relay terminal (74) Resis-
Max. 1 z
– battery (+) tance
Between wiring harness fuse (16) – B17 Resis-
Min. 1 Mz
(female) (1) and ground tance
Between wiring harness B17 (female) (2) – Resis-
Min. 1 Mz
CJR (female) (1) and ground tance
Between wiring harness CJR (female) (2) – Resis-
Ground fault in wiring Min. 1 Mz
E02 (female) (2) and ground tance
8 harness
(Contact with GND circuit) Between wiring harness E02 (female) (1) – Resis-
Min. 1 Mz
timer terminal (7) and ground tance
Between wiring harness timer terminal (8) – Resis-
Min. 1 Mz
relay terminal (61) and ground tance
Between wiring harness relay terminal (77) Resis-
Min. 1 Mz
– motor terminal M-2 and ground tance
Between wiring harness timer terminal (6) – Resis-
Min. 1 Mz
manual switch terminal ST1 and ground tance
20-546 HM300-1
Å (10)
1 Å
Failure content (2) When steering pump stops, emergency steering cannot be operated manually.
General Carry out following troubleshooting when automatic emergency steering operates. (If automatic emer-
information gency steering does not operate either, carry out troubleshooting for trouble (1) first.)

Defective manual switch Manual switch Operation of manual
1 Resistance
(Internal contact) terminal switch
Possible causes Switch (Pressed) Max. 1 z
Between ST1 – ST2
and the
(Switch unit) Switch (Released) Min. 1 Mz
standard values
when normal a Prepare with starting switch OFF, then carry out troubleshoot-
Disconnection in wiring ing without turning starting switch ON.
harness (Disconnection in Wiring harness between timer terminal (6) – Resis-
2 Max. 1 z
wiring or defective contact in manual switch terminal ST1 tance
connector) Wiring harness between manual switch ter- Resis-
Max. 1 z
minal ST2 – relay terminal (61) tance
HM300-1 20-547
(10)
1 Å Å
TROUBLESHOOTING OF
RETARDER CONTROLLER(q1)
SYSTEM (BK MODE)
BK MODE RELATED ELECTRICAL CIRCUIT DIAGRAM ...................................................................... 20-604

BK-1 Failure code [2G42ZG] (Accumulator (front): Drop in oil pressure (ZG)) ................................. 20-622
BK-2 Failure code [2G43ZG] (Accumulator (rear): Drop in oil pressure (ZG)) .................................. 20-622
BK-3 Failure code [D1C0KZ] (Brake cut relay: Disconnection or short circuit (KZ)) ......................... 20-623
BK-4 Failure code [D5ZFKZ] (Neutral signal 1: Disconnection or short circuit (KZ)) ........................ 20-625
BK-5 Failure code [D5ZGKZ] (Neutral signal 2: Disconnection or short circuit (KZ)) ........................ 20-626
BK-6 Failure code [DB10KK] (Retarder controller: Drop in power supply voltage, input (KK)) ......... 20-627
BK-7 Failure code [DB11KK] (Retarder controller main power supply line: Drop in power supply
voltage, input (KK)) ............................................................................ 20-629
BK-8 Failure code [DB12KK] (Retarder controller load power supply line:
Drop in power supply voltage, input (KK)) ......................................... 20-630
BK-9 Failure code [DB13KK] (Retarder controller battery direct power supply line:
Drop in power supply voltage, input (KK)) ......................................... 20-631
BK-10 Failure code [DB19KM] (Retarder controller wiring harness:
Mistaken operation or mistaken setting (KM)) ................................... 20-632
BK-11 Failure code [DB1SKQ] (Retarder controller S-NET line:
Model selection signal mismatch (KQ)) ............................................ 20-633
BK-12 Failure code [DHU2KX] (Accumulator oil pressure sensor (front):
Input signal outside range (KX)) ........................................................ 20-634
BK-13 Failure code [DHU3KX] (Accumulator oil pressure sensor (rear):
Input signal outside range (KX)) ........................................................ 20-636
BK-14 Failure code [DK51L5] (Retarder lever potentiometer: * See separate table (L5)) .................. 20-638
BK-15 Failure code [DK52KX] (Dump lever potentiometer 1: Input signal outside range (KX)) .......... 20-641
BK-16 Failure code [DK53L8] (Dump lever potentiometer 2: * See the table in Contents. (L8)) ......... 20-643
BK-17 Failure code [DK54KX] (Body positioner sensor: Input signal outside range (KX)) ................. 20-644
BK-18 Failure code [DLF4KA] (Transmission output shaft F speed sensor: Disconnection (KA)) ...... 20-646
BK-19 Failure code [DLT3KA] (Transmission output shaft R speed sensor: Disconnection (KA)) ...... 20-647
BK-20 Failure code [DW71KZ] (Exhaust brake solenoid: Disconnection or short circuit (KZ)) ........... 20-648
BK-21 Failure code [DW72KZ] (Dump lever kick-out solenoid: Disconnection or short circuit (KZ)) .. 20-649
BK-22 Failure code [DW73KZ] (Dump selector valve solenoid: Disconnection or short circuit (KZ)) . 20-651
BK-23 Failure code [DX11KA] (Rear brake pressure reducing valve
solenoid: Disconnection (KA)) ........................................................... 20-653
BK-24 Failure code [DX11KB] (Rear brake pressure reducing valve solenoid:
Short circuit (KB)) .............................................................................. 20-654
BK-25 Failure code [DX11KY] (Rear brake pressure reducing valve solenoid:
Short circuit in power supply line (KY)) ............................................. 20-655
BK-26 Failure code [DX12KA] (Front brake pressure reducing valve solenoid: Disconnection (KA)) . 20-656
BK-27 Failure code [DX12KB] (Front brake pressure reducing valve solenoid: Short circuit (KB)) .... 20-657
BK-28 Failure code [DX12KY] (Front brake pressure reducing valve solenoid:
Short circuit in power supply line (KY)) ............................................. 20-658
BK-29 Failure code [DX13KA] (Dump EPC valve solenoid: Disconnection (KA)) ............................... 20-659
BK-30 Failure code [DX13KB] (Dump EPC valve solenoid: Short circuit (KB)) .................................. 20-660
BK-31 Failure code [DX13KY] (Dump EPC valve solenoid: Short circuit in power supply line (KY)) .. 20-661
BK-32 Parking brake does not work properly ...................................................................................... 20-662
HM300-1 20-601
1 c
4
(9) c
TROUBLESHOOTING
* Failure phenomena of L Series problem codes (L*)*
Problem code Nature of problem (phenomenon, nature of problem that occurs)
L0 Fill signals on 2 or more channels for clutches not forming a set are input at same time
L1 Fill signal is ON when command current to ECMV is OFF
L2 Fuel pressure is higher than maximum set pressure
L3 Corresponding component cannot be controlled
L4 ON/OFF signals for 2 systems do not match
L5 Potentiometer signal and switch signal do not match
Engine speed signal, terminal C signal, signals for oil pressure switch, coolant temperature switch, etc.
L6
do not match operating condition or stopped condition of machine
L8 Analog signals for 2 systems do not match
LC Speed signals for 2 systems do not match
LH Fill signal is OFF when command current to ECMV is ON
20-602 HM300-1
c 1 c
(9)
TROUBLESHOOTING
TROUBLESHOOTING BK MODE RELATED ELECTRICAL CIRCUIT DIAGRAM
BK MODE RELATED ELECTRICAL CIRCUIT DIAGRAM
20-604 HM300-1
! 1 !
TROUBLESHOOTING
★ This circuit diagram has been made by extracting the retarder controller related circuits and parking brake
related circuits from the overall electrical circuit diagram.
HM300-1 20-605
1 c
(9) c
TROUBLESHOOTING
20-606 HM300-1
c 1 c
TROUBLESHOOTING
HM300-1 20-607
1 ! !
TROUBLESHOOTING
20-608 HM300-1
! 1 !
TROUBLESHOOTING

2G42ZG Accumulator (front): With engine running (continu- • Defective hydraulic, mechanical system
(BK-1) Drop in oil pressure (ZG) ously for at least 30 seconds), oil of front accumulator
pressure of less than 6.86 MPa
{70 kg/cm2} was input for front
accumulator oil pressure sensor
signal
2G43ZG Accumulator (rear): Drop in With engine running (continu- • Defective hydraulic, mechanical system
(BK-2) oil pressure (ZG) ously for at least 30 seconds), oil of rear accumulator
pressure of less than 6.86 MPa
{70 kg/cm2} was input for rear
accumulator oil pressure sensor
signal
D1C0KZ Brake cut relay: Disconnec- When output is sent to brake cut • Defective brake cut relay
(BK-3) tion or short circuit (KZ) relay circuit, excessive electric • Disconnection, short circuit with chassis
current flows; when there is out- ground, or hot short in relay signal circuit
put, no electric current flows; wiring harness
when output is OFF, electric cur- • Disconnection in relay GND circuit wiring
rent flows harness
D5ZFKZ Neutral signal 1: Disconnec- When output is sent to neutral • Defective transmission controller
(BK-4) tion or short circuit (KZ) signal 1 circuit, excessive elec- • Disconnection or short circuit with chas-
tric current flows; when there is sis ground in signal 1 circuit wiring har-
output, no electric current flows ness
D5ZGKZ Neutral signal 2: Disconnec- When output is sent to neutral • Defective transmission controller
(BK-5) tion or short circuit (KZ) signal 2 circuit, excessive elec- • Disconnection or short circuit with chas-
tric current flows; when there is sis ground in signal 2 circuit wiring har-
output, no electric current flows ness
DB10KK Retarder controller(q1): Drop Both main power source voltage • Other problem occurs at same time (fail-
(BK-6) in power source voltage, in- circuit and direct power source ure code AB00MA is displayed)
put (KK) voltage circuit went below 17 V • Battery tends to lose power
sis ground in power source circuit
• wiring harness
ness
DB11KK Retarder controller(q1) main Voltage difference between • Disconnection or short circuit with chas-
(BK-7) power supply line: Drop in main power source voltage cir- sis ground in main power source circuit
power supply voltage, input cuit and direct power source wiring harness
(KK) voltage went below 5 V (main • Defective retarder controller(q1)
power source < direct power
source)
DB12KK Retarder controller(q1) load When controller power source • Defective brake cut relay
(BK-8) power supply line: Drop in voltage circuit was normal, sole- • Disconnection or short circuit with chas-
power supply voltage, input noid power source voltage cir- sis ground in relay power source circuit
(KK) cuit went below 17 V wiring harness
sis ground in relay output circuit wiring
harness
20-610 HM300-1
c 4 c
1
(9)
TROUBLESHOOTING
• Takes no action • If the machine is used as it is, E03
there is danger that the brake will
lose its effect
• Takes no action • If the machine is used as it is, E03

there is danger that the brake will
lose its effect
• Relay resistance value • Turns output to brake cut relay • The whole system of the retarder E03
R14 (male) (1) – (2): 100 – 500Ω OFF controller(q1) stops working (re-
tarder, inter-axle differential lock,
dump, exhaust brake, neutral sig-
nal)
• Failure codes (DB12KK,
DHU2KX, DHU3KX) are dis-
played at same time
• Turns neutral signal 1 and sig- • Even when transmission output E01
nal 2 OFF shaft F speed goes above 4200
rpm, the transmission does not
shift to N
• Turns neutral signal 1 and sig- • Even when transmission output E01
nal 2 OFF shaft F speed goes above 4200
shift to N
• Main power source voltage • Takes no action (moves as • No great effect on machine E03
BRC1 (9)(17) – (8)(16): 20 – 30 V long as it is possible to actu-
• Direct power source voltage ate)
BRC1 (7) – (8)(16): 20 – 30 V
• Main power source voltage • Takes no action • No great effect on machine E03
BRC1 (9)(17) – (8)(16): 20 – 30 V
• Solenoid power source voltage • Turns all output circuits OFF • The whole system of the retarder E03
BRC2 (1)(12) – BRC1 (8)(16): • Turns 24V power supply of controller(q1) stops working (re-
20 – 30 V sensor OFF tarder, inter-axle differential lock,
nal)
• Failure codes (DHU2KX,
DHU3KX) are displayed at same
time
HM300-1 20-611
1 c
4
(9) c
TROUBLESHOOTING
DB13KK Retarder controller(q1) bat- Voltage of direct power source • Disconnection or short circuit with chas-
(BK-9) tery direct power supply line: voltage circuit went below 5 V sis ground in direct power source circuit
Drop in power supply voltage, wiring harness
input (KK) • Defective retarder controller(q1)
DB19KM Retarder controller(q1) wir- When starting switch is ON, in- • Mistaken connection of connector BRC3
(BK-10) ing harness: Mistaken opera- put connector check signal does (A, B) and connector BRC5 (A, B) (when
tion or mistaken setting (KM) not match setting inside control- system is working normally)
ler • Disconnection in signal 2 circuit wiring
harness
DB1SKQ Retarder controller(q1) S- Communication (S-NET) with • Other problem occurs at same time (fail-
(BK-11) NET line: Model selection sig- transmission controller is defec- ure codes [DAFSKQ] [DAQAKR]
nal mismatch (KQ) tive and it is impossible to obtain [DAQSKQ] is displayed)
model selection data • Disconnection in S-NET circuit wiring
harness
• Defective retarder controllerr(q1)
DHU2KX Accumulator oil pressure Voltage of signal circuit of front • Defective front accumulator oil pressure
(BK-12) sensor (front): Input signal accumulator oil pressure sensor sensor
outside range (KX) went below 0.5 V or above 4.5 V • Disconnection or short circuit with chas-
wiring harness
ing harness
cuit wiring harness
DHU3KX Accumulator oil pressure Voltage of signal circuit of rear • Defective rear accumulator oil pressure
(BK-13) sensor (rear): Input signal accumulator oil pressure sensor sensor
outside range (KX) went below 0.5 V or above 4.5 V • Disconnection or short circuit with chas-
wiring harness
ing harness
cuit wiring harness
20-612 HM300-1
c 4 c
1
(9)
TROUBLESHOOTING
• Direct power source voltage • Takes no action • No great effect on machine E03
BRC1 (7) – (8)(16): 20 – 30 V
• Wiring harness resistance value • Turns all outputs OFF • The whole system of the retarder E03
BRC5A (female) (1) – ground: • Does not record in trouble data controller(q1) stops working (re-
Max. 1Ω tarder, inter-axle differential lock,
nal)
played at same time
• Only inter-axle differential lock • Inter-axle differential lock system E03

system is not controlled does not work
• Sensor power source voltage • Takes no action • No great effect on machine E01
B25 (2) – (1): 20 – 30 V
B25 (3) – (1): 000 – 000 V
• Sensor power source voltage • Takes no action • No great effect on machine E01
B24 (2) – (1): 20 – 30 V
B24 (3) – (1): 1.8 – 3.5 V
HM300-1 20-613
1 c
4
(9) c
TROUBLESHOOTING
DK51L5 Retarder lever potentiometer: Signal voltage of potentiometer • Defective retarder lever(q2) (potentiom-
(BK-14) * See separate table (L5) of retarder lever circuit went be- eter, switch)
low 0.3 V or above 4.7 V, or po- • Disconnection, short circuit with chassis
tentiometer signal and switch ground, or hot short in potentiometer
signal do not match power source circuit signal circuit wiring
harness
• Disconnection in potentiometer GND cir-
cuit wiring harness
ground, or hot short in potentiometer sig-
nal signal circuit wiring harness
ground, or hot short in switch 1 circuit
wiring harness
ground, or hot short in switch 2 circuit
wiring harness
ing harness
DK52KX Dump lever potentiometer 1: Voltage of potentiometer 1 sig- • Defective dump lever (potentiometer)
(BK-15) Input signal outside range nal circuit or potentiometer 2 sig- • Disconnection, short circuit with chassis
(KX) nal circuit went below 0.3 V or ground, or hot short in power source cir-
above 4.7 V cuit wiring harness
ness
ing harness
ing harness
DK53L8 Dump lever potentiometer 2: Total voltage of potentiometer 1 • Defective dump lever (potentiometer)
(BK-16) * See Contents (L8) signal circuit and potentiometer • Disconnection, short circuit with chassis
2 signal circuit went below 4.4 V ground, or hot short in power source cir-
or above 5.6 V cuit wiring harness
ness
ing harness
ing harness

q2. The lever is not installed in E-SPEC.
20-614 HM300-1
c 4 c
1
(9)
TROUBLESHOOTING
• Potentiometer power source Depending on condition of occur- Depending on nature of action E03
voltage rence of failure • No great effect on machine
RTL (1) – (3): 4.1 – 4.8 V • Carries out control with poten- • Fine control of retarder is impossi-
• Potentiometer signal voltage tiometer signal ble (which is not used in E-SPEC)
RTL (2) – (3): 0.3 – 4.7 V • Limits output to solenoid to • Retarder does not work (foot
• Switch resistance value 70% brake works) (which is not used in
(lever at RELEASED position) • Turns output to solenoid OFF E-SPEC)
• RTL (male) (4) – (6):
Max. 1Ω
• RTL (male) (5) – (6):
Min. 1 MΩ
• Switch resistance value (lever
at APPLIED position)
• RTL (male) (4) - (6):
Min. 1 MΩ
• RTL (male) (5) - (6): Max. 1Ω
• Potentiometer power source • Recognizes dump lever posi- • Dump body does not move E03
voltage tion as HOLD
HSL (4) – (1): 4.6 – 5.4 V
• Potentiometer signal voltage
HSL (3) – (1) (signal 1):
0.3 – 4.7 V
HSL (2) – (1) (signal 2):
0.3 – 4.7 V
• Potentiometer power source • Recognizes dump lever posi- • Dump body does not move E03
voltage tion as HOLD
HSL (4) – (1): 4.6 – 5.4 V
• Potentiometer signal voltage
HSL (3) – (1) (signal 1):
0.3 – 4.7 V
HSL (2) – (1) (signal 2):
0.3 – 4.7 V
HM300-1 20-615
1 c
4
(9) c
TROUBLESHOOTING
DK54KX Body positioner sensor: Input Voltage of body positioner sen- • Defective body positioner sensor
(BK-17) signal outside range (KX) sor signal circuit went below 0.3 • Disconnection, short circuit with chassis
V or above 4.7 V ground, or hot short in sensor power
source circuit wiring harness
ing harness
cuit wiring harness
DLF4KA Transmission output shaft F Disconnection has occurred in • Defective transmission output shaft F
(BK-18) speed sensor: Disconnection signal circuit of transmission speed sensor or defective adjustment
(KA) output shaft F speed sensor and • Disconnection in sensor signal wiring
signal is not input harness
ing harness
DLT3KA Transmission output shaft R Disconnection has occurred in • Defective transmission output shaft R
(BK-19) speed sensor: Disconnection signal circuit of transmission speed sensor or defective adjustment
(KA) output shaft R speed sensor and • Disconnection in sensor signal wiring
signal is not input harness
DW71KZ Exhaust brake solenoid: Dis- When output is sent to exhaust • Defective exhaust brake solenoid
(BK-20) connection or short circuit brake solenoid circuit, excessive • Disconnection, short circuit with chassis
(KZ) electric current flows; when ground, or hot short in solenoid signal cir-
(Machine with exhaust brake) there is output, no electric cur- cuit wiring harness
rent flows; when output is OFF, • Disconnection in solenoid GND circuit
electric current flows wiring harness
DW72KZ Dump lever kick-out solenoid: When output is sent to dump le- • Defective dump lever (kick-out solenoid)
(BK-21) Disconnection or short circuit ver kick-out solenoid circuit, ex- • Disconnection, short circuit with chassis
(KZ) cessive electric current flows; ground, or hot short in solenoid signal cir-
when there is output, no electric cuit wiring harness
current flows; when output is • Disconnection in solenoid GND circuit
OFF, electric current flows wiring harness
DW73KZ Dump selector valve sole- When output is sent to dump se- • Defective dump pilot valve (selector so-
(BK-22) noid: Disconnection or short lector valve solenoid circuit, ex- lenoid)
circuit (KZ) cessive electric current flows; • Disconnection, short circuit with chassis
when there is output, no electric ground, or hot short in solenoid signal cir-
current flows; when output is cuit wiring harness
OFF, electric current flows • Disconnection in solenoid GND circuit
wiring harness
20-616 HM300-1
c 4 c
1
(9)
TROUBLESHOOTING
• Sensor power source voltage • Carries out dump control ac- • There is a big shock when dump E03
B34 (3) – (1): 4.6 – 5.4 V cording to signal from dump le- body is seated
• Sensor signal voltage ver • Dump lever positioner function
B34 (2) – (1) • Recognizes that dump body is does not work
When seated: 0.30 – 0.46 V not seated when carrying out • Maximum travel speed range is
When fully raised: 4.00 – 4.70 V control limited
• Machine cannot travel in reverse
if dump lever is not at FLOAT
• Sensor resistance value • Cancels inter-axle differential • Inter-axle differential lock does E01
FE1 (male) (1) – (2): 500 – 1000Ω lock command not work
• Does not output neutral signal • Even when transmission output
shaft F speed goes above 4200
shift to N
• Sensor resistance value • Cancels inter-axle differential • Inter-axle differential lock does E01
N3 (male) (1) – (2): 500 – 1000Ω lock command not work
• Solenoid resistance value • Turns output to exhaust brake • Exhaust brake does not work E01
B29 (male) (1) – (2): 20 – 60Ω solenoid OFF
• Solenoid resistance value • Turns output to dump lever • Dump lever is not locked in detent E01
LKO (male) (1) – (2): 39Ω ± 5% kick-out solenoid OFF
• Solenoid resistance value • Turns output to dump selector • Dump body does not move E03
B31 (male) (1) – (2): 15 – 35Ω valve solenoid OFF
• Turns output to dump EPC
valve solenoid OFF
HM300-1 20-617
1 c
(9) c
TROUBLESHOOTING
DX11KA Rear brake pressure reduc- When output is sent to rear • Defective rear brake pressure reducing
(BK-23) ing valve solenoid: Discon- brake pressure reducing valve valve solenoid
nection (KA) solenoid circuit, no electric cur- • Disconnection in solenoid (+) circuit wir-
rent flows ing harness
ing harness
DX11KB Rear brake pressure reduc- When output is sent to rear • Defective rear brake pressure reducing
(BK-24) ing valve solenoid: Short cir- brake pressure reducing valve valve solenoid
cuit (KB) solenoid circuit, excessive elec- • Short circuit or short circuit with chassis
tric current flows ground in solenoid (+) circuit wiring har-
ness
DX11KY Rear brake pressure reduc- When output to rear brake pres- • Hot short in solenoid (+) circuit wiring
(BK-25) ing valve solenoid: Short cir- sure reducing valve solenoid cir- harness
cuit in power source line (KY) cuit is OFF, electric current flows • Hot short in solenoid (–) circuit wiring
harness
DX12KA Front brake pressure reduc- When output is sent to front • Defective front brake pressure reducing
(BK-26) ing valve solenoid: Discon- brake pressure reducing valve valve solenoid
nection (KA) solenoid circuit, no electric cur- • Disconnection in solenoid (+) circuit wir-
rent flows ing harness
ing harness
DX12KB Front brake pressure reduc- When output is sent to front • Defective front brake pressure reducing
(BK-27) ing valve solenoid: Short cir- brake pressure reducing valve valve solenoid
cuit (KB) solenoid circuit, excessive elec- • Short circuit or short circuit with chassis
tric current flows ground in solenoid (+) circuit wiring har-
ness
DX12KY Front brake pressure reduc- When output to front brake pres- • Hot short in solenoid (+) circuit wiring
(BK-28) ing valve solenoid: Short cir- sure reducing valve solenoid cir- harness
cuit in power source line (KY) cuit is OFF, electric current flows • Hot short in solenoid (–) circuit wiring
harness
DX13KA Dump EPC valve solenoid: When output is sent to dump • Defective dump pilot valve (EPC sole-
(BK-29) Disconnection (KA) EPC valve solenoid circuit, no noid)
electric current flows • Disconnection in solenoid (+) circuit wir-
ing harness
ing harness
20-618 HM300-1
c 4 c
1
(9)
TROUBLESHOOTING
• Solenoid resistance value • Turns output to rear brake • Rear brake (center brake) does E03
B18 (male) (1) – (2): 10 – 30Ω pressure reducing valve sole- not work
noid OFF
• Solenoid resistance value • Turns output to rear brake • Rear brake (center brake) does E03
B18 (male) (1) – (2): 10 – 30Ω pressure reducing valve sole- not work
noid OFF
• Turns output to rear brake • The whole system of the retarder E03
pressure reducing valve sole- controller(q1) stops working (re-
noid OFF tarder, inter-axle differential lock,
• Turns output to brake cut relay dump, exhaust brake, neutral sig-
OFF nal)
played at same time
• Solenoid resistance value • Turns output to front brake • Front brake does not work E03
B19 (male) (1) – (2): 10 – 30Ω pressure reducing valve sole-
noid OFF
• Solenoid resistance value • Turns output to front brake • Front brake does not work E03
B19 (male) (1) – (2): 10 – 30Ω pressure reducing valve sole-
noid OFF
• Turns output to front brake • The whole system of the retarder E03
pressure reducing valve sole- controller(q1) stops working (re-
noid OFF tarder, inter-axle differential lock,
• Turns output to brake cut relay left and right differential lock,
OFF dump, exhaust brake, neutral sig-
nal)
played at same time
• Solenoid resistance value • Turns output to dump selector • Dump body does not work E03
valve solenoid OFF
HM300-1 20-619
(9)
1 !
4 !
TROUBLESHOOTING
DX13KB Dump EPC valve solenoid: When output is sent to dump • Defective dump pilot valve (EPC sole-
(BK-30) Short circuit (KB) EPC valve solenoid circuit, ex- noid)
cessive electric current flows • Short circuit or short circuit with chassis
ground in solenoid (+) circuit wiring har-
ness
DX13KY Dump EPC valve solenoid: When output to dump EPC valve • Hot short in solenoid (+) circuit wiring
(BK-31) Short circuit in power source solenoid circuit is OFF, electric harness
line (KY) current flows • Hot short in solenoid (–) circuit wiring
harness
20-620 HM300-1
c 4 c
1
(9)
TROUBLESHOOTING
• Solenoid resistance value • Turns output to dump selector • Dump body does not work E03
valve solenoid OFF
• Turns output to dump selector • Dump body does not work E03
valve solenoid OFF
valve solenoid OFF
HM300-1 20-621
1 c
(9) c
TROUBLESHOOTING
TROUBLESHOOTING BK-1
BK-1, BK-2
BK-1 FAILURE CODE [2G42ZG] (ACCUMULATOR (FRONT): DROP IN OIL PRESSURE (ZG))
★ Nature of failure:With the engine running (continuously for at least 30 seconds), oil pressure of less than
6.86 MPa {70 kg/cm2} was input for the front accumulator oil pressure sensor signal
Cause Remedy
1
Defective retarder controller(q1)
See TESTING AND Has accumulator oil pressure NO
ADJUSTING. (brake oil pressure) dropped? Repair
YES Carry out

Defective hydraulic, mechanical troubleshooting
system of accumulator oil of mechanical
pressure (brake oil pressure) system
BK-2 FAILURE CODE [2G43ZG] (ACCUMULATOR (REAR): DROP IN OIL PRESSURE (ZG))
★ Nature of failure:With the engine running (continuously for at least 30 seconds), oil pressure of less than
6.86 MPa {70 kg/cm2} was input for the rear accumulator oil pressure sensor signal
Cause Remedy
1
Defective retarder controller(q1)
See TESTING AND Has accumulator oil pressure NO
ADJUSTING. (brake oil pressure) dropped? Repair
YES Defective hydraulic, mechanical Carry out

system of accumulator oil troubleshooting
pressure (brake oil pressure) of mechanical
system
20-622 HM300-1
! (9)
1 !
4
BK-3 FAILURE CODE [D1C0KZ] (BRAKE CUT RELAY: DISCONNECTION OR

SHORT CIRCUIT (KZ))
★ Nature of failure:When output is sent to the brake cut relay circuit, excessive electric current flows; when
there is output, no electric current flows; when the output is OFF, electric current flows
Cause Remedy
1
• Turn starting switch OFF. Is resistance between BRC1 (female) NO
• Disconnect BRC1. (13) and ground 100 - 500 MΩ?
YES
2
• Turn starting switch ON. brake cut relay (R14) is interchanged
with other relay?
YES
Defective brake cut relay (R14) Replace
3
• Disconnect BRC1 and Is resistance between BRC1 (female) NO ground in wiring harness be- Repair or
(13) and ground more than 1 MΩ? tween BRC1 (female) (13) and replace
R14. R14 (female) (1)
YES
4
NO Defective contact or disconnec-
• Turn starting switch OFF. Is resistance between R14 (female) tion in wiring harness between Repair or
• Disconnect R14. (2) and ground less than 1 MΩ? R14 (female) (2) and ground replace
.
between BRC1 (female) (13) and replace
R14 (female) (1)
5
NO Hot short in wiring harness
• Disconnect BRC1 Is voltage between BRC1 (female) between BRC1 (female) (13) Repair or
• Turn starting switch ON. (13) and ground less than 1 V? and R14 (female) (1) replace
YES
Defective retarder controller(G1) Replace
HM300-1 20-623
1 c
4
(9) c
BK-3 Related electrical circuit diagram
20-624 HM300-1
c 1 c
BK-4 FAILURE CODE [D5ZFKZ] (NEUTRAL SIGNAL 1: DISCONNECTION OR SHORT

CIRCUIT (KZ))
★ Nature of failure:When output is sent to the neutral signal 1 circuit, excessive electric current flows; when
there is output, no electric current flows
Cause Remedy
• Turn starting switch OFF. Is resistance between BRC1 NO disconnection in wiring
• Disconnect BRC1 and (female) (6) and ATC5A (female) (7) Repair or
harness between BRC1 replace
ATC5A. less than 1 Ω? (female) (6) and ATC5A
YES (female) (7)
2
• Turn starting switch OFF. Is resistance between BRC1 Short circuit with chassis
NO ground in wiring harness Repair or
• Disconnect BRC1 and (female) (6) and ground more than
ATC5A. 1 MΩ? between BRC1 (female) replace
YES
3
• Disconnect BRC1 and Is voltage between BRC1 (female) NO Hot short in wiring harness Repair or
ATC5A. (6) and ground less than 1 V? between BRC1 (female) (6) replace
• Turn starting switch ON. and ATC5A (female) (7)
YES
4
Does condition become normal
when retarder controller(G1) is
NO Defective transmission
• Turn starting switch ON. Repair
replaced? controller
YES
Defective retarder controller(G1) Repair
HM300-1 20-625
1 c
4
(9) c
BK-5 FAILURE CODE [D5ZGKZ] (NEUTRAL SIGNAL 2: DISCONNECTION OR

SHORT CIRCUIT (KZ))
★ Nature of failure:When output is sent to the neutral signal 2 circuit, excessive electric current flows; when
there is output, no electric current flows
Cause Remedy
• Turn starting switch OFF. Is resistance between BRC1 NO disconnection in wiring
• Disconnect BRC1 and (female) (15) and ATC5A (female) Repair or
harness between BRC1 replace
ATC5A. (8) less than 1 Ω? (female) (15) and ATC5A
YES (female) (8)
2
• Turn starting switch OFF. Is resistance between BRC1 Short circuit with chassis
NO ground in wiring harness Repair or
• Disconnect BRC1 and (female) (15) and ground more than
ATC5A. 1 MΩ? between BRC1 (female) replace
YES
3
• Disconnect BRC1 and NO Hot short in wiring harness
Is voltage between BRC1 (female) between BRC1 (female) (15) Repair or
ATC5A. (15) and ground less than 1 V? replace
• Turn starting switch ON. and ATC5A (female) (8)
YES
4
Does condition become normal
when retarder controller(G1) is
NO Defective transmission
• Turn starting switch ON. Repair
replaced? controller
YES
20-626 HM300-1
c 4 c
1
(9)
BK-6 FAILURE CODE [DB10KK] (RETARDER CONTROLLER: DROP IN POWER SUPPLY

VOLTAGE, INPUT (KK))
★ Nature of failure:Both the main power source voltage circuit and the direct power source voltage circuit went
below 17 V
Cause Remedy
1
• Turn starting switch ON. Is other failure code [AB00MA] NO
• Operate machine displayed or recorded at same time?
monitor.
YES Go to trouble-
Another problem is occurring at shooting for
the same time displayed
code
2
• Insert T-adapter to BRC1. Is voltage between BRC1 (7) and (8) (16) NO
• Start engine (mid-range and between BRC1 (4)(17) and (8) (16)
speed). 20 30 V?
YES
3
• Turn starting switch OFF. Is resistance between BRC1 (female) NO tion in wiring harness between Repair or
• Disconnect BRC1. (8)(16) and ground less than 1 Ω? BRC1 (female) (8) (16) and replace
ground
YES
4
Is voltage of battery more than 24V NO Defective battery or defective Charge or
and gravity more than 1.26? charge replace
between battery - battery relay - Repair or
retarder controller(q1) BRC1 replace
(female) (7) (4) (17)
HM300-1 20-627
(9)
4 !
1 !
20-628 HM300-1
c 1 c
BK-7 FAILURE CODE [DB11KK] (RETARDER CONTROLLER(q1) MAIN POWER SUPPLY

LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK))
★ Nature of failure:The voltage difference between the main power source voltage circuit and the direct power
source voltage went below 5 V (main power source < direct power source)
★ Before starting troubleshooting, check that the circuit breaker is not OFF, and that fuse BT3-12 is normal (if
the circuit breaker is OFF or the fuse is blown, there has probably been a surge of current caused by a short
circuit, so check the related circuits).
Cause Remedy
1
Is voltage between BRC1 (4)(17) NO
BRC1. and (8)(16) 20 - 30 V?
YES
2 Defective contact or disconnection

• Remove fuse BT3-12. in wiring harness between fuse Repair or
Is voltage between fuse BT3-12 NO replace
• Turn starting switch inlet and ground 20 - 30 V? BT3-12 inlet - circuit breaker -
ON. battery relay terminal M
YES Defective contact or disconnection
in wiring harness between fuse Repair or
BT3-12 outlet and BRC1 (female) replace
(4) (17
HM300-1 20-629
1 c
4
(9) c
q1) LOAD POWER SUPPLY

BK-8 FAILURE CODE [DB12KK] (RETARDER CONTROLLER(q
LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK))
★ Nature of failure:When the controller power source voltage circuit was normal, the solenoid power source
voltage circuit went below 17 V
Cause Remedy
1
• Turn starting switch ON. NO
Is other failure code [D1C0KZ]
• Operate machine
displayed or recorded at same time?
monitor.
Go to
YES trouble-
Another problem is occurring at
the same time shooting for
displayed
code
2
• Insert T-adapter to BRC1 NO
and BRC2. Is voltage between BRC2 (1)(12) - BRC1
• Turn starting switch ON. (8)(16) 20 - 30 V?
YES
3
• Turn starting switch ON. brake cut relay (R14) is interchanged
with other relay?
YES
Defective brake cut relay (R14) Replace
• Disconnect R14. Is voltage between R14 (female) (5) NO disconnection in wiring harness Repair or
• Turn starting switch ON. and ground 20 - 30 V? between fuse BT3-12 outlet replace
BRC2 (female) (1) (12)
20-630 HM300-1
! 1 !
4
q1) BATTERY DIRECT POWER

BK-9 FAILURE CODE [DB13KK] (RETARDER CONTROLLER(q
SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK))
★ Nature of failure:The voltage of the direct power source voltage circuit went below 5 V
★ Before starting troubleshooting, check that the fusible link and fuse BT2-22 are normal (if the fuse is blown,
there has probably been a surge of current caused by a short circuit, so check the related circuits).
Cause Remedy
1
• Insert T-adapter to BRC1. NO
Is voltage between BRC1 (7)
• Turn starting switch and (8)(16) 20 - 30 V?
OFF.
YES
• Remove fuse BT2-22. Is voltage between fuse BT2-22 NO disconnection in wiring harness Repair or
• Turn starting switch inlet and ground 20 - 30 V? between fuse BT2-22 inlet - replace
OFF. fusible link - battery relay
terminal B
YES
Defective contact or disconnection Repair or
in wiring harness between fuse replace
BT2-22 outlet and BRC1 (female)
(7)
HM300-1 20-631
1 c
4 c
BK-10 q1) WIRING HARNESS:

FAILURE CODE [DB19KM] (RETARDER CONTROLLER(q
MISTAKEN OPERATION OR MISTAKEN SETTING (KM))
★ Nature of failure:When the starting switch is ON, the input connector check signal does not match the setting
inside the controller
Cause Remedy
Are connectors BRC3 (A, B) and NO

• Turn starting switch OFF. BRC5 (A, B) connected in correct Mistaken connection of Connect
position? controller connector again
YES
Is resistance between BRC5A NO Defective contact or disconnection Repair or

• Turn starting switch OFF. in wiring harness between BRC5A
• Disconnect BRC5A. (female) (1) and ground less than replace
1Ω? (female) (1) and ground
YES
20-632 HM300-1
c 1 c
4
BK-11 FAILURE CODE [DB1SKQ] (RETARDER CONTROLLER(q1) S-NET LINE: MODEL

SELECTION SIGNAL MISMATCH (KQ))
★ Nature of failure:The communication (S-NET) with the transmission controller is defective and it is impossi-
ble to obtain the model selection data
Cause Remedy
1
• Turn starting switch ON. Is other failure code [DAFSKQ] NO
• Operate machine [DAQAKQ] [DAQSKR] displayed
monitor. or recorded at same time? Go to
YES Another problem is occurring at trouble-
the same time shooting for
displayed
code
2
• Turn starting switch when retarder controller is Defective transmission controller Replace
ON. replaced?
YES
HM300-1 20-633
1 c
4
(9) c
BK-12 FAILURE CODE [DHU2KX] (ACCUMULATOR OIL PRESSURE SENSOR (FRONT):

★ Nature of failure:The voltage of the signal circuit of the front accumulator oil pressure sensor went below 0.5
V or above 4.5 V
Cause Remedy
1
• Insert T-adapter to Is voltage between BRC3B (5) and NO
BRC3A and BRC3B. BRC3A (16) 0.5 - 4.5 V?
YES
2
• Disconnect B25. Is voltage between B25 (female) (2) NO
YES
3
• Turn starting switch OFF. NO ground in wiring harness be- Repair or
• Disconnect BRC1 and Is resistance between B25 (female)
(2) and ground more than 1 MΩ? tween BRC1 (female) replace
B25. (1) and B25 (female) (2)
YES
4
• Insert T-adapter to BRC1. NO Defective retarder controller(G1)
Is voltage between BRC1 (1) and Replace
• Disconnect B25 ground 20 - 30 V?
B25 (female) (2)
5
• Turn starting switch OFF. Is resistance between B25 (female) NO
• Disconnect B25. (1) and ground less than 1 Ω?
YES
• Turn starting switch OFF. Is resistance between BRC3A NO disconnection in wiring harness Repair or
• Disconnect BRC3A and (female) (16) and B25 (female) (1) between BRC3A (female) (16) replace
B25. less than 1 Ω? and B25 (female) (1)
YES
7
• Insert T-adapter to B25. Is voltage between B25 (3) and NO
between BRC3B (female) (5) replace
and B25 (female) (3)
8
• Disconnect BRC3B and NO Hot short in wiring harness
Is voltage between B25 (female) (3) between BRC3B (female) (5) Repair or
B25. and ground less than 1 V? replace
• Turn starting switch ON. and B25 (female) (3)
YES
9
• Turn starting switch OFF. NO Short circuit with chassis ground in
Is resistance between B25 (female) wiring harness between BRC3B Repair or
• Disconnect BRC3B and (3) and ground more than 1 MΩ? replace
B25. (female) (5) and B25 (female) (3)
Defective front accumulator oil

pressure sensor Replace
20-634 HM300-1
c 4 c
1
(9)
HM300-1 20-635
1 c c
BK-13 FAILURE CODE [DHU3KX] (ACCUMULATOR OIL PRESSURE SENSOR (REAR):

★ Nature of failure:The voltage of the signal circuit of the rear accumulator oil pressure sensor went below 0.5
V or above 4.5 V
Cause Remedy
1
YES
2
• Disconnect B24. Is voltage between B24 (female) (2) NO
YES
3
• Turn starting switch OFF. NO ground in wiring harness be- Repair or
• Disconnect BRC1 and Is resistance between B24 (female)
(2) and ground more than 1 MΩ? tween BRC1 (female) replace
B24. (1) and B24 (female) (2)
YES
4
• Insert T-adapter to BRC1. NO Defective retarder controller(G1)
Is voltage between BRC1 (1) and Replace
• Disconnect B24. ground 20 - 30 V?
B24 (female) (2)
5
YES
• Disconnect BRC3A and (female) (16) and B24 (female) (1) between BRC3A (female) (16) replace
B24. less than 1 Ω? and B24 (female) (1)
YES
7
8
• Disconnect BRC3B and NO Hot short in wiring harness
Is voltage between B24 (female) (3) between BRC3B (female) (6) Repair or
B24 and ground less than 1 V? replace
YES

• Turn starting switch OFF. Is resistance between B24 (female) NO in wiring harness between Repair or
• Disconnect BRC3B and (3) and ground more than 1 MΩ? BRC3B (female) (6) and B24 replace
B24. (female) (3)
Defective rear accumulator oil

pressure sensor Replace
20-636 HM300-1
c 4 c
1
(9)
HM300-1 20-637
1 c c
BK-14 FAILURE CODE [DK51L5] (RETARDER LEVER POTENTIOMETER:

* SEE SEPARATE TABLE (L5))
★ Nature of failure:The signal voltage of the potentiometer of the retarder lever circuit went below 0.3 V or
above 4.7 V, or the potentiometer signal and switch signal do not match
Cause Remedy
1
YES
2
• Insert T-adapter to RTL. Is voltage between RTL (1) and NO
YES
3
• Disconnect BRC2 and NO Hot short in wiring harness be-
RTL. Is voltage between RTL (female) (1) tween BRC2 (female) (16) and Repair or
and ground less than 1 V? RTL (female) (1) replace
YES
4
• Turn starting switch OFF. Is resistance between RTL (female) NO in wiring harness between BRC2 Repair or
• Disconnect BRC2 and (1) and ground more than 1 MΩ? (female) (16) and RTL (female) replace
RTL. (1)
YES
5
• Insert T-adapter to BRC2.
Is voltage between BRC2 (16) and NO
• Disconnect RTL.
ground 4.1 - 4.8 V?
YES in wiring harness between BRC2 Repair or
(female) (16) and RTL (female) (1) replace
(includes resistor)
6
• Turn starting switch OFF. Is resistance between RTL (female) NO
• Disconnect RTL. (3) and ground less than 1 Ω?
YES
7
• Disconnect BRC3A and (female) (16) and RTL (female) (3) between BRC3A (female) (16) replace
RTL. less than 1 Ω? and RTL (female) (3)
YES
8
• Insert T-adapter to RTL. Is voltage between RTL (2) and NO
and RTL (female) (2)
9
• Disconnect BRC3B and NO Hot short in wiring harness Repair or
Is voltage between RTL (female) (2) between BRC3B (female) (16)
RTL. and ground less than 1 V? replace
• Turn starting switch ON. and RTL (female) (2)
YES
10
• Turn starting switch OFF. Is resistance between RTL (female) NO in wiring harness between Repair or
• Disconnect BRC3B and (2) and ground more than 1 MΩ? BRC3B (female) (16) and RTL replace
RTL.
(female) (2)
YES
Defective retarder lever Replace
potentiometer

A
20-638 HM300-1
c 4 c
1
(9)
A
Cause Remedy
11
• Insert T-adapter to Is voltage between BRC5A (female) NO
BRC5A. (6) and ground, and between (7)
• Turn starting switch ON. and ground as shown in Table 1?
YES
12
Is resistance between RTL (male) (4) and NO
• Turn starting switch OFF. (6), and between (5) and (6) as Defective retarder lever switch Replace
• Disconnect RTL. shown in Table 2?
YES
13
• Turn starting switch OFF. Is resistance between RTL (female) NO tion in wiring harness between Repair or
• Disconnect RTL. (6) and ground less than 1 Ω? RTL (female) (6) and ground replace
YES short circuit with chassis ground, Repair or
or hot short in wiring harness replace
between BRC5A (female) (6) and
RTL (female) (4) or between
BRC5A (female) (7) and RTL
(female) (5)
Table 1 Table 2
Lever at Lever at Lever at RE- Lever at
BRC5A (female) RELEASED APPLIED RTL (male) LEASED APPLIED
position(q2) position(q2) position(q2) position(q2)
Between (6) and Between (4)
Max. 1 V 20 – 30V Max. 1Ω Max. 1MΩ
ground and (6)
Between (7) and Between (5)
20 – 30V Max. 1 V Max. 1MΩ Max. 1Ω
ground and (6)
q2. Since the lever is not installed in E-SPEC, insert a screwdriver in the hole for the lever
and move it to the RELEASE or APPLY position.
HM300-1 20-639
(9)
1 !
4 !
20-640 HM300-1
c 1 c
BK-15 FAILURE CODE [DK52KX] (DUMP LEVER POTENTIOMETER 1:

★ Nature of failure:The voltage of potentiometer 1 signal circuit or potentiometer 2 signal circuit went below
0.3 V or above 4.7 V
Cause Remedy
1
• Insert T-adapter to HSL. Is voltage between HSL (4) and (1) NO
• Turn starting switch ON. 4.6 - 5.4 V?
YES
2
• Disconnect HSL. Is voltage between HSL (4) and NO
YES
3
• Disconnect BRC3A and Hot short in wiring harness be-
HSL. Is voltage between HSL (female) (4) NO tween BRC3A (female) (6) and Repair or
and ground less than 1 V? HSL (female) (4) replace
YES
4
• Turn starting switch OFF. Is resistance between HSL (female) NO in wiring harness between Repair or
• Disconnect BRC3A and (4) and ground more than 1 MΩ? BRC3A (female) (6) and HSL replace
HSL. (female) (4)
YES
5
• Insert T-adapter to BRC3A. NO
• Disconnect HSL.
Is voltage between BRC3A (6) and Defective retarder controller(G1) Replace
ground 4.6 - 5.4 V?
in wiring harness between BRC3A replace
(female) (6) and HSL (female) (4)
6
• Turn starting switch OFF. Is resistance between HSL (female) NO
• Disconnect HSL. (1) and ground less than 1 Ω?
YES Defective dump lever

(potentiometer) Replace
7
• Turn starting switch OFF. Is resistance between BRC3A NO Defective contact or disconnection Repair or
• Disconnect BRC3A and (female) (16) and HSL (female) (1) in wiring harness between BRC3A replace
HSL. less than 1 Ω? (female) (16) and HSL (female) (1)
YES
8
YES
9
• Insert T-adapter to HSL. Is voltage between HSL (3) and NO
YES in wiring harness between Repair or
BRC3B (female) (12) and HSL replace
(female) (3)
• Disconnect BRC3B and Is voltage between HSL (3) and NO disconnection in wiring harness Repair or
HSL. ground less than 1 V? between BRC3B (female) (12) replace
• Turn starting switch ON. and HSL (female) (3)
YES
• Turn starting switch OFF. Is resistance between HSL (3) and NO in wiring harness between Repair or
• Disconnect BRC3B and ground more than 1 MΩ? BRC3B (female) (12) and HSL replace
HSL. (female) (3)
YES Defective dump lever Replace
(potentiometer)
HM300-1 20-641
1 c
4
(9) c
A
Cause Remedy
12
YES
13
• Insert T-adapter to HSL. Is voltage between HSL (2) and ground 0.3 - NO
• Turn starting switch ON. 4.7 V?

BRC3B (female) (14) and HSL replace
(female) (2)
14
• Turn starting switch ON. NO Hot short in wiring harness be-
Is voltage between HSL (2) and tween BRC3B (female) (14) Repair or
• Disconnect BRC3B and ground less than 1 V?
HSL . and HSL (female) (2) replace
YES

• Disconnect BRC3B and NO in wiring harness between Repair or
HSL . Is resistance between HSL (2) and
groung more than 1 MΩ? BRC3B (female) (14) and HSL replace
• Turn starting switch OFF. (female) (2)
YES
Defective dump lever Replace
(potentiometer)
20-642 HM300-1
! (9)
1 !
4
BK-16 FAILURE CODE [DK53L8] (DUMP LEVER POTENTIOMETER 2:

★ Nature of failure:The total voltage of potentiometer 1 signal circuit and potentiometer 2 signal circuit went
above 5.6 V
Cause Remedy

Is other failure code [DK52KX] NO Defective dump lever
displayed or recorded at same (potentiometer) Replace
time?
YES Go to
Another problem is occurring at troubleshooting
the same time for displayed
code
HM300-1 20-643
1 c c
BK-17 FAILURE CODE [DK54KX] (BODY POSITIONER SENSOR: INPUT SIGNAL OUTSIDE
RANGE (KX))
★ Nature of failure:The voltage of the body positioner sensor signal circuit went below 0.3 V or above 4.7 V
1
• SEE TESTING AND Is trouble repaired by adjusting NO Cause Remedy
ADJUSTING. installation of potentiometer?
YES
Defective adjustment
2
BRC3A and BRC3B.
• Turn starting switch ON. BRC3A (16) 0.3 - 4.7 V?
YES
3
YES
4
• Disconnect BRC3A and NO Hot short in wiring harness be-
Is voltage between B34 (female) (3) tween BRC3A (female) (6) and Repair or
• Turn starting switch ON. B34 (female) (3)
YES

• Turn starting switch OFF. NO in wiring harness between Repair or
Is resistance between B34 (female)
• Disconnect BRC3A and BRC3A (female) (6) and B34 replace
(3) and ground more than 1 MΩ?
B34. (female) (3)
YES
6
• Insert T-adapter to BRC3A. NO
Is voltage between BRC3A (6) and
• Disconnect B34. ground 4.6 - 5.4 V?
in wiring harness between BRC3A replace
(female) (6) and B34 (female) (3)
7
YES
8
• Turn starting switch OFF. Is resistance between BRC3A NO Defective contact or disconnection Repair or
• Disconnect BRC3A and (female) (16) and B34 (female) (1) in wiring harness between BRC3A replace
B34. less than 1 Ω? (female) (16) and B34 (female) (1)
YES

A
20-644 HM300-1
c 4 c
1
(9)
A
Cause Remedy
9
BRC3B (female) (13) and B34 replace
(female) (2)
10
• Disconnect BRC3B and NO Hot short in wiring harness be-
Is voltage between B34 (female) (2) tween BRC3B (female) (13) Repair or
YES
11
Is resistance between B34 (female) NO in wiring harness between Repair or
• Disconnect BRC3B and (2) and groung more than 1 MΩ?
B34. BRC3B (female) (13) and B34 replace
(female) (2)
YES
Defective body positioner sensor Repair
HM300-1 20-645
(9)
1 ! !
BK-18 FAILURE CODE [DLF4KA] (TRANSMISSION OUTPUT SHAFT F SPEED SENSOR:

DISCONNECTION (KA))
★ Nature of failure: A disconnection has occurred in the signal circuit of the transmission output shaft F speed
Cause Remedy
1
• Turn starting switch OFF. Is resistance between BRC3A NO
• Disconnect BRC3A. (female) (12) and (14) 500 - 1000 Ω?
YES
2
• Turn starting switch OFF. Is resistance between FE1 (male) (1) NO Defective transmission output
• Disconnect FE1. and (2) 500 - 1000 Ω? Replace
shaft F speed sensor
YES tion in wiring harness between
BRC3A (female) (12) and Repair or
B09 (female) (1) or between replace
BRC3A (female) (14) and
3 B09 (female) (2)
• See TESTING AND Does condition become normal when NO
ADJUSTING. transmission output shaft F speed Defective retarder controller(q1) Replace
• Start engine. sensor is adjusted?
transmission output shaft F Adjust
speed sensor
20-646 HM300-1
! (9)
1 !
4
BK-19 FAILURE CODE [DLT3KA] (TRANSMISSION OUTPUT SHAFT R SPEED SENSOR:

DISCONNECTION (KA))
★ Nature of failure: A disconnection has occurred in the signal circuit of the transmission output shaft R speed
Cause Remedy
1
• Turn starting switch OFF. Is resistance between BRC3A NO
BRC3A. (14) 500 - 1000 Ω?
YES
2
• Turn starting switch OFF. Is resistance between N3 (male) (1) NO Defective transmission output
• Disconnect N3. and (2) 500 - 1000 Ω? Replace
shaft R speed sensor

BRC3A (female) (13) and N3 replace
(female) (1)
3
• See TESTING AND Does condition become normal when NO
ADJUSTING. transmission output shaft R speed Defective retarder controller(q1) Replace
• Start engine and travel. sensor is adjusted?
transmission output shaft R Adjust
speed sensor
HM300-1 20-647
(9)
1 !
4 !
BK-20 FAILURE CODE [DW71KZ] (EXHAUST BRAKE SOLENOID: DISCONNECTION OR

SHORT CIRCUIT (KZ)) (Machine with exhaust brake)
★ Nature of failure: When output is sent to the exhaust brake solenoid circuit, excessive electric current flows;
when there is output, no electric current flows; when the output is OFF, electric current flows
Cause Remedy
1
• Disconnect BRC1. (3) and ground 20 - 60 Ω?
YES
2
• Turn starting switch OFF. Is resistance between B29 (male) (1) and NO Defective exhaust brake Replace
• Disconnect B29. (2), and between (1) and ground as shown solenoid
in Table 1?
YES
Defective contact, disconnec-
3 tion, or short circuit with chassis
Is resistance between B29 (female) NO ground in wiring harness be- Repair or
• Turn starting switch OFF. replace
• Disconnect B29. (2) and ground less than 1 Ω? tween BRC1 (female) (3) and
B29 (female) (1)
between B29 (female) (2) and replace
ground
4
• Disconnect BRC1. Is voltage between BRC1 (female) NO Hot short in wiring harness
between BRC1 (female) (3) and Repair or
B29 (female) (1)
YES
Table 1
B29 (male) Resistance
Between (1) and (2) 20 – 60Ω
20-648 HM300-1
! (9)
1 !
4
BK-21 FAILURE CODE [DW72KZ] (DUMP LEVER KICK-OUT SOLENOID: DISCONNECTION

OR SHORT CIRCUIT (KZ))
★ Nature of failure: When output is sent to the dump lever kick-out solenoid circuit, excessive electric current
flows; when there is output, no electric current flows; when the output is OFF, electric cur-
rent flows
Cause Remedy
1
• Disconnect BRC1. (11) and ground 39 Ω ± 5%?
YES
2
• Turn starting switch OFF. Is resistance between LK0 (male) (1) NO Defective dump lever (kick-out Replace
• Disconnect LK0. and (2), and between (1) and ground solenoid)
as shown in Table 1?
YES
3 Defective contact or disconnec-

NO tion in wiring harness between Repair or
• Turn starting switch OFF. Is resistance between LK0 (female) LK0 (female) (2) and ground
(2) and ground less than 1 Ω? replace
• Disconnect LK0.
Defective contact,
harness between BRC1(female) replace
(11) and LK0 (female) (1)
4
• Disconnect BRC1. NO Hot short in wiring harness
Is voltage between BRC1 (female) between BRC1 (female) (11) Repair or
and LK0 (female) (1)
YES

Table 1
LK0 (male) Resistance
Between (1) and (2) 39Ω ± 5%
HM300-1 20-649
(9)
1 !
4 !
20-650 HM300-1
c 1 c
BK-22 FAILURE CODE [DW73KZ] (DUMP SELECTOR VALVE SOLENOID: DISCONNECTION

OR SHORT CIRCUIT (KZ))
★ Nature of failure: When output is sent to the dump selector valve solenoid circuit, excessive electric current
flows; when there is output, no electric current flows; when the output is OFF, electric cur-
rent flows
Cause Remedy
1
• Disconnect BRC1. (12) and ground 15 - 35 Ω?
YES
2
• Turn starting switch OFF. Is resistance between B31 (male) (1) NO Defective dump selector valve Replace
• Disconnect B31. and (2), and between (1) and ground solenoid
as shown in Table 1?
YES
3 Defective contact or disconnec-

• Turn starting switch OFF. Is resistance between B31 (female) NO tion in wiring harness between Repair or
• Disconnect B31. (2) and ground less than 1 Ω? B31 (female) (2) and ground replace
Defective contact,
YES disconnection, or short circuit Repair or
with chassis ground in wiring replace
harness between BRC1(female)
(12) and B31 (female) (1)
4
• Disconnect BRC1. Is voltage between BRC1 (female) NO Hot short in wiring harness
between BRC1 (female) (12) Repair or
YES

Table 1
B31 (male) Resistance
Between (1) and (2) 15 – 35Ω
HM300-1 20-651
(9)
1 !
4 !
20-652 HM300-1
c 1 c
BK-23 FAILURE CODE [DX11KA] (REAR BRAKE PRESSURE REDUCING VALVE

SOLENOID: DISCONNECTION (KA))
★ Nature of failure: When output is sent to the rear brake pressure reducing valve solenoid circuit, no electric
current flows
Cause Remedy
1
• Turn starting switch
Is resistance between BRC2 (female) NO
OFF. (9) and (19) 10 - 30 Ω?
• Disconnect BRC2.
YES
2
• Turn starting switch Is resistance between B18 (male) (1) NO Defective rear brake pressure Replace
OFF. and (2) 10 - 30 Ω? reducing valve solenoid
• Disconnect B18.
in wiring harness between BRC2 Repair or
(female) (9) and B18 (female) (1) or replace
between BRC2 (female) (19) and
B18 (female) (2)
HM300-1 20-653
1 c
4
(9) c
BK-24 FAILURE CODE [DX11KB] (REAR BRAKE PRESSURE REDUCING VALVE

SOLENOID: SHORT CIRCUIT (KB))
★ Nature of failure: When output is sent to the rear brake pressure reducing valve solenoid circuit, excessive
electric current flows
Cause Remedy
1
• Turn starting switch Is resistance between BRC2 NO
OFF. (female) (9) and (19), and between
• Disconnect BRC2. (9) and ground as shown in Table 1?
YES
2
• Turn starting switch Is resistance between B18 (male) (1) NO Defective rear brake pressure
OFF. and (2), and between (1) and ground reducing valve solenoid Replace
• Disconnect B18. as shown in Table 2?
Short circuit with chassis ground in
YES wiring harness between BRC2 Repair or
(female) (9) and B18 (female) (1) replace
or short circuit in wiring harness
B18 (female) (2)
Table 1 Table 2
BRC2 (female) Resistance value B18 (male) Resistance value
Between (9) and (19) 10 – 30Ω Between (1) and (2) 10 – 30Ω
Between (9) and ground Min. 1MΩ Between (1) and ground Min. 1MΩ
20-654 HM300-1
c 4 c
1
(9)
BK-25 FAILURE CODE [DX11KY] (REAR BRAKE PRESSURE REDUCING VALVE

SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY))
★ Nature of failure: When the output to the rear brake pressure reducing valve solenoid circuit is OFF, electric
current flows
Cause Remedy
1
Is voltage between BRC2 NO Hot short in wiring harness
• Disconnect BRC2. (female) (9) and ground less between BRC2 (female) (9) and Repair or
• Turn starting switch ON. than 1 V? B18 (female) (1) replace
YES
2
• Disconnect BRC2. Is voltage between BRC2 NO Hot short in wiring harness
• Turn starting switch (female) (19) and ground less between BRC2 (female) (19) and Repair or
ON. than 1 V? B18 (female) (2) replace
YES
HM300-1 20-655
(9)
1 !
4 !
BK-26 FAILURE CODE [DX12KA] (FRONT BRAKE PRESSURE REDUCING VALVE

SOLENOID: DISCONNECTION (KA))
★ Nature of failure: When output is sent to the front brake pressure reducing valve solenoid circuit, no electric
current flows
Cause Remedy
1
• Turn starting switch NO
Is resistance between BRC2
OFF. (female) (8) and (18) 10 - 30 Ω?
YES
2
• Turn starting switch Is resistance between B19 NO Defective front brake pressure
OFF. (male) (1) and (2) 10 - 30 Ω? reducing valve solenoid Replace
• Disconnect B19.
YES in wiring harness between BRC2 Repair or
(female) (8) and B19 (female) (1) or replace
B19 (female) (2)
20-656 HM300-1
c 4 c
1
(9)
BK-27 FAILURE CODE [DX12KB] (FRONT BRAKE PRESSURE REDUCING VALVE SOLE-
NOID: SHORT CIRCUIT (KB))
★ Nature of failure: When output is sent to the front brake pressure reducing valve solenoid circuit, excessive
electric current flows
Cause Remedy
1
OFF. (female) (8) and (18), and between
• Disconnect BRC2. (8) and ground as shown in Table 1?
YES
2
• Turn starting switch Is resistance between B19 (male) (1) NO Defective front brake pressure
OFF. and (2), and between (1) and ground reducing valve solenoid Replace
• Disconnect B19. as shown in Table 2?
YES wiring harness between BRC2
(female) (8) and B19 (female) (1) Repair or
B19 (female) (2)

Table 1 Table 2
HM300-1 20-657
1 c
4
(9) c
BK-28 FAILURE CODE [DX12KY] (FRONT BRAKE PRESSURE REDUCING VALVE

SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY))
★ Nature of failure: When the output to the front brake pressure reducing valve solenoid circuit is OFF, electric
current flows
Cause Remedy
1
Is voltage between BRC2 NO Hot short in wiring harness Repair or
• Disconnect BRC2. (female) (8) and ground less than between BRC2 (female) (8)
1 V? and B19 (female) (1)
YES
2
Is voltage between BRC2 NO Hot short in wiring harness Repair or
• Disconnect BRC2. between BRC2 (female) (18) and
• Turn starting switch ON. (female) (18) and ground less replace
than 1 V? B19 (female) (2)
YES
20-658 HM300-1
c 4 c
1
(9)
BK-29 FAILURE CODE [DX13KA] (DUMP EPC VALVE SOLENOID: DISCONNECTION (KA))
★ Nature of failure: When output is sent to the dump EPC valve solenoid circuit, no electric current flows
Cause Remedy
1
OFF. (female) (10) and (20) 5 - 20Ω?
YES
2
• Turn starting switch Is resistance between B32 (male) NO Defective dump EPC valve
OFF. (1) and (2) 5 - 20Ω? solenoid Replace
• Disconnect B32.
YES in wiring harness between BRC2
(female) (10) and B32 (female) (1) Repair or
or between BRC2 (female) (20) and replace
B32 (female) (2)
HM300-1 20-659
1 c
4 c
BK-30 FAILURE CODE [DX13KB] (DUMP EPC VALVE SOLENOID: SHORT CIRCUIT (KB))
★ Nature of failure: When output is sent to the dump EPC valve solenoid circuit, excessive electric current
flows
Cause Remedy
1
Is resistance between BRC2 (female) NO
• Turn starting switch OFF. (10) and (20), and between (10) and
• Disconnect BRC2. ground as shown in Table 1?
YES
2
IIs resistance between B32 (male) (1) NO
• Disconnect B32.
and (2), and between (1) and ground as Defective dump pilot valve (EPC Replace
shown in Table 2? solenoid)
YES Short circuit with chassis ground in Repair or
wiring harness between BRC2 replace
(female) (10) and B32 (female) (1)
or short circuit in wiring harness
B32 (female) (2)
Table 1 Table 2
20-660 HM300-1
c 4 c
1
(9)
BK-31 FAILURE CODE [DX13KY] (DUMP EPC VALVE SOLENOID: SHORT CIRCUIT IN
POWER SUPPLY LINE (KY))
★ Nature of failure: When the output to the dump EPC valve solenoid circuit is OFF, electric current flows
Cause Remedy
1
• Disconnect BRC2. Is voltage between BRC2 (female) (10) NO between BRC2 (female) (10) and
Repair or
• Turn starting switch ON. and ground less than 1 V? replace
B32 (female) (1)
YES
2
• Disconnect BRC2. Is voltage between BRC2 (female) NO between BRC2 (female) (20) and
Repair or
B32 (female) (2)
YES
HM300-1 20-661
1 c
4
(9) c
BK-32 PARKING BRAKE DOES NOT WORK PROPERLY
★ Nature of failure: The parking brake does not work properly (no failure code is displayed)
a) Even when parking brake switch is turned OFF, parking brake is not released
★ When the engine is stopped with the parking brake OFF, turn the switch to the PARKING position after start-
ing the engine. If it is not turned to PARKING, the parking brake cannot be released.
Cause Remedy

• Turn starting switch ON. parking brake safety relay (R19) is
YES
Defective parking brake safety Replace
relay (R19)
Is resistance between B14 (male) (1) and NO

• Turn starting switch OFF. (2), and between (1) and ground as
• Disconnect B14. Defective parking brake solenoid Replace
shown in Table 1?
YES
Is resistance between R33 (male) (1) and NO

• Turn starting switch OFF. (2), and between (1) and (3) as shown in
• Disconnect R33. Defective parking brake switch Replace
Table 2?
YES
• Disconnect B21.
• Start engine. Is voltage between B21 (female) (1) NO
• Cancel parking brake switch. and ground 20 - 30 V?
YES
• Disconnect R33. Defective contact or disconnection

• Start engine. Is voltage between R33 (female) (3) NO in wiring harness between fuse Repair or
• Cancel parking brake switch. and ground 20 - 30 V? BT2-6 and R33 (female) (3) replace
YES

• Disconnect R19.
• Start engine. Is voltage between R19 (female) NO in wiring harness between R33 Repair or
• Cancel parking brake switch. (1)(3) and ground 20 - 30 V? (female) (1) and R19 (female) replace
(1)(3)
YES
Go to 9 Go to 7
20-662 HM300-1
c 1 c
From 4 From 6
Cause Remedy
• Turn starting switch OFF. Is resistance between R19 (female) NO Defective contact or disconnection
• Disconnect R19. (2) and ground less than 1Ω?
(female) (2) and ground replace
YES
• Disconnect R19. NO Defective contact or disconnection

• Start engine. Is voltage between R19 (female) (5) in wiring harness between fuse Repair or
• Cancel parking brake switch. and ground 20 - 30 V? BT2-6 and R19 (female) (5) replace

• Disconnect B20. NO
• Start engine. Is voltage between B20 (female) (1)
YES
• Disconnect B21. Is resistance between B21 (male) (1) NO Defective front accumulator oil Replace
• Start engine.. and (2) less than 1 Ω? pressure switch
in wiring harness between B21 Repair or
• Disconnect B14.
Is voltage between B14 (female) (1) NO
• Start engine.
(female) (2) and ground replace
• Disconnect B20. Is resistance between B20 (male) (1) NO Defective rear accumulator oil
• Start engine. and (2) less than 1Ω? pressure switch Replace

Table 1 Table 2
When parking
When parking
B14 (male) Resistance R33 (male) brake switch is at
brake switch OFF
PARKING
Between (1) and (2) 30 – 50Ω Between (1) and (2) Min. 1 MΩ Max. 1Ω
Between (1) and ground Min. 1 MΩ Between (1) and (3) Max. 1Ω Min. 1 MΩ
HM300-1 20-663
1 c c
b) Even when parking brake switch is at PARKING position, parking brake is not applied
Cause Remedy
• Disconnect R33.
• Start engine. Does parking brake work when R33 NO
• Set parking brake switch to is disconnected?
PARKING.
YES
Defective parking brake switch Replace
• Disconnect B21.
• Start engine. Does parking brake work when B21 NO
• Set parking brake switch to is disconnected?
PARKING.
YES Hot short in wiring harness between Repair or
R33 (female) (2) and B21 (female) replace
(1)
• Disconnect B20. Hot short in wiring harness between

• Start engine. Does parking brake work when B20 is NO B20 (female) (2) and B14 (female) Repair or
• Set parking brake switch to disconnected? (1) replace
PARKING.
YES Hot short in wiring harness between
B21 (female) (2) and B20 (female) Repair or
(1) replace
20-664 HM300-1
c 1 c
(9)
TROUBLESHOOTING OF
MACHINE MONITOR SYSTEM
(MON MODE)
MON MODE RELATED ELECTRICAL CIRCUIT DIAGRAM ................................................................... 20-702

MON-1 Failure code [B@C6NS] (Front brake oil: Overheat (NS)) ..................................................... 20-710
MON-2 Failure code [B@C8NS] (Center brake oil: Overheat (NS)) ................................................... 20-710
MON-3 Failure code [B@CENS] (Torque converter: Overheat (NS)) ................................................. 20-710
MON-4 Failure code [DAF0KM] (Monitor panel: Mistaken operation or mistaken setting (KM)) ........ 20- 711
MON-5 Failure code [DAF9KM] (Monitor panel: Mistaken operation or mistaken setting (KM)) ........ 20-712
MON-6 Failure code [DAFSKQ] (Monitor panel: Non match in model selection signal (KQ)) ............ 20-713
MON-7 Failure code [DAQSKR] (Transmission controller S-NET: Defective communication,
abnormality in corresponding component system (KR)) ................ 20-714
MON-8 Failure code [DB1SKR] (Retarder controller(q1) S-NET: Defective communication,
MON-9 Failure code [DB2SKR] (Engine controller S-NET: Defective communication,
MON-10 Failure code [DV00KB] (Alarm buzzer: Short circuit (KB)) ..................................................... 20-720
MON-11 When starting switch is turned ON, machine monitor gives no display .................................. 20-721
MON-12 When starting switch is OFF, machine monitor cannot be operated ...................................... 20-722
MON-13 Alarm buzzer does not sound ................................................................................................ 20-723
MON-14 Gauges, caution lamps, character display on machine monitor do not give correct display .. 20-724
MON-15 Actuation check of machine monitor cannot be performed properly ...................................... 20-725
MON-16 Character display cannot be switched properly ..................................................................... 20-726
MON-17 Power mode selector function does not work properly .......................................................... 20-729
MON-18 AISS function does not work properly .................................................................................... 20-730
MON-19 Exhaust brake does not work properly (machines equipped with exhaust brake) ................. 20-731
MON-20 Seat belt caution lamp display is not shown properly ............................................................ 20-733
MON-21 Turn signal lamp, hazard lamp do not work properly ............................................................. 20-735
MON-22 Night lighting is not normal ..................................................................................................... 20-740
HM300-1 20-701
1 c
4
(9) c
TROUBLESHOOTING
TROUBLESHOOTING MON MODE RELATED ELECTRICAL CIRCUIT DIAGRAM
MON MODE RELATED ELECTRICAL CIRCUIT DIAGRAM
20-702 HM300-1
c 1 c
TROUBLESHOOTING
★ This circuit diagram has been made by extracting the machine monitor related circuits from the overall elec-
trical circuit diagram.
HM300-1 20-703
1 ! !
TROUBLESHOOTING
20-704 HM300-1
! 1 !
TROUBLESHOOTING
HM300-1 20-705
1 c c
TROUBLESHOOTING

Front brake oil: Overheat Front brake cooling oil is over- • Front brake cooling oil is overheated
B@C6NS
(NS) heated (when system is working normally)
(MON-1)
• Defective machine monitor
Center brake oil: Overheat Center brake cooling oil is over- • Center brake cooling oil is overheated
B@C8NS
(NS) heated (when system is working normally)
(MON-2)
Torque converter: Overheat Torque converter is overheated • Torque converter oil is overheated (when
B@CENS
(NS) system is working normally)
(MON-3)
Monitor panel: Mistaken op- Option setting of rotary switch at • Defective setting of rotary switch,
eration or mistaken setting rear of machine monitor and dipswitch, or option connector (when
(KM)) dipswitches does not match sig- system is working normally)
DAF0KM
nal from option setting connec- • Disconnection or short circuit with chas-
(MON-4)
tor sis ground in option connector circuit wir-
ing harness
Monitor panel: Mistaken op- Check signal of connector does • Mistaken connection of connector DPC2
eration or mistaken setting not match internal setting of ma- (A, B) and connector DPC3 (A, B) (when
(KM)) chine monitor system is working normally)
DAF9KM
(MON-5)
sis ground in signal 1 circuit wiring har-
ness
Monitor panel: Non match in Communication (S-NET) with • Disconnection, short circuit with chassis
model selection signal (KQ) transmission controller is defec- ground, or hot short in S-NET (+) circuit
DAFSKQ tive and model selector informa- wiring harness
(MON-6) tion cannot be received, or • Disconnection in S-NET (–) circuit
setting of transmission controller • Defective transmission controller
rotary switch is not correct • Defective machine monitor
Transmission controller S- S-NET data cannot be received • Disconnection, short circuit with chassis
NET: Defective communica- from transmission controller ground, or hot short in S-NET (+) circuit
DAQSKR
tion, abnormality in corre- wiring harness
(MON-7)
sponding component system • Defective transmission controller
(KR) • Defective machine monitor
Retarder controller(q1) S- S-NET data cannot be received • Disconnection, short circuit with chassis
NET: Defective communica- from retarder controller(q1) ground, or hot short in S-NET (+) circuit
DB1SKR
tion, abnormality in corre- wiring harness
(MON-8)
sponding component system • Defective retarder controller(q1)
(KR) • Defective machine monitor
20-706 HM300-1
c 4 c
1
(9)
TROUBLESHOOTING
★ The code (MON-**) given below the failure code is the troubleshooting number.
• Takes no action • If machine continues to be used

as it is, there is danger that front E02
brake will brake

as it is, there is danger that center E02
brake will brake

as it is, there is danger that torque E02
converter will brake
• Wiring harness resistance value • Holds abnormal condition until • Some functions (if equipped) do
DPC3A (female) starting switch is turned OFF not work
(4)(6)(7)(13)(14)(15) – ground • Does not recognize functions
• When connector is connected: (options) where setting does E03
Max. 1 Ω not match
• When connector is disconnect- • Does not record as trouble
ed: Min. 1 MΩ data
• Signal voltage • Holds abnormal condition until

DPC2A (female) (5) – ground: starting switch is turned OFF
20 – 30 V • Does not record as trouble
data E03
• Holds abnormal condition until • No meters or gauges give display

starting switch is turned OFF • Some panel switches and lamps
• Controls as HM300 do not work
E03
• S-NET voltage • Holds condition existing when • Meters, gauges, cautions, special E03
Between DPC4 (1)(2) and (4)(5): problem occurred function receiving data from trans-
6–9V mission controller do not work or
Between ATC4 (6)(12) and (10): give any display
6–9V
• S-NET voltage • Holds condition existing when • Cautions, special function receiv- E03
Between DPC4 (1)(2) and (4)(5): problem occurred ing data from retarder control-
6–9V ler(q1) do not work or give any
Between BRC4 (6)(12) and (10): display
6–9V
HM300-1 20-707
1 c
4
(9) c
TROUBLESHOOTING
Engine controller S-NET: Unable to receive S-NET infor- • Wiring harness in S-NET (+) circuit dis-
Defective communication, mation from engine controller connected or connected defectively or
DB2SKR abnormality in corresponding short-circuited
(MON-9) component system (KR) • Engine controller faulty
• Machine monitor faulty
Alarm buzzer: Alarm buzzer output circuit • Alarm buzzer faulty

Short-circuiting (KB) short-circuited • Wiring harness in alarm buzzer output
DV00KB circuit short-circuited
(MON-10) • Machine monitor faulty
20-708 HM300-1
c 1 c
(9)
TROUBLESHOOTING
• S-NET voltage • Holds condition existing when • Cautions, special function receiv- E03
• Between DPC4 (1)(2) and problem occurred ing data from engine controller do
(4)(5): not work or give any display
6–9V
• Between CN2 (8)(18) and (6):
6–9V
• Output circuit voltage • Holds abnormal condition until • Alarm buzzer does not sound
DPC1 (13) – (9)(10): starting switch is turned OFF
When buzzer is stopped: • Turns buzzer output circuit
E01
20 – 30 V OFF
When buzzer is sounding:
Max. 1 V
HM300-1 20-709
1 c
(9) c
TROUBLESHOOTING
TROUBLESHOOTING MON-1
MON-1, MON-2, MON-3
MON-1 FAILURE CODE [B@C6NS] (FRONT BRAKE OIL: OVERHEAT (NS))
★ Nature of failure: The front brake cooling oil is overheated
Cause Remedy
1
Is front brake cooling oil NO
• Stop engine Defective machine monitor Replace
overheated?
YES
Front brake cooling oil is —
overheated
MON-2 FAILURE CODE [B@C8NS] (CENTER BRAKE OIL: OVERHEAT (NS))
★ Nature of failure: The center brake cooling oil is overheated
Cause Remedy
1
Is center brake cooling oil NO
• Stop engine Defective machine monitor Replace
overheated?
YES
Center brake cooling oil is —
overheated
MON-3 FAILURE CODE [B@CENS] (TORQUE CONVERTER: OVERHEAT (NS))
★ Nature of failure: The torque converter is overheated
Cause Remedy
1
NO
• Stop engine. Is torque converter overheated? Defective machine monitor Replace
YES
Torque converter is overheated —
20-710 HM300-1
c 1 c
(9)
MON-4 FAILURE CODE [DAF0KM] (MONITOR PANEL: MISTAKEN OPERATION OR

★ Nature of failure: The option setting of the rotary switch at the rear of the machine monitor and dipswitches
does not match the signal from the option setting connector
Cause Remedy
1
• See TESTING AND Is setting of rotary switch, NO Defective setting of rotary
ADJUSTING. dipswitch, or option connector switch, dipswitch, or option Set again
normal? connector
YES
• Turn starting switch OFF. Is resistance between DPC3A
• Disconnect DPC3A. NO disconnection in wiring harness Repair or
• OP connector connection
(female)(4)(6)(7)(13)(14)(15) between DPC3A (female)
(16) and ground less than 1Ω? replace
circuit (4)(6)(7)(13)(14)(15)(16) and
ground
YES
3
• Turn starting switch OFF. Is resistance between DPC3A NO Short circuit with chassis ground
• Disconnect DPC3A. (female)(4)(6)(7)(13)(14)(15)(16) in wiring harness between Repair or
• OP connector and ground more than 1 MΩ? DPC3A(female) (4)(6)(7)(13) replace
disconnection circuit (14)(15)(16) and ground
YES
Defective machine monitor Replace
MON-4 Related electrical circuit diagram
HM300-1 20-711
1 c
(9) c
MON-5 FAILURE CODE [DAF9KM] (MONITOR PANEL: MISTAKEN OPERATION OR

★ Nature of failure: The check signal of the connector does not match the internal setting of the machine mon-
itor
Cause Remedy
1
Are connectors DPC2A, DPC3A NO
• Turn starting switch OFF. and DPC2B, DPC4 connected at Mistaken connection of machine Connect
correct position? monitor connectors again
YES
2
• Insert T-adapter to DPC2A. Is voltage between DPC2A (5) NO disconnection in wiring harness Repair or
• Turn starting switch ON. and ground 20 – 30 V? between DPC2A (female) (5) replace
and fuse BT2-2
YES
20-712 HM300-1
c 1 c
(9)
MON-6 FAILURE CODE [DAFSKQ] (MONITOR PANEL: NON MATCH IN MODEL SELECTION
SIGNAL (KQ))
★ Nature of failure: Communication (S-NET) with the transmission controller is defective and the model selec-
tor information cannot be received, or the setting of the transmission controller rotary
switch is not correct
Cause Remedy
1
• Turn starting switch ON. Is other failure code [DAQAKQ] NO
• Operate machine monitor. also displayed or recorded at
same time? Go to
troubleshoot-
YES Other problem is occurring at ing of
same time displayed
2 code
When troubleshooting for failure
code [DAQSKR] is carried out, is Defective S-NET
condition normal (S-NET NO
communication circuit between Repair or
communication circuit between machine monitor and replace
machine monitor and transmission
controller)? transmission controller
YES
3
• Turn starting switch ON. when machine monitor is Defective transmission controller Replace
replaced?
YES
HM300-1 20-713
1 c
(9) c
MON-7 FAILURE CODE [DAQSKR] (TRANSMISSION CONTROLLER S-NET: DEFECTIVE

COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM
(KR))
★ Nature of failure: The S-NET data cannot be received from the transmission controller
★ Check that the continuity of the junction connectors (JCB, JCC, JCD, JCE, JCF, JCG) is normal.
Cause Remedy
1
Are other failure codes [DB1SKR] NO
• Turn starting switch ON. and [DB2SKR] also displayed or
recorded at same time?
YES

Is voltage between ATC4 NO in wiring harness between ATC4 Repair or
• Disconnect ATC4.
• Turn starting switch ON. (female) (6)(12) and ground 6 – (female) (6) – JCB (female) (3) and replace
9 V? ATC4 (female) (12) – JCD (female)
(3)
YES Defective transmission controller Replace

3 between DPC4 (female) (1) - JCD
• Disconnect DPC4, Is voltage between DPC4 (female) (1)(2) - BRC4 (female)
NO (12), ATC4 (female) (12), CN2 Repair or
BRC4, ATC4,and CN2. (female) (1)(2) and ground less
• Turn starting switch ON. than 1V? (female) (18) and between DPC4 replace
(female) (2) - JCB (female) (1)(2) -
BRC4 (female) (6), ATC4 (female)
(6), CN2 (female) (8)
YES
4 wiring harness between DPC4
• Turn starting switch OFF. Is resistance between DPC4 NO (female) (1) - JCD (female) (1)(2) - Repair or
• Disconnect DPC4, BRC4, (female) (1)(2) and ground more BRC4 (female) (12), ATC4 (female) replace
ATC4,and CN2. than 1 MΩ? (12), CN2 (female) (18) and
between DPC4 (female) (2) - JCB
(female) (1)(2) - BRC4 (female) (6),
ATC4 (female) (6), CN2 (female) (8)
YES
5
Is voltage between JCD (female) Defective contact or disconnection
• Disconnect JCD and JCB. NO in wiring harness between DPC4 Repair or
• Turn starting switch ON. (1), JCB (female) (1) and ground
6 – 9 V? (female) (1) - JCD (female) (1) and replace
between DPC4 (female) (2) - JCB (2)
YES
One of machine monitor, retarder
controller(q1), transmission Replace
controller, or engine controller is
defective
20-714 HM300-1
c 4 c
1
(9)
HM300-1 20-715
1 c c
MON-8 FAILURE CODE [DB1SKR] (RETARDER CONTROLLER(q1) S-NET: DEFECTIVE COM-

MUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR))
★ Nature of failure: The S-NET data cannot be received from the retarder controller(q1)
Cause Remedy
1
Are other failure codes [DB2SKR] NO
• Turn starting switch ON. and [DBQSKR] also displayed or
YES

• Disconnect ATC4. Is voltage between BRC4 NO in wiring harness between BRC4 Repair or
• Turn starting switch ON. (female) (6)(12) and ground 6 - (female) (6) – JCB (female) (2) and replace
9 V? BRC4 (female) (12) – JCD (female)
(2)
YES Defective retarder controller(q1) Replace
3 Hot short in wiring harness between

Is voltage between DPC4 DPC4 (female) (1) - JCD (female)
• Disconnect DPC4, NO (1)(2) - BRC4 (female) (12), ATC4
BRC4, ATC4,and CN2. (female) (1)(2) and ground less Repair or
(female) (12), CN2 (female) (18)
• Turn starting switch ON. than 1V? and between DPC4 (female) (2) - replace
JCB (female) (1)(2) - BRC4 (female)
(6), ATC4 (female) (6), CN2 (female)
(8)
YES

• Turn starting switch OFF. Is resistance between DPC4 NO wiring harness between DPC4 Repair or
• Disconnect DPC4, BRC4, (female) (1)(2) and ground more (female) (1) - JCD (female) (1)(2) - replace
ATC4,and CN2. than 1 MΩ? BRC4 (female) (12), ATC4 (female)
(12), CN2 (female) (18) and
YES ATC4 (female) (6), CN2 (female) (8)
5
• Disconnect JCD and JCB. Is voltage between JCD (female) NO
(1), JCB (female) (1) and ground Defective contact or disconnection Repair or
• Turn starting switch ON. in wiring harness between DPC4 replace
6 – 9 V? (female) (1) - JCD (female) (1) and
YES
defective
20-716 HM300-1
c 4 c
1
(9)
HM300-1 20-717
1 c c
MON-9 FAILURE CODE [DB2SKR] (ENGINE CONTROLLER S-NET: DEFECTIVE COMMUNI-

CATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR))
★ Nature of failure: The S-NET data cannot be received from the engine controller
Cause Remedy
1
Are other failure codes [DAQSKR] NO
• Turn starting switch ON. and [DB1SKR] also displayed or
YES
2
• Disconnect ATC4. Is voltage between CN2 NO in wiring harness between CN2 Repair or
• Turn starting switch ON. (female) (8)(18) and ground 6 – (female) (8) –JCB (female) (4) and replace
9 V? CN2 (female) (18) – JCD (female) (4)
YES Defective engine controller Replace
3 Hot short in wiring harness between

DPC4 (female) (1) - JCD (female)
• Disconnect DPC4, Is voltage between DPC4 NO (1)(2) - BRC4 (female) (12), ATC4
BRC4, ATC4,and CN2. (female) (1)(2) and ground less (female) (12), CN2 (female) (18) Repair or
• Turn starting switch ON. than 1V? and between DPC4 (female) (2) - replace
JCB (female) (1)(2) - BRC4
(female) (6), ATC4 (female) (6),
CN2 (female) (8)
YES

• Turn starting switch OFF. Is resistance between DPC4 NO wiring harness between DPC4 Repair or
• Disconnect DPC4, BRC4, (female) (1)(2) and ground more (female) (1) - JCD (female) (1)(2) -
BRC4 (female) (12), ATC4 (female) replace
ATC4,and CN2. than 1 MΩ?
(12), CN2 (female) (18) and
YES ATC4 (female) (6), CN2 (female) (8)
5
• Disconnect JCD and JCB. Is voltage between JCD (female) NO
(1), JCB (female) (1) and ground Defective contact or disconnection Repair or
• Turn starting switch ON. in wiring harness between DPC4 replace
6 – 9 V? (female) (1) - JCD (female) (1) and
YES
defective
20-718 HM300-1
c 4 c
1
(9)
HM300-1 20-719
1 c c
MON-10 FAILURE CODE [DV00KB] (ALARM BUZZER: SHORT CIRCUIT (KB))

7
★ Nature of failure: A short circuit with the power source has occurred in the output circuit of the alarm buzzer
Cause Remedy
1
• Disconnect BZ2 and Is voltage between DPC1 (female) NO
DPC1. (13) - (9)(10) less than1 V?
YES
Defective alarm buzzer Replace
2
• Disconnect fuse BT2-2 Is voltage between DPC1 (female) NO Hot short in wiring harness
and DPC1. between DPC1 (female) (13) Repair or
• Turn starting switch ON. (13) - (9)(10) less than 1 V? replace
and BZ2 (female) (2)
YES
20-720 HM300-1
c 1 c
(9)
MON-11 WHEN STARTING SWITCH IS TURNED ON, MACHINE MONITOR GIVES NO

DISPLAY
★ Nature of failure: When the engine starting switch is turned ON, none of the machine monitor lamps light up
or none of the gauges is displayed. (No failure code is displayed, though)
★ Before starting troubleshooting, check that fuse BT2-20, BT2-2, and the fusible link are normal (if any fuse
is blown, there has probably been a surge of current caused by a short circuit, so check the related circuits).
Cause Remedy
1
• Insert T-adapter to DPC1. Is voltage between DPC1 (6)(7) NO
• Turn starting switch ON. – (9)(10) 20 – 30 V?
YES
2
Is voltage between DPC1 (6)(7) NO
• Insert T-adapter to DPC1.
• Turn starting switch ON. and ground 20 – 30 V?
between DPC1 (female) (9)(10) replace
and ground
NO disconnection in wiring harness
• Disconnect fuse BT2-1. Is voltage between fuse BT2-1 between fuse BT2-1 inlet - Repair or
• Turn starting switch ON. inlet and ground 20 - 30 V? starting switch - BT2-20 - battery replace
relay B
and fuse BT2-2 outlet
HM300-1 20-721
1 c
(9) c
MON-12 WHEN STARTING SWITCH IS OFF, MACHINE MONITOR CANNOT BE OPERATED
★ Nature of failure: Even when the starting switch is turned OFF, the service meter & odometer, turn signal
pilot lamp, and head light beam pilot lamp do not flash (no failure code is displayed).
★ Check that the monitor does not give a display when any of the switches (machine monitor mode selector
switch 1, combination switch, or hazard lamp switch) are operated.
Cause Remedy
1
When starting switch is turned NO Carry out
• Turn starting switch ON. ON, does machine monitor give Defective main power source troubleshoo
normal display? system ting MON-
12.
YES
2
• Insert T-adapter to DPC1. Is voltage between DPC1 (4)(5) – NO
• Turn starting switch OFF. (9)(10) 20 – 30 V?
YES
3
• Disconnect fuse BT2-22. Is voltage between fuse BT2-21 NO disconnection in wiring harness Repair or
• Turn starting switch ON. inlet and ground 20 – 30 V? between fuse BT2-21 inlet and replace
J01 (female)
and fuse BT2-22 outlet
20-722 HM300-1
c 1 c
(9)
MON-13 ALARM BUZZER DOES NOT SOUND
★ Nature of failure: When the starting switch is ON, when the emergency stop items are lighted up, or when
the central warning lamp is lighted up, the alarm buzzer does not sound (no failure code
is displayed).
Cause Remedy
1
• Disconnect DPC1. Is voltage between DPC1 NO
• Turn starting switch ON. (female) (13) and ground 20 – 30
V?
YES
2
• Disconnect BZ2. Is voltage between BZ2 (female) NO disconnection in wiring harness Repair or
• Turn starting switch ON. (1) and ground 20 – 30 V? between fuse BT2-2 outlet and replace
BZ2 (female) (1)
YES
3
• Turn starting switch OFF. Is resistance between DPC1 Defective contact or
NO disconnection in wiring harness Repair or
• Disconnect DPC1 and (female) (13) and BZ2 (female)
BZ2. (1) less than 1 Ω? between DPC1 (female) (13) replace
and BZ2 (female) (2)
YES
Defective alarm buzzer Replace
HM300-1 20-723
1 c
(9) c
MON-14 GAUGES, CAUTION LAMPS, CHARACTER DISPLAY ON MACHINE MONITOR DO

NOT GIVE CORRECT DISPLAY
★ Nature of failure: The display of the gauges, lamps, and character display is not normal (no failure code is
displayed).
a) Gauge display is different from condition of machine
Cause Remedy
1
Does gauge work normally when NO
• Turn starting switch ON. machine monitor check switch is Defective machine monitor Replace
operated?
YES
2 Carry out
• Turn starting switch ON. When input condition of NO Defective signal system of troubleshoot-
• Operate machine applicable signal is monitored, is applicable sensor ing for signal
monitor. it found to be normal? system
YES
b) Caution lamp display is different from condition of machine
Cause Remedy
1
Do lamps light up and go off NO
• Turn starting switch ON. when machine monitor check Defective machine monitor Replace
switch is operated?
YES
2 Carry out
When input condition of troubleshoo-
• Turn starting switch ON. NO Defective switch or signal ting for
• Operate machine applicable signal is monitored, is system of applicable sensor signal
monitor. it found to be normal? system
YES
c) Nothing is displayed on character display, or display is not correct
Cause Remedy
1
When machine monitor check NO
• Turn starting switch ON. switch is operated, does display Defective machine monitor Replace
give normal display?
YES
20-724 HM300-1
c 1 c
(9)
MON-15 ACTUATION CHECK OF MACHINE MONITOR CANNOT BE PERFORMED

PROPERLY
★ Nature of failure: Even when the machine monitor check switch is pressed, no lamps or gauges work, or
even when the machine monitor check switch is released, all the lamps stay ON.
Cause Remedy
1
DPC2A. Is voltage between DPC2A (10) NO
YES
2
• Turn starting switch OFF. Is resistance between CK1 (male) NO Defective machine monitor Replace
• Disconnect CK1. (3) and (6) as shown in Table 2? check switch
YES
3
• Disconnect CK1. Is voltage between CK1 (female) in wiring harness between fuse Repair or
• Turn starting switch ON. (3) and ground 20 – 30 V? BT2-2 outlet and CK1 (female) (3) replace
YES or hot short in wiring harness Repair or
between DPC2A (female) (10) replace
and CK1 (female) (6)
Table 1 Table 2
Machine monitor Machine monitor
DPC2A Voltage CK1 (male) Resistance value
check switch check switch
Between (10) Release Max. 1 V Between (3) Release Min. 1 MΩ

and ground Press 20 – 30 V and (6) Press Max. 1 Ω
HM300-1 20-725
1 c
(9) c
MON-16 Character display cannot be switched properly
★ Nature of failure: Even when machine monitor mode selection switches 1 or 2 are operated, the display on
the character display does not change (no failure code is displayed).
a) Machine monitor mode selector switch 1 system is not normal
Cause Remedy
1
• Insert T-adapter to Is voltage between DPC2A (8) NO
DPC2A.
YES
2
• Turn starting switch OFF. Is resistance between CH1 (male) NO Defective machine monitor Replace
• Disconnect CH1. (2) and (3) as shown in Table 2? mode selector switch 1
YES
• Disconnect CH1. Is voltage between CH1 (female) NO disconnection in wiring harness Repair or
CH1 (female) (3)
YES hot short in wiring harness between Repair or
DPC2A (female) (8) and CH1 replace
(female) (2)
4
DPC2A.
YES
5

and CH1 (female) (1)
Table 1 Table 2
DPC2A mode selector Voltage CH1 (male) mode selector Resistance value
switch 1 switch 1
Between (8) Press [ ] 20 – 30 V Between (2) Press [ ] Max. 1 Ω

and ground Neutral Max. 1 V and (3) Neutral Min. 1 MΩ
Between (14) Neutral Max. 1 V Between (1) Neutral Min. 1 MΩ

and ground Press [ ] 20 – 30 V and (3) Press [ ] Max. 1 Ω
20-726 HM300-1
c 1 c
(9)
b) Machine monitor mode selector switch 2 system is not normal
Cause Remedy
1
DPC2A.
YES
2
YES
• Disconnect CH2. Is voltage between CH2 (female) NO disconnection in wiring harness Repair or
CH2 (female) (3)
DPC2A (female) (6) and CH1 replace
(female) (2)
4
DPC2A.
YES
5

and CH2 (female) (1)
Table 3 Table 4
DPC2A mode selector Voltage CH2 (male) mode selector Resistance value
switch 2 switch 2
Between (6) Press [>] 20 – 30 V Between (2) Press [>] Max. 1 Ω


and ground Press [<] 20 – 30 V and (3) Press [<] Max. 1 Ω
HM300-1 20-727
1 c
(9) c
20-728 HM300-1
c 1 c
MON-17 POWER MODE SELECTOR FUNCTION DOES NOT WORK PROPERLY
★ Nature of failure: Even when the power mode selector switch is operated, the power mode switching func-
tion does not work normally, or the power mode pilot lamp does not light up and go out
normally (no failure code is displayed).
Cause Remedy
1
DPC2A. and ground as shown in Table 1?
YES
2
Is resistance between PWM NO Defective power mode selector
• Turn starting switch OFF. Replace
• Disconnect PWM. (male) (1) and (3) as shown in switch
Table 2?
YES
3
• Disconnect PWM. Is voltage between PWM (female) NO disconnection in wiring harness Repair or
PWM (female) (1)
DPC2A (female) (13) and PWM replace
(female) (3)
4 Go to
Does condition become normal NO troubleshoot-
• Turn starting switch ON. when machine monitor is Defective control system of
engine controller ing for
replaced? applicable
circuit
YES
Table 1 Table 2
Power mode se- Power mode se-
DPC2A Voltage PWM (male) Resistance value
lector switch lector switch
Between (13) Up Max. 1 V Between (1) Up Min. 1 MΩ

and ground Down 20 – 30 V and (3) Down Max. 1 Ω
HM300-1 20-729
1 c
(9) c
MON-18 AISS FUNCTION DOES NOT WORK PROPERLY
★ Nature of failure: Even when the AISS LOW switch is operated, the AISS function does not work normally
(no failure code is displayed).
Cause Remedy
1
YES
2
Is resistance between AISS NO
(male) (1) and (3) as shown in Defective AISS LOW switch Replace
• Disconnect AISS.
Table 2?
YES
3
• Disconnect AISS. Is voltage between AISS (female) NO disconnection in wiring harness Repair or
AISS (female) (1)
DPC2A (female) (2) and AISS replace
(female) (3)
4 Go to
Does condition become normal NO troubleshoot-
• Turn starting switch ON. when machine monitor is Defective control system of
engine controller ing for
replaced? applicable
circuit
YES
Table 1 Table 2
DPC2A AISS LOW switch Voltage AISS (male) AISS LOW switch Resistance value
Between (2) Up Max. 1 V Between (1) Up Min. 1 MΩ

20-730 HM300-1
c 1 c
(9)
MON-19 EXHAUST BRAKE DOES NOT WORK PROPERLY (MACHINES EQUIPPED WITH
EXHAUST BRAKE)
★ Nature of failure: Even when the exhaust brake switch is operated, the exhaust brake does not work nor-
mally, or the exhaust brake pilot lamp does not light up and go out normally (no failure code
is displayed).
Cause Remedy
1
YES
2
. Turn starting switch OFF. Is resistance between EXH (male) NO
. Disconnect EXH. (1) and (2) as shown in Table 2? Defective exhaust brake switch Replace
YES
3
• Disconnect EXH. Is voltage between EXH (female) NO disconnection in wiring harness Repair or
• Turn starting switch ON. (1) and ground 20– 30 V? between fuse BT2-2 outlet and replace
EXH (female) (1)
DPC2A (female) (11) and EXH replace
(female) (2)
4
• Insert T-adapter to Is voltage between DPC2A (3) and NO
DPC2A. ground as shown in Table 1?
YES
5
• Turn starting switch OFF. Is resistance between EXH (male) NO
• Disconnect EXH. (1) and (3) as shown in Table 2?
Defective exhaust brake switch Replace

between DPC2A (female) (3) and replace
EXH (female) (3)
6 Go to
troubleshoot-
Does condition become normal NO Defective control system of ing for
• Turn starting switch ON. when machine monitor is replaced? retarder controller applicable
circuit
YES
Table 1 Table 2
Exhaust brake Exhaust brake
DPC2A Voltage EXH (male) Resistance value
switch switch
Between (11) Up 20 – 30 V Between (1) Up Max. 1 Ω


HM300-1 20-731
1 c
(9) c
20-732 HM300-1
c 1 c
MON-20 SEAT BELT CAUTION LAMP DISPLAY IS NOT SHOWN PROPERLY
★ Nature of failure: Operation of the seat belt and the seat belt caution lamp display are not normal (no failure
code is displayed).
a) Seat belt is fitted, but lamp lights up

Cause Remedy
1
• Insert T-adapter to NO
DPC2B. Is voltage between DPC2B (11)
• Turn starting switch ON. and ground 20 – 30 V?
YES
2
• Turn starting switch OFF. Is resistance between SBS (male) NO
(1) and (2) less than 1 Ω? Defective seat belt switch Replace
• Disconnect SBS.
YES
3
• Disconnect SBS. Is voltage between SBS (female) NO disconnection in wiring harness Repair or
• Turn starting switch ON. (1) and ground 20 – 30 V? between fuse BT4-2 and SBS replace
(female) (1)
between DPC2B (female) (11) replace
and SBS (female) (2)
b) Seat belt is not fitted, but lamp does not light
Cause Remedy
1
• Insert T-adapter to Is voltage between DPC2B (11) NO
DPC2B. and ground less than 1 V?
YES
2
• Turn starting switch OFF. Is resistance between SBS (male) NO
• Disconnect SBS. (1) and (2) more than 1 MΩ? Defective seat belt switch Replace

DPC2B (female) (11) and SBS
Repair or
(female) (2) replace
HM300-1 20-733
1 c
(9) c
20-734 HM300-1
c 1 c
MON-21 TURN SIGNAL LAMP, HAZARD LAMP DO NOT WORK PROPERLY
★ Nature of failure: The turn signal lamp and hazard lamp do not work normally (no failure code is displayed).
★ Before starting troubleshooting, check that fuse BT2-24 and BT3-4 are normal (if either fuse is blown, there
has probably been a surge of current caused by a short circuit, so check the related circuits).
★ The turn signal lamps are divided into front, rear, left, and right from the switch and relay, so if only one of
the lamps does not light up, there is probably a broken bulb, defective wiring harness at the signal end (be-
tween the dividing point and the lamp), or defective wiring harness at the GND end (between the lamp and
ground).
a) Even when turn signal lever and hazard lamp switch are operated, no turn signal lamps light up
Cause Remedy
1
• Turn starting switch ON. when hazard relay 2 (R17) is
YES
Defective hazard relay 2 (R17) Replace
2
• Disconnect FBL. Is voltage between FLB (wiring NO disconnection in wiring harness Repair or
• Turn starting switch ON. harness end) and ground 20 – 30 V? between R17 (female) (3) and replace
FLB
YES
3
• Turn starting switch OFF. Is resistance between FLL (wiring Defective contact or
• Disconnect FLL, CM, harness end) – CM (female) (6),
and R16. R16 (female) (1)(3) less than 1 Ω? between FLL and wiring harness replace
dividing point
YES
Defective flasher Replace
b) When turn signal lever and hazard lamp switch are operated, turn signal lamps light up but do not
flash
Cause Remedy
1
• Disconnect FLL, CM, Is voltage between FLL (wiring NO Hot short in wiring harness
and R16. harness end) and ground less between FLL - CM (female) (6) - Repair or
• Turn starting switch ON. than 1 V? R16 (female) (1)(3) replace
YES
Defective flasher Replace
HM300-1 20-735
1 c
(9) c
c) Even when turn signal lever is operated, turn signal lamps on both sides (left and right), or on one
side only do not flash (they flash normally when hazard lamp switch is operated)
Cause Remedy
1
YES
2
• Turn starting switch ON. (6) and ground 20 – 30 V? between fuse BT1-4 and R17 replace
(female) (6)
YES
3
• Disconnect CM. Is voltage between CM (female) NO disconnection in wiring harness Repair or
• Turn starting switch ON. (6) and ground 20 – 30 V? between CM (female) (6) and replace
wiring harness dividing point
YES
Defective turn signal lever Replace
20-736 HM300-1
c 1 c
d) Even when hazard lamp switch is turned ON, no turn signal lamps flash (they flash normally when
turn signal lever is operated)
Cause Remedy
1
YES Defective hazard relay 1 (R16) Replace
or hazard relay 2 (R17)
2
• Turn starting switch ON. (5) and ground 20 – 30 V? between fuse BT2-24 and R17 replace
(female) (5)
YES
3
• Turn starting switch ON. (1)(3) and ground 20 – 30 V? between FLL and R16 (female) replace
(1)(3)
YES
4
Is voltage between R16 (female) NO
• Disconnect R16 and R17. (5) – ground and between R17
• Turn hazard switch ON.
(female) (1) – ground 20 – 30 V?
YES in wiring harness between R16 Repair or
(female) (6) – ground or between replace
R17 (female) (2) – ground
5
• Turn starting switch OFF. Is resistance between HAZ (male) NO
• Disconnect HAZ. (1) and (3) as shown in Table 1? Defective hazard lamp switch Replace
YES
6
• Turn starting switch OFF. Is voltage between HAZ (female) NO Defective contact or
• Disconnect HAZ. (1) and ground 20 – 30 V? between fuse BT2-24 and HAZ replace
(female) (1)
in wiring harness between HAZ Repair or
(female) (3) –R16 (female) (5) or replace
R17 (female) (1)
Table 1
Hazard lamp
HAZ (male) Resistance value
switch
Between (1) OFF Min. 1 MΩ

and (3) ON Max. 1 Ω
HM300-1 20-737
1 c c
e) Even when hazard lamp switch is turned OFF, turn signal lamps flash (they flash normally when turn
signal lever is operated)
Cause Remedy
1
YES
2
• Turn starting switch OFF. Is resistance between HAZ (male) NO
• Disconnect HAZ. (1) and (3) as shown in Table 1? Defective hazard lamp switch Replace

HAZ (female) (3) – R16 (female) (5) Repair or
or R17 (female) (1) replace
Table 1
Hazard lamp
HAZ (male) Resistance value
switch
OFF Min. 1 MΩ
Between (1) and (3)
ON Max. 1 Ω
f) Turn signal pilot lamp does not flash normally (turn signal lamps flash normally)
Cause Remedy
• Insert T-adapter to Is voltage between DPC2A (7) – NO in wiring harness between DPC2A
DPC2A. ground and between (16) – ground (female) (7) – R16 (female) (4) or Repair or
• Turn starting switch ON. as shown in Table 2? between DPC2A (female) (16) – replace
R16 (female) (2)
YES
Table 2
DPC2A Turn signal lever Voltage Remarks
Right Max. 1 V/20 – 30 V Voltage varies in turn
Between (7) and ground
Neutral Max. 1 V
Neutral Max. 1 V
Left Max. 1 V/20 – 30 V Voltage varies in turn
20-738 HM300-1
c 1 c
(9)
HM300-1 20-739
1 c c
MON-22 NIGHT LIGHTING IS NOT NORMAL
★ Nature of failure: The night lighting of the machine monitor, head lamps, and passing lamps do not work nor-
mally (no failure code is displayed).
★ Before starting troubleshooting, check that fuse BT1-2, BT1-6, BT1-8, BT1-10, and BT1-12 are normal (if
any fuse is blown, there has probably been a surge of current caused by a short circuit, so check the related
circuits).
★ The lamps and night lighting are divided into item of each equipment from the switch and relay, so if only
one item of equipment does not light up, there is probably a broken bulb, defective wiring harness at the
signal end (between the dividing point and the lamp), or defective wiring harness at the GND end (between
the lamp and ground).
a) Even when lamp switch is operated to 1st stage or 2nd stage, none of side lamps, night lighting, or
head lamps light up
Cause Remedy
1
• Disconnect CM. Is voltage between CM (female) NO in wiring harness between fuse Repair or
• Turn starting switch ON. (1) and ground 20 – 30 V? BT1-2 and CM (female) (1) replace
YES
Defective lamp switch Replace
b) When lamp switch is operated to 1st stage, side lamps and night lighting do not light up
Cause Remedy
1
OFF. Is resistance between CM (male) NO Defective lamp switch Replace
• Disconnect CM. (1) and (2) as shown in Table 1?

between CM (female) (2) and replace
Table 1
CM (male) Lamp Switch Resistance Value
OFF Max. 1 MΩ
Between (1) and (2)
1st stage Min. 1 Ω
20-740 HM300-1
c 1 c
(9)
c) Lamp switch is turned OFF, but side lamps and night lighting light up
Cause Remedy
1
OFF. Is resistance between CM (male) NO Defective lamp switch Replace
• Disconnect CM. (1) and (2) as shown in Table 1?

CM (female) (2) and side lamp, Repair or
machine monitor, night lighting replace
dimmer switch
Table 1
OFF Max. 1 MΩ
Between (1) and (2)
1st stage Min. 1 Ω
d) Even when night lighting dimmer switch is operated, brightness of night lighting cannot be adjusted
Cause Remedy
1
• Insert T-adapter to LS. Is voltage between LS (1) and NO
• Set lamp switch to 1st stage. (3) 20 – 30 V?
YES
2
• Turn starting switch OFF. Is resistance between LS (female) in wiring harness between LS Repair or
• Disconnect LS. (3) and ground less than 1 Ω? (female) (3) and ground replace
YES Defective contact or disconnection in
wiring harness between LS (female) Repair or
(1) and wiring harness dividing point replace
3
• Insert T-adapter to LS. NO Defective night lighting dimmer
• Turn starting switch ON. Is voltage between LS (2) and Replace
• Set lamp switch to 1st stage. (3) as shown in Table 2? switch (rheostat)
YES Defective contact or disconnection in

wiring harness between LS (female) Repair or
(2) and wiring harness dividing point replace
Table 2
LS Switch position Voltage
Left end 6 – 10 V
Between (2) and (3)
Right end 18 – 27 V
HM300-1 20-741
(9)
1 ! !
e) Even when lamp switch is operated to 2nd stage, head lamps do not light up
Cause Remedy
1
•Turn starting switch OFF. Is resistance between CM (male) NO
• Disconnect CM. (1) and (3) as shown in Table 3? Defective lamp switch Replace
YES
2
• Disconnect R31.
• Set lamp switch to 2nd stage. (1)(2)(3)(4) and ground 20 – 30 V? between CM (female) (3) and R31 replace
(female) (1)(2)(3)(4)
YES
Defective passing relay Replace
Table 3
OFF Max. 1 MΩ
Between (1) and (2)
2nd stage Min. 1 Ω
20-742 HM300-1
c 1 c
(9)
f) Head lamp Hi beam does not light up (Lo beam lights up)
Cause Remedy
1
• Disconnect R29. Defective contact or
• Turn starting switch ON. Is voltage between R29 (female) NO disconnection in wiring harness Repair or
• Set lamp switch to 2nd stage. (1)(3) and ground 20 – 30 V? between fuse BT1-2 and R29 replace
(female) (1)(3)
YES
2
• Disconnect R29. Is voltage between R29 (female) NO
• Set lamp switch to 2nd stage. (5) and (6) as shown in Table 4?
YES
3
• Turn starting switch OFF. Is resistance between R29 (female) in wiring harness between R29 Repair or
• Disconnect R29. (6) and ground less than 1 Ω? (female) (6) and ground replace
YES
4
• Turn starting switch OFF. Is resistance between CM (male) NO
• Disconnect CM. Defective passing switch Replace
(4) and (5) as shown in Table 5?
YES
5
• Insert T-adapter to CM. Is voltage between CM (4) and NO disconnection in wiring harness Repair or
• Turn starting switch ON. ground 20 – 30 V? between CM (female) (4) and replace
in wiring harness between CM Repair or
(female) (5) and R29 (female) (5) replace
6
Does condition become normal Defective contact or
• Turn starting switch ON. when head lamp Hi relay (R29)
is interchanged with other relay? between R29 (female) (2)(4) replace
and head lamp
YES
Defective head lamp Hi relay Replace
Table 4
R29 (female) Dimmer switch Voltage Remarks
Operate between Each time switch is operated,
Between (5) and (6) Min. 1 V/20 – 30 V
Hi and Lo voltage changes
Table 5
CM (male) Dimmer switch Voltage Remarks
Operate between Min. 1 Ω/ Each time switch is operated,
Between (4) and (5)
Hi and Lo Max. 1 MΩ resistance changes
HM300-1 20-743
1 c
(9) c
g) Head lamp Lo beam does not light up (Hi beam lights up)
Cause Remedy
1
• Disconnect R30. Defective passing relay or defective
• Turn starting switch ON. Is voltage between R30 (female) NO contact or disconnection in wiring Repair or
• Set lamp switch to 2nd stage. (3) and ground 20 – 30 V? harness between fuse R31 (female) replace
(5)(7) and R30 (female) (3)
YES
2
• Disconnect R30. Is voltage between R29 (female) NO
• Set lamp switch to 2nd stage. (1) and (2) as shown in Table 6?
YES
3
• Turn starting switch OFF. Is resistance between R30 (female) in wiring harness between R30 Repair or
• Disconnect R30. (2) and ground less than 1 Ω? (female) (2) and ground replace
YES
4
• Turn starting switch OFF. Is resistance between CM (male) NO
• Disconnect CM. Defective passing switch Replace
(4) and (5) as shown in Table 7?
YES
5
• Insert T-adapter to CM. Is voltage between CM (4) and NO disconnection in wiring harness Repair or
• Turn starting switch ON. ground 20 – 30 V? between CM (female) (4) and replace
between CM (female) (5) and R30 Repair or
(female) (1) replace
6
Does condition become normal Defective contact or
• Turn starting switch ON. when head lamp Lo relay (R30)
is interchanged with other relay? between R30 (female) (6) and replace
head lamp
YES
Defective head lamp Lo relay Replace
Table 6
R30 (female) Passing switch Voltage Remarks
Operate between Hi Each time switch is operated,
Between (1) and (2) Min. 1 V/20 – 30 V
and Lo voltage changes
Table 7
CM (male) Passing switch Voltage Remarks
Operate between Hi Min. 1 Ω/ Each time switch is operated,
Between (4) and (5)
and Lo Max. 1 MΩ resistance changes
20-744 HM300-1
c 1 c
(9)
h) When head lamp is operated to Hi beam, machine monitor pilot lamp does not light up (Hi beam
lights up)
Cause Remedy
1
• Insert T-adapter to DPC2A.
Is voltage between DPC2A (5) NO in wiring harness between DPC2A Repair or
• Set lamp switch to 2nd stage. and ground as shown in Table 8? (female) (5) and wiring harness replace
dividing point
YES
Table 8
DPC2A Passing switch Voltage
Lo Min. 1 V
Hi 20 – 30 V
HM300-1 20-745
1 c
(9) c
20-746 HM300-1
c 1 c
TROUBLESHOOTING OF
HYDRAULIC, MECHANICAL
SYSTEM (H MODE)
H-1 Machine does not start ................................................................................................................ 20-802

H-2 Machine does not travel smoothly (machine jerks) ..................................................................... 20-803
H-3 Lock-up clutch cannot be disengaged (engine stalls) ................................................................. 20-803
H-4 Excessive shock when starting or shifting ................................................................................... 20-804
H-5 Transmission does not shift up .................................................................................................... 20-805
H-6 Machine lacks power or speed when traveling ............................................................................ 20-806
H-7 Time lag is excessive when starting or shifting gear ................................................................... 20-809
H-8 Torque converter oil temperature is high ..................................................................................... 20-810
H-9 Torque converter oil pressure is low ............................................................................................ 20- 811
H-10 Front brake is ineffective, or effective only on one side ............................................................... 20-812
H-11 Center brake is ineffective, or effective only on one side ............................................................ 20-813
H-12 Steering wheel is heavy ............................................................................................................... 20-814
H-13 Steering wheel does not work ..................................................................................................... 20-815
H-14 Steering wheel vibrates ............................................................................................................... 20-816
H-15 Dump body lifting speed is slow, or lacks power ......................................................................... 20-817
H-16 Dump does not work ................................................................................................................... 20-818
H-17 Excessive hydraulic drift of dump body ....................................................................................... 20-819
Remedy symbol Remedy

X Replace
Repair
A Adjust
C Clean
HM300-1 20-801
1 c c
TROUBLESHOOTING H-1
H-1 MACHINE DOES NOT START
Ask the operator the following questions Causes

• Did the problem suddenly happen? a b c d e f g h i j k l m n
Yes = Internal seizure, damage
• When this happened, was there any abnormal
noise?
Yes = Broken part
Drop in set pressure of power train main relief valve
Defective operation of speed clutch ECMV solenoid

Checks before troubleshooting
Air sucked in at suction side of power train pump
Defective operation of speed clutch ECMV valve

Defective power train pump drive system (PTO)
• Is the oil level in the transmission case correct?
Defective speed clutch piston sealing, groove

• Is the torque converter, transmission input shaft bro-
ken? (Monitor with the transmission input shaft
Defective speed clutch shaft seal ring

speed sensor.)
Defective function of speed sensor

Clogged power train pump strainer
• Is the drive shaft broken?
Breakage inside torque converter

• Is there any dragging of the foot brake, retarder
Breakage inside transmission

Defective power train pump
(which is not used in E-SPEC), exhaust brake (ma-
chines equipped with exhaust brake), or parking
Defective speed clutch

brake?
Seized speed clutch

• Is the retarder lever potentiometer returned to the
RELEASE position? (E-SPEC)
• Is any failure code related to the power train dis-
played?
No. Problems Remedy

C
1 Abnormal noise comes from between power train pump and filter
2 Machine does not start in any speed range (Item 1 normal)
3 Machine starts normally in certain speed range
4 Machine does not start when torque converter oil temperature rises
5 Measure power Low at every speed range
6 train main relief Becomes lower at certain speed range
7 pressure Oil pressure gauge is unstable and fluctuates excessively
8 When pressure pickup port plug is removed and engine is

cranked, no oil comes out
9 Clutch oil pressure is abnormal
10 Power train main relief pressure is low
Clutch used
Hi Lo 1st 2nd 3rd R
R2
R1
N
Speed range
F1
F2
F3
F4
F5
F6
20-802 HM300-1
c 4 c
1
(9)
TROUBLESHOOTING
TROUBLESHOOTING H-2
H-2, H-3
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE JERKS)
• There is hunting.
Causes
• Lock-up pilot lamp flashes
a b


• Is any failure code related to the power train displayed?
Worn speed clutch seal ring

No. Remedy See H-6
Problems
Does not travel smoothly
H-3 LOCK-UP CLUTCH CANNOT BE DISENGAGED (ENGINE STALLS)
Checks before troubleshooting Causes

• Is the oil level in the transmission case correct? a b c
Defective operation of lock-up ECMV solenoid

Defective operation of lock-up ECMV valve
Seized lock-up clutch
Remedy C
No. Problems
1 When lock-up clutch pressure is measured, it does not become 0
2 When lock-up clutch pressure is measured, it becomes 0, but lock-up clutch is not disengaged
3 Operation of lock-up ECMV valve is normal
4 Operation of lock-up ECMV solenoid is normal
HM300-1 20-803
1 c
(9) c
TROUBLESHOOTING H-4
H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING
Judgement standard
Causes
There is some shock, but it is difficult to judge if the shock is
a b c
excessive or not, so judge that it is excessive in the following
cases.
Defective operation of speed clutch ECMV pressure control valve spool

• It is clear that the shock has suddenly become excessive.
Defective operation of speed clutch ECMV flow detection valve spool

• The shock is excessive compared with other machines of
the same class.

Defective operation of speed clutch ECMV solenoid

Remedy C C
No. Problems
Excessive shock when starting or shifting
20-804 HM300-1
c 1 c
TROUBLESHOOTING H-5
H-5 Transmission does not shift up

• Is any failure code related to the power train displayed? a b c d
q This is the most probable cause, but for details, see H-6.
Defective speed clutch piston seal ring, groove

Defective operation of speed clutch ECMV
Clutch used
Slipping or damage of lock-up clutch

Hi Lo 1st 2nd 3rd R
R2
R1
N
Speed range
F1
F2
F3
F4
F5
F6
C
Remedy
No. Problems
Shifts up when traveling downhill
Does not shift up, regardless of road surface
HM300-1 20-805
1 c
(9) c
TROUBLESHOOTING H-6
H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING
a) Abnormality at all speed ranges

Causes
a b c d e f g h i j k
• Is there any external oil leakage from the piping or valve
Torque converter lock-up does not engage (carry out troubleshooting for H-6b)
Excessive oil leakage inside torque converter (defective seal ring, loose plug)
connections (joints)?
• Is there any dragging of the foot brake, retarder (which is
Defective operation of torque converter relief valve, deteriorated spring

not used in E-SPEC), exhaust brake (machines equipped
with exhaust brake), or parking brake?
• Is the retarder lever potentiometer returned to the RE-
LEASE position? (E-SPEC)
Defect inside torque converter (turbine rivet broken)

Defective torque converter outlet piping, cooler

Defective torque converter freewheel
Drop in performance of engine
No. Problems Remedy

C
1 Abnormal noise comes from between power train pump and filter
2 Torque converter stall speed is high
3 Torque converter stall speed is low
4 Measure power Low at every speed range (Item 2 normal)
5 train main relief Oil pressure gauge is unstable and fluctuates excessively
6 pressure Becomes low when lock-up is engaged
7 Hydraulic pressure at torque converter inlet port is low (Items 4 - 6 normal)
8 Hydraulic pressure at torque converter outlet port is low (Item 7 normal)
Pieces of iron and aluminium stuck to strainer and drain plug of transmis-
9 sion case
10 Hydraulic pressure at power train pump outlet port is low
11 When carrying out troubleshooting for Item 10, if oil temperature rises, oil pressure drops
20-806 HM300-1
c 4 c
1
(9)
TROUBLESHOOTING H-6
b) Abnormality at some speed ranges Causes

a b c d e f g h i j k l
• Is there any dragging of the foot brake, retarder (which is
not used in E-SPEC), exhaust brake (machines equipped
with exhaust brake), or parking brake?
• Is the retarder lever potentiometer returned to the RE-
LEASE position? (E-SPEC)
2nd clutch disc worn or seized, seal ring worn
3rd clutch disc worn or seized, seal ring worn
1st clutch disc worn or seized, seal ring worn
Lo clutch disc worn or seized, seal ring worn
Hi clutch disc worn or seized, seal ring worn
R clutch disc worn or seized, seal ring worn
Defective operation of 2nd clutch ECMV
Defective operation of 3rd clutch ECMV
Defective operation of 1st clutch ECMV
Clutch used
Defective operation of Lo clutch ECMV
Defective operation of Hi clutch ECMV
Defective operation of R clutch ECMV
Hi Lo 1st 2nd 3rd R
R2
R1
N
Speed range
F1
F2
F3
F4
F5
F6
No. Problems Remedy
1 F2, F4, and F6 are abnormal, but other speed ranges are normal
Same as Item 1, but condition returns to normal when ECMV for Hi
2
clutch is replaced with ECMV for R clutch
3 F1, F3, and F4 are abnormal, but other speed ranges are normal
Same as Item 3, but condition returns to normal when ECMV for Lo
4
5 F1, F2, and R1 are abnormal, but other speed ranges are normal
Same as Item 5, but condition returns to normal when ECMV for 1st
6
7 F3, F4, and R2 are abnormal, but other speed ranges are normal
Same as Item 7, but condition returns to normal when ECMV for 2nd
8
9 F5 and F6 are abnormal, but other speed ranges are normal
Same as Item 9, but condition returns to normal when ECMV for 3rd
10
R1 and R2 are abnormal, but other speed ranges are normal
11
Same as Item 11, but condition returns to normal when ECMV for R
12
clutch is replaced with ECMV for Hi clutch
HM300-1 20-807
1 c
4
(9) c
TROUBLESHOOTING H-6
c) Torque converter lock-up does not engage Causes

a b c d e f g
Ask the operator the following questions
• Did the problem suddenly happen?
Yes = Internal seizure, damage
• When this happened, was there any abnormal noise?
Yes = Broken part
Defective operation of lock-up ECMV solenoid spool
Defective operation of lock-up ECMV valve spool
• Is there any external oil leakage from piping or valve con-
nections (joints)?
Worn lock-up clutch piston seal ring
Defective lock-up ECMV solenoid
Cracked lock-up clutch case
Worn lock-up clutch disc
No. Problems Remedy
2 With Item 1 normal, lock-up clutch pressure is low or 0
With Item 2 abnormal, no disconnection, short circuit, or short circuit with ground is
3
found in lock-up ECMV solenoid
With Item 2 abnormal, disconnection, short circuit, or short circuit with
4
ground is found in lock-up ECMV solenoid
5 With Items 1 - 4 normal, lock-up oil pressure is low
6 With Items 1 - 4 normal, lock-up oil pressure is normal
7 When oil pressure is measured, main relief pressure and lock-up clutch pressure are both low
8 Lock-up takes time to engage
20-808 HM300-1
c 1 c
(9)
TROUBLESHOOTING H-7
H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR

• Is the oil level in the transmission case cor-
a b c d e f g h i j k l m n o p q r
rect?
• Is there any external oil leakage from the
piping or valve connections (joints)?
• Is operation of control valve normal?
• Is any failure code related to the power train
displayed?
2nd clutch disc worn or defective seal ring, worn seal ring
3rd clutch disc worn or defective seal ring, worn seal ring
1st clutch disc worn or defective seal ring, worn seal ring
Lo clutch disc worn or defective seal ring, worn seal ring
Hi clutch disc worn or defective seal ring, worn seal ring
R clutch disc worn or defective seal ring, worn seal ring

Defective operation of 2nd clutch ECMV

Defective shaft seal ring of speed clutch
Defective operation of 3rd clutch ECMV

Defective operation of 1st clutch ECMV
Defective operation of Lo clutch ECMV
Defective operation of Hi clutch ECMV
Defective operation of R clutch ECMV

Defective oil tightness of speed clutch
Clutch used
Hi Lo 1st 2nd 3rd R

R2 Defective power train pump
R1
N
Speed range
F1
F2
F3
F4
F5
F6
No. Problems Remedy C
1 Abnormal noise comes from around power train pump

2 There is time lag in any speed range
3 There is time lag when shifting to F2, F4, F6
4 There is time lag when shifting to F1, F3, F4
5 There is time lag when shifting to F1, F2, R1
6 There is time lag when shifting to F3, F4, R2
7 There is time lag when shifting to F5, F6
8 There is time lag when shifting to R1, R2
9 Clutch pressure is low when placed in any speed range

10 Torque converter oil temperature goes above
operating range
HM300-1 20-809
1 c c
TROUBLESHOOTING H-8
H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH
Ask the operator the following questions Causes

• Does oil temperature go up when torque converter is a b c d e
stalled and go down when torque converter is not stalled?
Yes = Normal (but if stalling is frequent, selection of speed
range is incorrect)
Oil leakage inside torque converter (defective seal ring, loose bolt,
• Is oil level in transmission case correct?
Defective operation of torque converter relief valve


Clogged power train filter
crack in pump or turbine)

Remedy
No. Problems C
1 Power train pump makes abnormal noise when oil temperature is low
2 Low idle and high idle speeds are low
3 Torque converter outlet port oil pressure is low ★
4 Torque converter inlet port oil pressure is low
5 Clutch pressure is low
6 Excessive leakage inside torque converter
★ If the results of all troubleshooting items are normal, this is the probable cause.
20-810 HM300-1
c 1 c
(9)
TROUBLESHOOTING H-9
H-9 TORQUE CONVERTER OIL PRESSURE IS LOW

a b c d e
• Is there any external oil leakage from the piping or
valve connections (joints)?
• Is any failure code related to the power train dis-
played?
Drop in set pressure of torque converter relief valve

Excessive leakage inside torque converter


No. Problems Remedy C C
1 Abnormal noise comes from power train pump
3 Torque converter inlet port pressure is low
4 Torque converter inlet pressure is low (lock-up pressure and clutch pressure are normal)
5 When torque converter relief valve is adjusted, inlet pressure becomes high
HM300-1 20-811
1 c c
TROUBLESHOOTING H-10
H-10 FRONT BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE

• Is the oil level in the transmission case correct? a b c d e f g h i j k l m n o
• Is the brake pedal play correct?
• Is there any leakage of oil from the brake piping or
deformation of the piping?
Drop in accumulator gas pressure (gas leakage, defective piston seal)

• Is the tire inflation and tread condition normal?
• Is any failure code related to the brakes displayed?
Defective rear brake pressure reducing valve

Air sucked in at suction side of PPC pump
Defective operation of wheel brake piston

Defective PPC pump drive system (PTO)
Defective accumulator charge valve
Defective wheel brake piston seal
Breakage inside wheel brake

Defective brake valve (front)
Defective slack adjuster
Defective retarder lever

Worn wheel brake disc
Defective PPC pump
Air in brake circuit

Improper axle oil
No. Problems Remedy
1 Brake has no effect only when brake pedal is depressed

2 When brake pedal is depressed, it is light
3 When brake pedal is depressed, it is heavy
4 Even when retarder lever is pulled, retarder has no effect
(This is not related to E-SPEC)
5 Extremely large operating effort is needed to obtain
specified braking effect
6 When brakes are applied, abnormal noise is heard from brake portion of axle
7 Hydraulic and steering do not work
8 Abnormal noise is heard from around PTO
9 Abnormal noise is heard from around transmission oil pan
or PPC pump
When oil is drained from inside axle case, large amounts
10
of metal particles are found
11 Accumulator charge pressure is low
12 Brake immediately loses power after engine is stopped
13 There is time lag before brake starts to take effect
14 Brake oil pressure is low
15 Brake disc wear amount is high
16 When air is bled from brake system, air comes out
20-812 HM300-1
c 1 c
4
H-11 CENTER BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE

• Is the oil level in the transmission case correct? a b c d e f g h i j k l m n o
• Is the brake pedal play correct?
• Is there any leakage of oil from the brake piping or de-
formation of the piping?
Drop in accumulator gas pressure (gas leakage, defective piston seal)

• Is the tire inflation and tread condition normal?
• Is any failure code related to the brakes displayed?
Air sucked in at suction side of PPC pump
Defective operation of wheel brake piston

Defective PPC pump drive system (PTO)
Defective accumulator charge valve
Defective brake valve (center, rear)
Defective wheel brake piston seal
Defective retarder solenoid valve

Breakage inside wheel brake
Defective slack adjuster
Defective retarder lever

Worn wheel brake disc
Defective PPC pump
Air in brake circuit

Improper axle oil
No. Problems Remedy
1 Brake has no effect only when brake pedal is depressed
2 When brake pedal is depressed, it is light
3 When brake pedal is depressed, it is heavy
4 Even when retarder lever is pulled, retarder has no effect
Extremely large operating effort is needed to obtain
5 specified braking effect
When brakes are applied, abnormal noise is heard from
6 brake portion of axle
7 Hydraulic and steering do not work
8 Abnormal noise is heard from around PTO
Abnormal noise is heard from around transmission oil pan
9 or PPC pump
When oil is drained from inside axle case, large amounts
10 of metal particles are found
11 Accumulator charge pressure is low
12 Brake immediately loses power after engine is stopped
13 There is time lag before brake starts to take effect
14 Brake oil pressure is low
15 Brake disc wear amount is high
16 When air is bled from brake system, air comes out
HM300-1 20-813
1 c
(9) c
H-12 STEERING WHEEL IS HEAVY

• Is the oil level in the hydraulic tank correct?
a b c d e f g h i
• Is there any external oil leakage between the pump – flow
amplifier valve – steering valve?
• Is the steering wheel play correct?
• Is any failure code related to the steering displayed?
Drop in set pressure of flow amplifier valve relief valve or defective oil tightness
Defective operation of flow amplifier valve spool or stuck spool
Air sucked in at suction end of hydraulic and steering pump
Defective hydraulic and steering pump drive system (PTO)
Damaged suction tube of hydraulic and steering pump

Clogged hydraulic and steering pump strainer
Defective hydraulic and steering pump
Defective steering cylinder

Defective steering valve
Remedy A
No. Problems C
1 Dump cylinder also does not work

2 When pressure pickup port plug is removed and engine is cranked, no oil comes out
3 Dump is normal
Steering oil pressure is low at end of cylinder stroke
4
(Item 3 normal)
5 Item 4 is abnormal, relief noise is heard from relief valve
6 Abnormal noise comes from between hydraulic, steering pump - filter
7 Steering wheel works when engine is at low idle
When steering cylinder is turned fully to right (left), and hose on opposite side is
8
disconnected, oil flows out continuously
9 Hydraulic and steering pump discharge amount is too low
10 Excessive play in steering wheel
20-814 HM300-1
c 1 c
(9)
H-13 STEERING WHEEL DOES NOT WORK

• Is the oil level in the hydraulic tank correct? a b c d e f g h i
• Is there any external oil leakage between the pump – flow
amplifier valve – steering valve?
• Is the steering wheel play correct?
• Is the brake (service brake or retarder brake) operated?
• Is any failure code related to the steering displayed?
Damaged suction tube of hydraulic and steering pump

Defective steering cylinder

Defective steering valve
Remedy A
No. Problems C
1 Dump cylinder also does not work

3 Dump is normal
Steering oil pressure is low at end of cylinder stroke
4
(Item 3 normal)
6 Abnormal noise comes from between hydraulic, steering pump - filter
7 Steering wheel works when engine is at low idle
When steering cylinder is turned fully to right (left), and hose on opposite side is
8
disconnected, oil flows out continuously
9 Hydraulic and steering pump discharge amount is too low
10 Excessive play in steering wheel
HM300-1 20-815
1 c
4
(9) c
H-14 STEERING WHEEL VIBRATES

Causes
• Is any failure code related to the steering displayed? a b
Leakage of air inside steering cylinder

Air in hydraulic oil
No. Remedy A
Problems
Steering wheel vibrates
20-816 HM300-1
c 1 c
H-15 DUMP BODY LIFTING SPEED IS SLOW, OR LACKS POWER

• Is the oil level in the hydraulic tank correct? a b c d e f g h i j k l
• Is there any external oil leakage between the pump –
dump valve – dump cylinder?
• Is signal value of dump lever within normal range?
• Is any failure code related to the dump displayed?
Drop in set pressure of dump valve relief valve or defective oil tightness
Air sucked in at suction side of hydraulic and steering pump
Defective operation of check valve of dump valve

Broken hydraulic and steering pump suction tube
Drop in dump EPC valve or defective operation


Defective dump EPC pump
Defective dump cylinder

Defective dump lever
Remedy A A
No. Problems C
1 Steering also does not work normally

2 Steering works normally
3 Steering relief pressure and dump relief pressure is low
5 Dump relief pressure is too high at engine high idle
6 Dump relief pressure is low
8 Dump body does not rise smoothly (moves irregularly)
9 Hydraulic and steering pump discharge amount is low
10 Items 1 - 9 are normal but dump body lifting speed is slow
11 Abnormal noise comes from between hydraulic and steering pump - filter
12 Dump EPC valve oil pressure is low
HM300-1 20-817
1 c
4
(9) c
H-16 DUMP DOES NOT WORK

• Is the oil level in the hydraulic tank correct? a b c d e f g h i j k l m
• Is signal value of dump lever within normal range?
• Is any failure code related to the dump displayed?
• Is the battery charge circuit caution lamp lighting up?
(If the alternator signal R is not output normally, the dump
controller does not operate.)
Drop in set pressure of dump valve relief valve or defective oil tightness
Broken suction tube of hydraulic and steering pump
Defective operation of check valve of dump valve

Drop in dump EPC valve or defective operation

Defective dump EPC pump
Defective dump cylinder

Defective dump lever
A A
Remedy
No. Problems C
2 Steering also does not work normally
3 Steering works normally
Item 2 is abnormal, steering relief pressure and dump relief pressure
4
is low
6 Dump relief pressure is low
8 Dump relief pressure is low at engine high idle
9 Normal when engine is at low idle
10 Hydraulic and steering pump discharge amount is low
When dump body is raised, and hose at head end of dump cylinder is
11 disconnected, oil flows out
20-818 HM300-1
c 4 c
1
(9)
H-17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY

Causes
• Is any failure code related to the dump displayed? a b

Slipping or damage of lock-up clutch
Remedy
No. Problems
1 Raise dump body and disconnect hose at head Oil flows out
2 end of dump cylinder Oil does not flow out
HM300-1 20-819
1 c
(9) c
TROUBLESHOOTING OF THE ENGINE BODY

(S MODE)
Points to remember when troubleshooting .............................................................................................. 20-902

Method of using troubleshooting charts ................................................................................................... 20-903
S-1 Starting performance is poor (starting always takes time) .............................................................. 20-907
S-2 Engine does not start ..................................................................................................................... 20-908
S-3 Engine does not pick up smoothly (follow-up is poor) .................................................................... 20- 911
S-4 Engine stops during operations ...................................................................................................... 20-912
S-5 Engine does not rotate smoothly (hunting) ..................................................................................... 20-913
S-6 Engine lacks output (or lacks power) ............................................................................................. 20-914
S-7 Exhaust smoke is black (incomplete combustion) .......................................................................... 20-915
S-8 Oil consumption is excessive (or exhaust smoke is blue) .............................................................. 20-916
S-9 Oil becomes contaminated quickly ................................................................................................. 20-917
S-10 Fuel consumption is excessive ....................................................................................................... 20-918
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down) ............................................ 20-919
S-12 Oil pressure caution lamp lights up (drop in oil pressure) .............................................................. 20-920
S-13 Oil level rises (water, fuel in oil) ...................................................................................................... 20-921
S-14 Coolant temperature becomes too high (overheating) ................................................................... 20-922
S-15 Abnormal noise is made ................................................................................................................. 20-923
S-16 Vibration is excessive ..................................................................................................................... 20-924
HM300-1 20-901
(5)
(9)
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

k Stop the machine in a level place, and check that the safety pins and blocks are securely fitted, and the park-
ing brake is securely applied.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is still hot, boiling coolant may spurt out and cause serious
burns. Always wait for the coolant temperature to go down before removing the radiator cap.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing a plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent
reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand
the structure and function. However, a short cut to effective troubleshooting is to ask the operator various ques-
tions to form some idea of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not 3. Checks before troubleshooting

hurry to disassemble the components 1) Is there any sign of abnormality in the ma-
If components are disassembled immediately chine or engine?
any failure occurs: 2) Always carry out the Checks before starting.
• Parts that have no connection with the failure 3) Carry out other checks if necessary.
or other unnecessary parts will be disassem- 4) Other maintenance items can be checked
bled. externally, so check any item that is consid-
• It will become impossible to find the cause of ered to be necessary.
the failure. 5) Check for any error display on the controller.
It will also cause a waste of man-hours, parts, or
oil or grease, and at the same time, will also lose 4. Confirming failure
the confidence of the user or operator. Confirm the extent of the failure yourself, and
For this reason, when carrying out troubleshoot- judge whether to handle it as a real failure or as
ing, it is necessary to carry out thorough prior in- a problem with the method of operation, etc.
vestigation and to carry out troubleshooting in a When operating the machine to re-enact the
accordance with the fixed procedure. troubleshooting symptoms, do not carry out
any investigation or measurement that may
2. Points to ask user or operator make the problem worse.
1) Have any other problems occurred apart
from the problem that has been reported? 5. Troubleshooting
2) Was there anything strange about the ma- Use the results of the investigation and inspec-
chine before the failure occurred? tion in Items 2 – 4 to narrow down the causes of
3) Did the failure occur suddenly, or were there failure, then use the troubleshooting matrix or
problems with the machine condition before flowchart to locate the position of the failure ex-
this? actly.
4) Under what conditions did the failure occur? a The basic procedure for troubleshooting is
5) Had any repairs been carried out before the as follows.
failure? When were these repairs carried 1) Start from the simple points.
out? 2) Start from the most likely points.
6) Has the same kind of failure occurred be- 3) Investigate other related parts or informa-
fore? tion.
6. Measures to remove root cause of failure

Even if the failure is repaired, if the root cause of
the failure is not repaired, the same failure will
occur again.
To prevent this, always investigate why the prob-
lem occurred. Then, remove the root cause.
20-902 HM300-1
(5)
(9)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspeciton with-
out using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make fi-
nal confirmation.
[Questions]
Sections A + B in the chart on the right corre-
sponds to the items where answers can be ob-
tained from the user. The items in B are items
that can be obtained from the user, depending
on the user’s level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under C in
the chart on the right correspond to this.
[Causes]
The serviceman narrows down the causes from
information A that he has obtained from the
user and the results of C that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with Q, and of these, causes that have a high prob-
ability are marked with w.
Check each of the [Questions] and [Check items]
in turn, and marked the Q or w in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is the
most probable cause, so start troubleshooting for
that item to make final confirmation of the cause.
As a rule, do not use it when calculating the points
for locating the cause, but it can be included if nec-
essary to determine the order for troubleshooting.
Use the E in the Cause column as reference for
[Degree of use (Operated for long period)] in the
[Questions] section as reference.
HM300-1 20-903
(5)
(9)
<Example of troubleshooting> Exhaust smoke is black
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)

General causes why exhaust smoke is black
• Insufficient intake of air
• There is excessive fuel.
• Abnormal fuel injection condition
• Improper selection of fuel
• Engine overheating
a See troubleshooting for [Overheat].
• Controller controlled by delayed mode
(The injection amount (output) is limited be-
cause an error has occurred in the electrical
system.)
20-904 HM300-1
(5)
HM300-1 20-905
(5)
TROUBLESHOOTING S-1
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)
General causes why starting performance is poor

• Defective electrical system
• Insufficient supply of fuel
a With the common rail fuel injection system, the fuel in-
jection timing is recognized electrically, so even when
the starting operation is carried out, the engine may not
start until the crankshaft has completed two rotations.
However, this does not indicate any abnormality.
HM300-1 20-907
(5)
TROUBLESHOOTING S-2
S-2 ENGINE DOES NOT START
a) Engine does not turn

General causes why engine does not turn
• Internal parts of engine seized
a See “Engine stops during operations”.
• Defective electrical system
• Failure in power train
a Carry out troubleshooting of the machine.
20-908 HM300-1
(5)
TROUBLESHOOTING S-2
b) Engine turns but no exhaust smoke comes out

General causes why engine turns but no exhaust
smoke comes out
• Fuel is not being supplied
• Supply of fuel is extremely small
• Improper selection of fuel (particularly in winter)
HM300-1 20-909
(5)
TROUBLESHOOTING S-2
c) Exhaust smoke comes out but engine does not start

(Fuel is being injected)
General causes why exhaust smoke comes out but en-
gine does not start
• Lack of rotating force due to defective electrical sys-
tem
20-910 HM300-1
(5)
TROUBLESHOOTING S-3
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)
General causes why engine does not pick up smoothly

(The injection amount (output) is limited because an error has
occurred in the electrical system.)
HM300-1 20-911
(5)
(9)
TROUBLESHOOTING S-4
S-4 ENGINE STOPS DURING OPERATIONS
General causes why engine stops

• Internal part of engine seized
• Failure in power train
a Carry out troubleshooting of the machine.
20-912 HM300-1
(5)
TROUBLESHOOTING S-5
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)
General causes why engine does not rotate smoothly

• Air in fuel system
• Speed sensor is not normal
(abnormality not big enough to generate error display)
HM300-1 20-913
(5)
TROUBLESHOOTING S-6
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)
General causes why engine lacks output

(The injection amount (output) is limited because an er-
ror has occurred in the electrical system.)
20-914 HM300-1
(5)
(9)
TROUBLESHOOTING S-7
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)
General causes why exhaust smoke is black

• There is excessive fuel.
(The injection amount (output) is limited because an error
has occurred in the electrical system.)
HM300-1 20-915
(5)
TROUBLESHOOTING S-8
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)
General causes why oil consumption is excessive

• Abnormal combustion of oil
• The engine has been run at low or high idle for a long
time continuously (more than 20 minutes continuous op-
eration is not allowed).
• External leakage of oil
• Wear of lubrication system
20-916 HM300-1
(5)
(9)
TROUBLESHOOTING S-9
S-9 OIL BECOMES CONTAMINATED QUICKLY
General causes why oil becomes contaminated quickly

• Entry of exhaust gas into oil due to internal wear
• Clogging of lubrication passage
• Improper fuel used
• Improper oil used
• Operation under excessive load
HM300-1 20-917
(5)
TROUBLESHOOTING S-10
S-10 FUEL CONSUMPTION IS EXCESSIVE
General causes why fuel consumption is excessive

• Leakage of fuel
• Improper condition of fuel injection (injection pressure, injection timing)
• Excessive injection of fuel
20-918 HM300-1
(5)
(9)
S-11 OIL IS IN COOLANT (OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN)
General causes why oil is in coolant

• Internal leakage in lubrication system
• Internal leakage in cooling system
HM300-1 20-919
(5)
(9)
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)
General causes why oil pressure drops

• Leakage, clogging, wear of lubricating system
• Defective oil pressure control
• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating
20-920 HM300-1
(5)
(9)
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)
General causes why oil level rises

• Coolant in oil (cloudy white)
• Fuel in oil (diluted, smells of diesel fuel)
a If there is oil in the coolant, carry out troubleshooting for “Oil is in cool-
ant”.
HM300-1 20-921
(5)
(9)
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
General causes why coolant temperature becomes too high

• Lack of cooling air (deformation, damage of fan)
• Drop in heat dissipation efficiency
• Defective cooling circulation system
• Rise in oil temperature in power train
a Carry out troubleshooting for machine.
20-922 HM300-1
(5)
(9)
S-15 ABNORMAL NOISE IS MADE
General causes why abnormal noise is made

• Abnormality due to defective parts
• Abnormal combustion
• Air sucked in from intake system
a Judge if the noise is an internal noise or an external noise.

a If the engine is not thoroughly warmed up, the engine sound be-
comes slightly louder because it is operated in the low temper-
ature mode, but this is not an abnormality.
a When the engine is accelerated, it enters the acceleration mode
and the engine noise is higher for 3 seconds, but this is not an
abnormality.
HM300-1 20-923
(5)
S-16 VIBRATION IS EXCESSIVE
General causes why vibration is excessive

• Defective parts (abnormal wear, breakage)
• Improper alignment with machine
• Abnormal combustion
a If there is abnormal noise together with the vibration, carry out trouble-
shooting also for “Abnormal noise is made”.
20-924 HM300-1
(5)
30 DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL..................30- 3 REMOVAL AND INSTALLATION OF
Removal and installation of assemblies..30- 3 TRANSMISSION AND
Disassembly and assembly of FRONT DIFFERENTIAL ASSEMBLY........... 30- 39
assemblies ............................................30- 4 Special tool ............................................. 30- 39
PRECAUTIONS WHEN CARRYING Removal.................................................. 30- 39
OUT OPERATION.......................................30- 5 Installation............................................... 30- 44
SPECIAL TOOL LIST ..................................30- 6-1 CONNECTION AND DISCONNECTION OF
REMOVAL AND INSTALLATION OF FRONT DIFFERENTIAL ASSEMBLY AND
FUEL SUPPLY PUMP ASSEMBLY ............30- 7 TRANSMISSION ASSEMBLY ...................... 30- 46
Special tool ............................................30- 7 Disconnection ......................................... 30- 46
Removal ................................................30- 7 Connection.............................................. 30- 47
Installation .............................................30- 8 DISASSEMBLY AND ASSEMBLY OF
REMOVAL AND INSTALLATION OF TORQUE CONVERTER ASSEMBLY........... 30- 48
FUEL INJECTOR ASSEMBLY ....................30- 10 Special tool ............................................. 30- 48
Removal ................................................30- 10 Disassembly............................................ 30- 48
Installation .............................................30- 11 Assembly ................................................ 30- 51
REMOVAL AND INSTALLATION OF Sketches of special tools ........................ 30- 56
NOZZLE TIP................................................30- 14 DISASSEMBLY AND ASSEMBLY OF
SPECIAL TOOL ....................................30- 14 TRANSMISSION ASSEMBLY ...................... 30- 57
Removal ................................................30- 14 Special tool ............................................. 30- 57
Installation .............................................30- 15 Disassembly............................................ 30- 57
Sketches of special tools .......................30- 16 Assembly ................................................ 30- 74
REMOVAL AND INSTALLATION OF Sketches of special tools ........................ 30-100
CYLINDER HEAD ASSEMBLY ...................30- 17 DISASSEMBLY AND ASSEMBLY OF
Special tool ............................................30- 17 FRONT DIFFERENTIAL ASSEMBLY........... 30-103
Removal ................................................30- 17 Special tool ............................................. 30-103
Installation .............................................30- 21 Disassembly............................................ 30-103
REMOVAL AND INSTALLATION OF Assembly ................................................ 30-107
ENGINE ASSEMBLY ..................................30- 25 Sketches of special tools ........................ 30-117
Special tool ............................................30- 25 REMOVAL AND INSTALLATION OF
Removal ................................................30- 25 CENTER DIFFERENTIAL
Installation .............................................30- 29 ASSEMBLY................................................... 30-118
REMOVAL AND INSTALLATION OF Special tool ............................................. 30-118
RADIATOR ASSEMBLY..............................30- 30 Removal.................................................. 30-118
Removal ................................................30- 30 Installation............................................... 30-120
Installation .............................................30- 32 DISASSEMBLY AND ASSEMBLY OF
REMOVAL AND INSTALLATION OF CENTER DIFFERENTIAL ASSEMBLY ........ 30-122
OUTPUT SHAFT ASSEMBLY.....................30- 33 Special tool ............................................. 30-122
Removal ................................................30- 33 Disassembly............................................ 30-122
Installation .............................................30- 34 Assembly ................................................ 30-127
ASSEMBLY AND DISASSEMBLY OF Sketches of special tools ........................ 30-139
OUTPUT SHAFT ASSEMBLY.....................30- 36 REMOVAL AND INSTALLATION OF
Disassembly ..........................................30- 36 REAR DIFFERENTIAL ASSEMBLY ............. 30-142
Assembly ...............................................30- 37 Removal.................................................. 30-142
Installation............................................... 30-143
HM300-1 30-1
(10)
2
DISASSEMBLY AND ASSEMBLY OF Removal ................................................. 30-204
REAR DIFFERENTIAL ASSEMBLY ............. 30-144 Installation .............................................. 30-205
Special tool ............................................. 30-144 REMOVAL AND INSTALLATION OF
Disassembly............................................ 30-144 HITCH FRAME ASSEMBLY......................... 30-206
Assembly ................................................ 30-148 Special tool............................................. 30-206
Sketches of special tools ........................ 30-158 Removal ................................................. 30-206
REMOVAL AND INSTALLATION OF Installation .............................................. 30-211
FRONT FINAL DRIVE AND Sketches of special tools........................ 30-215
BRAKE ASSEMBLY ..................................... 30-159 DISASSEMBLY AND ASSEMBLY OF
Removal.................................................. 30-159 HITCH FRAME ASSEMBLY......................... 30-216
Installation............................................... 30-160 Special tool............................................. 30-216
DISASSEMBLY AND ASSEMBLY OF Disassembly ........................................... 30-216
FRONT FINAL DRIVE AND Assembly................................................ 30-217
BRAKE ASSEMBLY ..................................... 30-161 Sketches of special tools........................ 30-222
Special tool ............................................. 30-161 DISASSEMBLY AND
Disassembly............................................ 30-161 ASSEMBLY OF
Assembly ................................................ 30-165 STEERING VALVE ASSEMBLY .................. 30-223
Sketches of special tools ........................ 30-172 Disassembly ........................................... 30-225
REMOVAL AND INSTALLATION OF Assembly................................................ 30-228
CENTER FINAL DRIVE AND REMOVAL AND INSTALLATION OF
BRAKE ASSEMBLY ..................................... 30-175 FLOW AMP VALVE...................................... 30-233
Removal.................................................. 30-175 Removal ................................................. 30-233
Installation............................................... 30-176 Installation .............................................. 30-234
DISASSEMBLY AND ASSEMBLY OF REMOVAL AND INSTALLATION OF
CENTER FINAL DRIVE AND HOIST VALVE ASSEMBLY.......................... 30-235
BRAKE ASSEMBLY ..................................... 30-177 Removal ................................................. 30-235
Special tool ............................................. 30-177 Installation ........................................... 30-235-1
Disassembly............................................ 30-177 DISASSEMBLY AND ASSEMBLY OF
Assembly ................................................ 30-179 STEERING CYLINDER ASSEMBLY............ 30-236
Sketches of special tools ........................ 30-185 Special tool............................................. 30-236
DISASSEMBLY AND ASSEMBLY OF Disassembly ........................................... 30-236
REAR FINAL DRIVE ASSEMBLY................. 30-188 Assembly................................................ 30-237
Special tool ............................................. 30-188 DISASSEMBLY AND ASSEMBLY OF
Disassembly............................................ 30-188 HOIST CYLINDER ASSEMBLY ................... 30-239
Assembly ................................................ 30-190 Special tool............................................. 30-239
Sketches of special tools ........................ 30-195 Disassembly ........................................... 30-239
REMOVAL AND INSTALLATION OF Assembly................................................ 30-241
CENTER AXLE ASSEMBLY......................... 30-196 REMOVAL AND INSTALLATION OF
Removal.................................................. 30-196 BODY ASSEMBLY ....................................... 30-243
Installation............................................... 30-197 Removal ................................................. 30-243
REMOVAL AND INSTALLATION OF Installation .............................................. 30-244
REAR AXLE ASSEMBLY ............................. 30-198
Removal.................................................. 30-198
Installation............................................... 30-200
REMOVAL AND INSTALLATION OF
FRONT SUSPENSION CYLINDER
ASSEMBLY................................................... 30-201
Removal.................................................. 30-201
Installation............................................... 30-202
INSTALLATION AND REMOVAL OF
REAR SUSPENSION CYLINDER
ASSEMBLY................................................... 30-203
Removal.................................................. 30-203
Installation............................................... 30-203
DISASSEMBLY AND ASSEMBLY OF FRONT AND
REAR SUSPENSION CYLINDER ASSEMBLY
...................................................................30-203-1
EQUALIZER BAR ......................................... 30-204
30-2 HM300-1
(14)
2
30 DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
HOW TO READ THIS MANUAL

ASSEMBLIES
Special tools Installation of parts

• Special tools that are deemed necessary for re- • Except where otherwise instructed, install parts
moval or installation of parts are listed. is the reverse order of removal.
• List of the special tools contains the following • Instructions and precautions for installing parts
kind of information. are shown with q 1 mark in the INSTALLATION
1) Necessity Section, identifying which step the instructions
: Special tools which cannot be substitut- are intended for.
ed, should always be used. • Marks shown in the INSTALLATION Section
z Special tools which are very useful if stand for the following.
available, can be substituted with com- ¤ This mark indicates safety-related pre-
mercially available tools. cautions which must be followed when
2) Distinction of new and existing special tools doing the work.
N: Tools with new part numbers, newly ★ This mark gives guidance or precau-
developed for this model. tions when doing the procedure.
R: Tools with upgraded part numbers, re- 2 This mark stands for a specific coating
3 This mark indicates the specified

modeled from already available tools agent to be used.
for other models.
Blanks: Tools already available for other torque.
5
models, used without any modifica-
tion. This mark indicates an amount of oil or
3) Circle mark (c) in sketch column: water to be added.
A circle mark means that a sketch of the spe-
cial tool is presented in the section of Sketches of special tools
Sketches for Special Tools.
• Various special tools are illustrated for the con-
★ Part No. of special tools starting with 79*T
venience of local manufacture.
means that they are locally made parts and as
such not interchangeable with those made by
Komatsu in Japan e.g. 79*T---xxx---xxxx.
Removal of parts
• The REMOVAL Section contains procedures,
precautions and the amount of oil or water to be
drained.
• Various symbols used in the REMOVAL Section
are explained and listed below.
¤ This mark indicates safety-related pre-
cautions which must be followed when
doing the work.
★ This mark gives guidance or precautions
when doing the procedure.
q1 This mark shows that there are instruc-
tions or precautions for installing parts.
6 This mark shows oil or water to be
4 Mass of a part or component.

drained.
HM300-1 30-3
(9)c
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
DISASSEMBLY AND ASSEMBLY OF

ASSEMBLIES
Special tools Assembly

• Special tools which are deemed ncessary for • Section titled ASSEMBLY contain procedures,
disassembly and assembly are listed in this sec- precautions and the know-how for the work, as
tion. well as the amount of oil or water to be added.
• List of the special tools contains the following • Various symbols used in the ASSEMBLY Sec-
kind of information. tion are explained and listed below.
1) Neccessity ¤ This mark indicates safety-related pre-
: Special tools which cannot be substitut- cautions which must be followed when
ed, should always be used. doing the work.
z Special tools which are very useful if ★ This mark gives guidance or precau-
available, can be substituted with com- tions when doing the procedure.
mercially available tools. 2 This mark stands for a specific coating
3 This mark indicates the specified

2) Distinction of new and existing special tools agent to be used.
N: Tools with new part numbers, newly
developed for this model. torque.
5
R: Tools with upgraded part numbers, re-
modeled from already available tools This mark indicates an amount of oil or
for other models. water to be added.
Blanks: Tools already available for other
models, used without any modifica- Sketches of special tools
tion.
• Various special tools are illustrated for the con-
3) Circle mark (c) in sketch column:
venience of local manufacture.
A circle mark means that a sketch of the spe-
cial tool is presented in the section of
Sketches for Special Tools.
★ Part No. of special tools starting with 79*T
means that they are locally made parts and as
such not interchangeable with those made by
Komatsu in Japan e.g. 79*T---xxx---xxxx.
Disassembly
• The DISASSEMBLY Section contains proce-
dures, precautions and the amount of oil or water
to be drained.
• Various symbols used in the DISASSEMBLY
Section are explained and listed below.
¤ This mark indicates safety-related pre-
cautions which must be followed when
doing the work.
★ This mark gives guidance or precautions
when doing the procedure.
q1 This mark shows that there are instruc-
tions or precautions for installing parts.
6 This mark shows oil or water to be
4 Mass of a part or component.

drained.
30-4 HM300-1
(9) c
PRECAUTIONS WHEN CARRYING
DISASSEMBLY AND ASSEMBLY OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general pre-
cautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
• If the coolant contains antifreeze dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary places
before removal to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when discon-
necting the connectors. Do not pull the wires.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
• Check the number of thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering
after removal.
★ Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Nut (elbow end)
number
02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
2) Split flange type hoses and tubes
Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions (mm)
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
HM300-1 30-5
(9)c
PRECAUTIONS WHEN CARRYING
DISASSEMBLY AND ASSEMBLY OUT OPERATION
2. Precautions when carrying out installation work

• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with 2 - 3 drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no
dirt or damage, then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press fitting parts, coat the surface with anti-friction compound (LM-P).
• After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect se-
curely.
• When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the
direction of the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
★ When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hy-
draulic equipment removed for repair, always bleed the air as follows:
1. Start the engine and run at low idling.
2. Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times, stopping the cyl-
inder 100 mm from the end of its stroke.
3. Next, operate the hydraulic cylinder 3 - 4 times to the end of its stroke.
4. After doing this, run the engine at normal speed.
★ When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

• If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine
to circulate the water through the system. Then check the water level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run
the engine to circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment has been removed, always bleed the air from the system after reassem-
bling the parts. For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
30-6 HM300-1
(9) c
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

★ Tools with part number 79cT-ccc-cccc cannot be supplied (they are items to be locally
manufactured).
★ Necessity: : Cannot be substiuted, should always be installed (used).
z: Extremely useful if available, can be substiuted with commercially availabe part.
★ New/remodel: N: Tools with new part numbers, newly developed for this model.
R: Tools with upgraded part numbers, remodeled from items already available for other
models.
Blank:Tools already available for other models, used without any modification.
★ Tools marked c in the Sketch column are tools introduced in special sketches (See SKETCHES OF
SPECIAL TOOLS).
Neces- New/
Component Symbol Part No. Part Name Q’ty Sketch Nature work remarks
sity remodel
795-471-1800 Remover 1
1 • 795-471-1810 • Plate 1
2 • 795-471-1820 • Bolt 1 Removal, Installation of
A1
3 • 795-471-1830 • Bracket 1 fuel supply pump
4 • 01435-01035 • Bolt 3
5 • 01435-01025 • Bolt 1
Engine assembly
Tightening of cylinder
2 790-331-1110 Wrench 1
head bolt
Removal, Installation of
3 795T-471-1550 Wrench 1 c
A Nozzle tip
792-220-1110 Centering tool 2 Carrying out shaft of
4 engine assembly and
01050-61225 Bolt 8 translation assembly
790-501-5000 Unit repair stand z 1
Disassembly, assembly of
1 790-901-2110 Bracket z 1
Torque converter torque converter assembly
C 792T-213-1210 Plate z 1 N c
assembly
Remove of pump bearing
2 792-213-1110 Wrench 1
nut
Remove of PTO bearing
1 790-102-1871 Nut wrench 1
nut
Press-fitting of lower shaft
2 796-465-1120 Push tool 1
bearing (side of 3rd)
Press-fitting of lower shaft
3 792T-423-1110 Push tool 1 c
bearing (side of 2nd)
792T-213-1220 Push tool 1 N c
Press-fitting of dust seal of
4 790-101-5421 Clip 1
input coupling
01010-81240 Bolt 1
Transmission
D 752T-213-1230 Push tool 1 N c
assembly Press-fitting of dust seal of
5 790-101-5421 Clip 1
input coupling
01010-81240 Bolt 1
Press-fitting of PTO
6 790-201-2730 Spacer 1
bearing
Press-fitting of idoler gear
7 792T-413-1120 Push tool 1 c
bearing
Press-fitingt of output
8 792T-215-1120 Push tool 1 N c
coupling cover
9 799-301-1500 Oil leak tester 1 Test of clutch assembly
HM300-1 30-6-1
3
(6)
Neces- New/
sity remodel
Press-fit bearing of output
1 792T-227-1110 Push tool 1 N c
shaft
792T-423-1130 Push tool 1 c
Front differential Press-fitting of side carrier
2 • 790-101-5421 • Clip 1
assembly oil seal
• 01010-51240 • Bolt 1
Press-fitting of bevel pin-
3 790-201-2840 Spacer 1
ion bearing
792T-423-1130 Push tool 1 c
Press-fitting of oil seal of
2 • 790-101-5421 • Clip 1
transfer input shaft cage
• 01010-51240 • Bolt 1
790-101-5401 Push tool kit 1
• 790-101-5441 • Plate 1 Press-fitting oil seal of
4
• 790-101-5421 • Clip 1 bearing cage
• 01010-51240 • Bolt 1
Press-fitting side seal of
5 790-201-2770 Spacer 1
bearing cage
Unit repair stand
790-501-5000 1
(AC100V)
Center differential Unit repair stand Disassembly and assem-
6 790-501-5200 1 bly of center differential
assembly (AC110V,AC220V)
H assembly
790-901-2110 Bracket 1
792T-222-1210 Plate 1 N c
Adjustment of bearing
7 792-103-0901 Wrench 1
pre-load
Press-fitting of transfer
8 792T-223-1120 Push tool 1 N c
input shaft bearing
792T-423-1140 Push tool 1 c
Press-fitting oil seal of
9 • 790-101-5421 • Clip 1
transfer input shaft cage
• 01010-51240 • Bolt 1
Press-fitting of bevel
10 792T-223-1110 • Clip 1 N c
pinion bearing
Unit repair stand
790-501-5000 1
(AC100V)
Unit repair stand Disassembly , assembly of
6 790-501-5200 1
(AC110V,AC220V) rear differential
Rear differential 790-901-2110 Bracket 1
assembly 792T-222-1210 Plate 1 N c
Adjustment of bearing
7 792-103-0901 Wrench 1
pre-load
Press-fitting of bevel
10 792T-223-1110 • Clip 1 N c
pinion bearing
792T-227-1120 Fixture 3 N c
792T-223-1140 Plate 3 N c
01010-61240 Bolt 3
Front final drive Removal, installation of
J 1 01643-31232 Washer 3
brake assembly brake assembly
01580-01210 Nut 3
01010-61245 Bolt 3
01010-62440 Bolt 3
30-6-2 HM300-1
3
(9)
Neces- New/
sity remodel
Press fitting of shaft
2 792T-222-1220 Push tool 1 N c
bearing
792T-227-1130 Push tool 1 N c
Press fitting of shaft oil
3 790-101-5221 Grip 1
seal
01010-81225 Bolt 1
Front final drive 4 791-580-1520 Installer 1
Installation of floating seal
brake assembly 5 791-580-1510 Installer 1
793T-622-1110 Push tool 1 c
Press fitting of outer gear
6 790-101-5421 Grip 1
oil seal
01010-81240 Bolt 1
Press fitting of inner hub
7 797T-622-1240 Push tool 1 c
bearing
Press fitting of shaft
2 792T-222-1220 Push tool 1 N c
bearing
4 791-580-1520 Installer 1
Installation of floating seal
5 791-580-1510 Installer 1
J
793T-622-1110 Push tool 1 c
Press fitting of outer gear
6 790-101-5421 Grip 1
oil seal
01010-81240 Bolt 1
Center final drive Press fitting of inner hub
7 797T-622-1240 Push tool 1 c
brake assembly bearing
792T-227-1130 Fixture 3 N c
792T-223-1140 Plate 3 N c
01010-61240 Bolt 3
Removal , installation of
8 01643-31232 Washer 3
brake assembly
01580-01210 Nut 3
01010-61245 Bolt 3
01010-62440 Bolt 3
Press fitting of wheel hub
2 792T-222-1220 Push tool 1 N c
Rear final drive bearing
assembly Press fitting of inner hub
7 797T-622-1240 Push tool 1 c
bearing
1 792T-246-1130 Plate 1 N c
Press-fitting of dust seal
2 792T-246-1140 Plate 1 N c
3 792T-246-1110 Push tool 1 N c Press-fitting of bearing
Hitch frame
K 790-101-5201 Push tool kit 1
assembly
• 790-101-5314 • Plate 1
4 Press-fitting of dust seal
• 790-101-5221 • Grip 1
• 01010-51225 • Bolt 1
Disassembly 792-201-3141 Push tool 1

assembly of sus- Q 1 790-101-5221 Grip 1 Press fitting of roll bushing
pension 01010-51225 Bolt 1
HM300-1 30-6-3
(14)
3
Neces- New/
sity remodel
Cylinder repair
790-502-1003 1 Disassembly , assembly of
1 stand
cylinder assembly
790-101-1102 Hydraulic pump 1
2 790-102-3802 Wrench assembly 1
cylinder head
Socket(width Removal , installation of
3 790-102-1320 t 1
across flats:70mm) Nut
790-720-1000 Expander t 1
4 796-720-1660 Ring t 1 Installation of piston ring
Steering cylinder
assembly 07281-01159 Clamp t 1
790-201-1702 Push tool KIT t 1
790-101-5021 • Grip 1
5 Press-fitting of bushing
01010-50816 • Bolt 1
790-202-1781 • Push tool 1
790-101-5021 • Grip 1
6 Press-fitting of dust seal
01010-50816 • Bolt 1
790-201-1590 • Plate 1
Cylinder repair
U 790-502-1003 t 1 Disassembly , assembly of
1 stand
cylinder assembly
790-101-1102 Hydraulic pump t 1
2 790-102-3802 Wrench assembly t 1
cylinder head
790-720-1000 Expander t 1
4 796-720-1660 Ring t 1 Installation of piston ring
07281-01159 Clamp t 1
790-101-5021 • Grip 1
Hoist cylinder
assembly 5 01010-50816 • Bolt 1 Press-fitting of bushing
790-201-1831 • Push tool 1
790-201-1871 • Push tool 1
790-101-5021 • Grip 1
6 01010-50816 • Bolt 1 Press-fitting of dust seal
790-201-1640 • Plate 1
790-201-1680 • Plate 1
790-102-4300 Wrench assembly t 1
7 Tighten piston assembly
790-102-4310 Pin t 1
Operator's cab
V 792-454-1100 Pump assembly t 1 N Tilting of operator's cab
assembly
799-703-1200 Service tool KIT t 1
799-703-1100 Vacuum(100V) t 1
Air conditioner Extraction and charging
X 799-703-1111 Vacuum(220V) t 1
assembly the refrigerant gas
799-703-1121 Vacuum(240V) t 1
799-703-1400 Gas leak tester t 1
30-6-4 HM300-1
(8)
3
(14)
DISASSEMBLY AND ASSEMBLY FUEL SUPPLY PUMP ASSEMBLY
REMOVAL AND
INSTALLATION OF
FUEL SUPPLY PUMP
ASSEMBLY
SPECIAL TOOL
Dis-
Neces- Ske-
Mark Part No. Part Name sity Q'ty tinc- tch
tion*
795-471-1800 Remover ■ 1
1 • 795-471-1810 • Plate 1
2 • 795-471-1820 • Bolt 1
A1 5. Remove the clamp and cover, and disconnect
3 • 795-471-1830 • Bracket 1
high pressure tubes (7) and (8) between the fuel
4 • 01435-01035 • Bolt 3
supply pump and common rail.
5 • 01435-01025 • Bolt 1
*Distinction of new part and improved part 6. Remove the clamps at 4 points and disconnect
fuel filter tubes (9) and (10).
REMOVAL 7. Remove the clamp and disconnect lubrication
k Disconnect the negative (-) terminal of battery tube (11).
beforehand.
k Turn the parking brake switch on and put
wooden blocks under the wheels.
1. Release the remaining pressure in the fuel sys-
tem, referring to the section of "RELEASING
REMAINING PRESSURE IN FUEL SYSTEM"
in TESTING AND ADJUSTING.
2. Open up engine hood (1).
8. Remove the fuel supply pump assembly.

1) Remove the No. 1 head cover.
2) Rotate the crankshaft forward to bring the
stamped "1.6TOP" line of the damper to
pointer (12) and set the No. 1 cylinder to the
compression top dead center.
★ When the No. 1 cylinder is at the com-
pression top dead center, the rocker
arms of the intake valve and exhaust
3. Disconnect wiring connectors (PCV1) (2), (PCV
valve of the No. 1 cylinder can be
2) (3) and (G) (4).
moved by the valve clearance with the
4. Disconnect fuel supply hose (5) and fuel return hand. If the rocker arms cannot be
hose (6). moved, rotate the crankshaft one more
★ Before disconnecting the hoses, move the turn.
fuel valve to the CLOSE side.
HM300-1 30-7
2
(9)
3) Remove cover (13). 7) Rotate the crankshaft 1 turn again (forward)

to set lower gear fixing bolt hole "f" up, and
then tighten bolt A1-4 with your fingers.
4) Remove gear mounting nut (14) and washer

(14a).
a Take great care not to drop the nut and
washer in the case. 8) Install bracket A1-3 to the case.
9) Rotate the crankshaft to match tap hole "e"
of plate A1-1 and secure bracket A1-3 with
bolt A1-5.
• At this time, the key of the supply pump
must be at the upper position.
5) Insert plate A1-1 with its shouldered side

toward the gear and tighten bolt A1-2 with
your fingers (about 5 turns).
10) Remove 4 mounting bolts (15) and mount bracket

(16).
• Tighten 1 mounting bolt on the upper
side temporarily as a guide bolt.
6) Tighten gear fixing bolt A1-4 with your fin-

gers.
a Set tap hole "e" of plate A1-1 down.
30-7-1 HM300-1
(6)
11) Tighten bolt A1-2 and remove the gear and
3 Removing torque of gear:

fuel supply pump assembly (17).
Approx. 196 – 294 Nm

{Approx. 20 – 30 kgm}
a Take care not to drop the woodruff key of
the supply pump shaft.
a Do not remove bracket A1-3 until you will
install the supply pump assembly again.
HM300-1 30-7-2
(6)
INSTALLATION 3) Tighten fuel supply pump drive gear

• Installation is carried out in the reverse order to mounting nut (14) and washer (14a)
removal. temporarily.
4) Remove bracket A1-3 and plate A1-1.
5) Tighten fuel supply pump drive gear
3
mounting nut (14).
Fuel hose joint bolt:
14.8 - 19.6 Nm {1.51 - 2.0 kgm} 3 Mounting nut:
127 – 147 Nm {13 – 15 kgm}
k Do not attempt to bend the high pressure

tubes for modification before use.
k For the clamp fixing high pressure tubes,
be sure to use a genuine parts and adhere
to the specified tightening torque.
k Install the high pressure tube, keeping dis-
tance of over 10 mm from the wiring har-
ness.
★ Make a visual check of the taper seal por-
tion of the high pressure tube connecting
part ("a" portion: an area up to 10 mm away
from the tip). If damage "b" like a vertical slit ★ Install the fuel supply pump and high pres-
or damage "c" like spot dents is found on sure tubes (7) and (8) between the fuel sup-
the surface, or if the step in "d" portion (the ply pump and common rail in the following
tip of taper seal portion: portion 2 mm from manner.
the tip) gets caught with the claw due to its
1) Install fuel supply pump (17) and brackets
deformation, the high pressure tube will
(16A) and (16B), and temporarily tighten
likely cause fuel spill. In that case, replace high pressure tubes (7) and (8) manually.
such a defective high pressure tube with
new one. 2) Tighten high pressure tubes (7) and (8).
3 Sleeve nut on common rail side:
39.2 - 58.8 Nm {4 - 6 kgm}
3 Sleeve nut on fuel supply pump
side:
39.2 - 49 Nm {4 - 5 kgm}
3) Tighten 4 mounting bolts (15) for the fuel
supply pump.
2 Fuel supply pump mounting bolt
: Gasket sealant (LG-6)
4) Tighten brackets (16A) and (16B).
5) Temporarily install clamp brackets (18) and
★ Install the fuel supply pump according to the (19) as well as high pressure clamp (20) by
following procedure. tightening manually.
1) Remove bolt A1-2 from plate A1-1.
2) Insert fuel supply pump (17) with key 6) Tighten high pressure clamp (20).
(18) up and matched to the keyway of 3 Clamp bolt:
the gear, and then secure it temporarily. 11.8 - 14.7 Nm {1.2 - 1.5 kgm}
30-8 HM300-1
2
(9)
7) Tighten clamp bracket (18) first and clamp • Check for fuel leak
bracket (19) thereafter. Check for fuel leak, referring to the section
3
of "CHECKING FOR LEAKAGE IN FUEL
Bracket mounting bolt:
11.8 - 14.7 Nm {1.2 - 1.5 kgm} CIRCUIT" in TESTING AND ADJUSTING.
8) Install high pressure clamp (21) and clamp • Air bleeding

bracket (22) temporarily. Bleed air from the fuel circuit, referring to
9) Tighten clamp (21). the section of "BLEEDING AIR FROM FUEL
3
CIRCUIT" in TESTING AND ADJUSTING.
Clamp bolt:
8.82 - 14.7 Nm {0.9 - 1.5 kgm}
10) Tighten clamp bracket (22).
11) Install high pressure clamp (23).
3 Clamp bolt:
8.82 - 14.7 Nm {0.9 - 1.5 kgm}
★ Install the fuel supply pump in the way that

the slit of the cover on the pump side faces
the cylinder block and the slit of the cover on
the common rail side faces down.
3 Fuel filter tube joint bolt:

24.5 - 34.3 Nm {2.5 - 3.5 kgm}
3 Lubrication tube joint bolt:

9.8 - 12.7 Nm {1.0 - 1.3 kgm}
3 Cover mounting bolt:

14.7 - 17.6 Nm {1.5 - 1.8 kgm}
HM300-1 30-9
2
(9)
DISASSEMBLY AND ASSEMBLY FUEL INJECTOR ASSEMBLY
REMOVAL AND
INSTALLATION OF
FUEL INJECTOR ASSEMBLY
REMOVAL
k Disconnect the negative (-) terminal of battery
beforehand.
wooden blocks under the wheels.
2. Remove the common rail cover cum high pres- 6. Loosen and remove sleeve nut (8) for high pres-
sure tube clamp (1). sure tube (7) on the common rail side and
sleeve nut (9) for high pressure tube on the fuel
injector side.
(The attached photo shows the No.1 fuel injec-
tor as it is removed and installed)
7. Remove head cover (10).
3. Remove cover (2) on the common rail side and

cover (3) on the fuel injector side.
8. Disconnect wiring harness (11) from the fuel

injector.
9. Remove injector holder mounting bolt (12) and
remove fuel injector assembly (13) together with
the holder.
★ Do not pinch the electromagnetic portion of
the injector with pliers.
4. Remove portal frame (4).

5. Remove high pressure tube clamps (5) or (6)
corresponding to the fuel injector to be removed
and installed.
30-10 HM300-1
2
(9)
INSTALLATION
• Installation is carried out in the reverse order to
removal.
k Do not attempt to bend the high pressure

tubes for modification before use.
k For the clamp which fixes high pressure
tubes, be sure to use a genuine parts and
adhere to the specified tightening torque.
k Install the high pressure tube, keeping dis-
tance of over 10 mm from the wiring har-
ness.
★ Make a visual check of the taper seal por-
tion of the high pressure tube connecting
part ("a" portion: an area up to 10 mm away
from the tip). If damage "b" like a vertical slit
or damage "c" like spot dents is found on
the surface, or if the step in "d" portion (the
tip of taper seal portion: portion 2 mm from
the tip) gets caught with the claw due to its
deformation, the high pressure tube will
likely cause fuel spill. In that case, replace
such a defective high pressure tube with
new one.
HM300-1 30-11
(6)
2
★ Install high pressure tube (7) between the 4) Tighten the mounting bolt for clamp bracket
common rail and fuel injector in the following (14).
manner. 5) Install common rail cover and high pressure
1) Tighten 6 sleeve nuts (8) and (9) for high tube clamp (1) and portal frame (4) tempo-
pressure tube (7). rarily.
3 High pressure tube sleeve nut: 6) Tighten common rail cover and high pres-
39.2 - 49 Nm {4 - 5 kgm} sure tube clamp (1) first and portal frame (4)
2) Temporarily install clamps (5) and (6) for the thereafter.
high pressure tube by tightening manually. 3 Clamp bolt:
3) Tighten clamps (5) and (6) for the high pres- 11.8 - 14.7 Nm {1.2 - 1.5 kgm}
sure tube.
3 Clamp bolt:
11.8 - 14.7 Nm {1.2 - 1.5 kgm}
30-12 HM300-1
2
★ Turn the slit of the cover on the common rail

side to face the cylinder block.
★ Turn the slit of cover (3) on the fuel injector
side to face "a" position in the figure.
• Check for fuel leak

Check for fuel leak, referring to the section of
"CHECKING FOR LEAKAGE IN FUEL CIR-
CUIT" in TESTING AND ADJUSTING.
• Air bleeding
3 Head cover mounting bolt: Bleed air from the fuel circuit, referring to the
8.33 - 10.8 Nm {0.9 - 1.1 kgm} section of "BLEEDING AIR FROM FUEL CIR-
CUIT" in TESTING AND ADJUSTING.
3 Wiring harness mounting nut:

2.0 - 2.4 Nm {0.2 - 0.24 kgm}
★ Install the fuel injector assembly in the fol-

lowing manner.
1) Fit gasket (b) and O-ring (c) to fuel injector
(a).
2) Put holder (d) in injector (a) and install to the
rocker housing temporarily.
★ Align the injector key with the rocker
housing keyway, and push in until the
injector seal face comes into contact
with the seal face on the cylinder head
side.
3) Coat the face of spherical washer (e) with
engine oil.
4) Tighten bolt (f) for the holder.
3 Injector holder mounting bolt:
58.8 - 73.5 Nm {6.0 - 7.5 kgm}
HM300-1 30-13
2
(9)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF NOZZLE TIP
REMOVAL AND 3. Loosen retaining nut (4) with 19 mm deep

socket (3).
INSTALLATION OF
NOZZLE TIP
★ [EPA regulations]
For countries subject to EPA regulations, the

entire nozzle assembly of the common rail
engine shall be replaced if any of its compo-
nents needs to be replaced. For other countries,
the following procedure may be applied for
replacing the nozzle tip.
SPECIAL TOOL
Dis- 4. Remove retaining nut (4) from injector assembly
Neces- Ske-
Mark Part No. Part Name sity Q'ty tinc- tch
tion* (3).
A3 795T-471-1550 Wrench ■ 1 c
5. Lift nozzle assembly (5) perpendicularly upward
*Distinction of new part and improved part to remove it.
★ Do not remove tip guide (6). (Disassembling
REMOVAL the portion after the tip guide is not allowed.)
1. Fix tool A3 in vice [1]. ★ Be careful not to get the assembly dirty.
★ Do not pinch the injector directly in the vice.
2. Set injector assembly (3) on tool A3.
30-14 HM300-1
2
INSTALLATION 5. Mount nozzle assembly (3) and manually

1. Fit tool A3 in vice (1). tighten retaining nut (2).
★ Do not pinch the injector directly in the vice.
6. Set 19-mm deep socket [2] in the torque

2. Set injector assembly (1) on tool A3. wrench, then tighten the retaining nut by follow-
ing the steps below.
3. Completely clean the lower body and screw ★ Apply rust prevention oil on the nozzle body.
sections of retaining nut (2) with parts cleaner,
and apply air blow. 1) Tighten with torque of 88.3 Nm {9.0 kgm}.
2) Attach identification mark (6) to retaining nut
(2) and lower body (5).
3) Tighten at an angle of 45f (angle tighten-
ing).
4. Mount new nozzle assembly (3) so that the

assembly fits the knock pin of tip guide (4).
★ Be careful not to drop the tip.
HM300-1 30-15
2
SKETCHES OF SPECIAL TOOLS

Note: Komatsu cannot accept any responsibility for special
tools manufactured according to these sketches.
A3 Wrench
30-16 HM300-1
2
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
REMOVAL AND
INSTALLATION OF
CYLINDER HEAD ASSEMBLY
SPECIAL TOOL
Neces Distin Ske-
Mark Part No. Part Name sity Q'ty ction* tch
A2 790-331-1110 Wrench ■ 1
*Distinction of new part and improved part
REMOVAL
k Disconnect the negative (-) terminal of battery 6. Disconnect the following connectors and wiring
beforehand. harnesses.
k Turn the parking brake switch on and put • (6): PIM
wooden blocks under the wheels. • (7): THL
1. Open up the engine hood, and tilt the operator's • (8): EG4
cab with a crane or a built-in tilt-up cylinder. • (9): EG5
k Fasten the operator's cab securely with a
bar.
• For detailed procedures of removing and
installing the operator's cab, refer to the
section of "METHOD OF TILTING CAB UP"
2. Open the engine undercover.
3. Drain engine coolant from the radiator as well
as the steering and torque converter (brake) oil
cooler.
6 Radiator, steering and torque con-
verter (brake) oil cooler:51l
4. Separate coolant reservoir tank hose (1) and
wiring connector (T01) (2), and sling engine
upper bar and coolant reservoir tank assembly
(3) to remove.
4 Engine upper bar assembly:35kg
5. Disconnect after-cooler tube and hose (4) on

the suction side and after-cooler hose (5) on the
exhaust side.
HM300-1 30-17
2
(9)
• (10): B Terminal 10. Remove exhaust pipe (22) between the turbo-
• (11): Terminal (PHO) charger and the exhaust muffler.
• (12): Terminal (HT) 11. Separate exhaust brake linkage (23) at the tur-
• (13): Terminal (OF)
bocharger side and remove bracket (24).
• (14) 2 locations: Grounding terminal
★ Before separating, measure the installed
dimensions.
• CN1 - CN-6 (15)
12. Disconnect turbocharger lubrication inlet tube

(25) and lubrication return tube (26).
7. Disconnect air hose (16) between the air

cleaner and the turbocharger.
8. Remove thermal insulation covers (17) to (20)
from the turbocharger and the exhaust manifold.
9. Remove exhaust pipe thermal insulation cover
(21).
30-18 HM300-1
2
(6)
13. Sling turbocharger and exhaust manifold assem- 17. Disconnect oil feeding pipe (34).
bly (27) to remove.
★ Be careful not to bend the turbocharger
lubrication tube.
4 Turbocharger and exhaust manifold
assembly:70kg
18. Disconnect turbocharger lubrication inlet tube

(35).
14. Disconnect 2 oil tubes (28), and then remove oil

filter and bracket assembly (29).
19. Separate 3 clamps (36) for the high pressure

tube from the bracket.
15. Disconnect 2 fuel filter tubes (30), and then

remove fuel filter and bracket assembly (31).
16. Disconnect 2 water hoses (32), and then

remove corrosion resistor and bracket assembly
(33).
HM300-1 30-19
2
(9)
20. Sling air intake connector assembly (37) to

install.
4 Air intake connector assembly: 55kg
25. Remove the fuel injectors in the following man-

ner.
1) Disconnect wiring harness (43) from the fuel
21. Remove common rail cover and high pressure injector.
tube clamp (38). 2) Remove holder mounting bolt (44), and then
22. Remove 6 covers (39) from the fuel injector remove fuel injector assembly (45) with the
side. holder.
★ Do not pinch the portion of electromagnetic
valve on the upper part of the injector with
★ Likewise remove 6 covers from the common pliers.
rail side, too.
23. Disconnect water tube (40) and spill tube (41).
24. Remove cylinder head cover (42) correspond-

ing to the cylinder head to be removed and
installed.
30-20 HM300-1
2
26. Remove the rocker arm and rocker shaft INSTALLATION

assembly in the following manner. • Installation is carried out in the reverse order to
1) Loosen lock nut (46), and then loosen removal.
adjustscrew (47) by 2 to 3 turns.
2) Remove the mounting bolt and remove
★ Two clamps are used. Install them in the
rocker arm and rocker shaft assembly (48).
way that clamping position of one of the two
★ If it is necessary to replace cross head
is shifted by 180f from that of the other and
(49), loosen lock nut (50) and also
loosen adjustscrew (51) by 2 to 3 turns, both can still be tightened from the same
then remove the cross head. direction.
(The cylinder head may be removed and 3 After cooler hose clamp:
installed with the cross head installed.) 9.8 ± 0.5 Nm {100 ± 5 kgm}
3 B terminal nut:
2.45 - 2.94 Nm {0.25 - 0.3 kgm}
3 HT terminal nut:
1.86 - 2.45 Nm {0.19 - 0.25 kgm}
3 Air hose clamp:

8.8 ± 0.5 Nm {90 ± 5 kgm}
★ Seal the mating part of the exhaust pipe

27. Remove 6 mounting bolts (52), and then thermal insulation covers closely with an
remove rocker housing (53). accessory belt.
28. Remove 6 head bolts (54) and the supplemental

bolts, and then remove cylinder head assembly ★ Install the exhaust brake linkage to the
(55). dimensions measured before the separa-
tion.
HM300-1 30-21
2
(9)
★ Tighten the exhaust manifold mounting bolts

3
in the following order, and then tighten the Corrosion resistor and bracket assem-
other bolts, starting from the center bolt. bly mounting bolt:
3 Exhaust manifold mounting bolt: 44.1 - 58.8 Nm {4.5 - 6 kgm}
58.8 - 73.5 Nm {6 - 7.5 kgm} 3 Corrosion resistor hose clamp:
3.3 ± 0.49 Nm {0.34 ± 0.05 kgm}
3 Oil supply hose clamp:

5.9 ± 0.49 Nm {0.6 ± 0.05 kgm}
3 Turbocharger lubrication inlet tube

(joint bolt on cylinder block side):
24.5 - 34.3 Nm {2.5 - 3.5 kgm}
★ For procedures of installing high pressure

★ Install the oil tube and oil filter bracket in the tube between the common rail and fuel
following manner. injector tube, refer to the section of
"REMOVAL AND INSTALLATION OF FUEL
1) Tighten oil filter bracket mounting bolt (a)
INJECTOR ASSEMBLY" .
temporarily.
2) Tighten oil tube mounting bolts (b) and (c)
3
temporarily.
Water and spill tube joint bolt:
3) Tighten the mounting bolts in the order of 9.8 - 12.7 Nm {1.0 - 1.3 kgm}
(c), (b) and (a).

9.8 ± 1 Nm {1.0 ± 0.1 kgm}
3 Injector wiring harness mounting nut:

2.0 - 2.4 Nm {0.2 - 0.24 kgm}
3 Injector holder mounting bolt:

58.8 - 73.5 Nm {6 - 7.5 kgm}
3 Fuel filter tube joint bolt:

24.5 - 34.3 Nm {2.5 - 3.5 kgm}
30-22 HM300-1
2
(9)
★ Screw the bolts in the cylinder block manu-

3 Rocker shaft mounting bolt: ally at least by 2 turns or more.
58.8 - 73.5 Nm {6 - 7.5 kgm} ★ Before installing, measure the stem length
★ For procedures of adjusting the valve clear- "a" of all the bolts and check before use that
ance, refer to the section of "ADJUSTING each bolt has not exceeded the maximum
VALVE CLEARANCE" in TESTING AND limit of length. If there is a bolt elongated
ADJUSTING. beyond the maximum limit, do not use it
again but replace with new one.
0 • Max. tolerable length of bolt: Below
★ Install cross head (49) in the following man- 171.4 mm.
ner.
1) Install above the valve stem in the condition
that lock nut (50) and adjustscrew (47) are
loosened.
2) Check that adjustscrew (47) is not in contact
with the valve stem.
3) Depress gently where cross head (49) is in
contact with the rocker arm, and hold the
condition that it is in contact with valve stem
(a) on the push rod side.
4) Keeping the above condition, tighten adjust-
screw (47) until it comes into contact with ★ Should any bolt be tightened beyond the
the valve stem. specified angle, remove the bolt once and
measure the stem length again.
5) Tighten the adjust-screw (47) to further 20
degrees after it contacts the valve stem.
6) Tighten lock nut (50), while holding adjust-
screw (47) with a driver so that it will not
start turning.
3 Lock nut:
58.8 - 73.5 Nm {6 - 7.5 kgm}
★ Before assembling, coat the cross head
guide and the upper surface of cross head
thoroughly with EO30-CD oil.
3 Rocker housing mounting bolt:

58.8 - 73.5 Nm {6 - 7.5 kgm}
★ Clean the cross head lower surface, cylin-

der block upper surface and cylinder liners
thoroughly with dry cloth or cloth with clean-
ing agent.
★ Coat the bolt threads and bolt neck with LM-
P or EO30-CD.
HM300-1 30-23
2
(9)
★ Tighten the cylinder head bolts in the follow- ★ When tightening for the 3rd run, use tool A2
ing manner and in the order shown in the (angle tightening wrench).
figure.
3 Cylinder head bolt:
1st run : 98.1 ± 9.8 Nm {10 ± 1 kgm}
2nd run
: 156.9 - 166.7 Nm {16 - 17 kgm}
3rd run: Mark the head bolt and cylinder
head point (f) with a felt- tip pen, then
turn the bolt by 90f+300 .
★ Tighten "7" bolt to 66.2 ± 7.4 Nm {6.75 ±
0.75kgm}
★ After tighten the bolt, punch a mark at point
(g) on the bolt head. When the punch mark
counts 5, do not use such a bolt any more,
but replace it with new one.
30-24 HM300-1
2
DISASSEMBLY AND ASSEMBLY ENGINE ASSEMBLY
REMOVAL AND
INSTALLATION OF
ENGINE ASSEMBLY
SPECIAL TOOL
Disti
Neces Ske-
Mark Part No. Part name Q'ty nctio tch
sity
n*
792-220-1110 Centering tool t 2
A4
01050-61225 Bolt t 8
REMOVAL
k When tilting the cab, observe the following
precautions to prevent a serious injury or fatal
accident caused by fall of the cab.
ahead position and stop the machine on the
level ground.
k Lock the dump lever with the dump lever lock
knob.
k Turn the parking brake switch ON and chock
the wheels.
k
k
Set the lock bar to the frame and lock front
Fasten the operator's cab securely with a
and rear frame.
bar.
• Precautions in tilting cab • For detailed procedures of removing and
k
installing the operator's cab, refer to the
When tilting the cab, check that the lock lever
section of "METHOD OF TILTING CAB UP"
is fixed securely.
k
Do not start the engine while the cab is tilted.
k When it is obliged to start the engine for test- 3. Remove the engine undercover.
ing etc., check that there is nobody under the 4. Drain engine coolant from the engine as well as
cab. steering and torque converter (brake) oil cooler.
k
6
Do not operate the gear shift lever or dump
Radiator, steering and torque con-
lever.
k
verter (brake) oil cooler: 51l
Do not give a large shock to the machine.
k
5. Disconnect coolant reservoir tank hose (1) and
Do not tilt the cab while it is loaded.
wiring connector (T01) (2), and sling engine
k
upper bar and coolant reservoir tank assembly
Disconnect the negative (–) terminal of battery
(3) to remove.
4
beforehand.
k If the water temperature in the radiator is high, Engine upper bar assembly: 35kg
you may get scalded. Accordingly, wait until
the water temperature lowers, then drain.
1. Open up the engine hood, and tilt the operator's

cab with a built-in tilt-up cylinder or with a crane.
2. Pull lock lever (2-1) and set lock bar (2) with the
care the direction of the lock bar (2) at the front
left of the cab.
k Check that the lock lever closes and the
cab (6) is held securely in position by the
lock bar (2).
HM300-1 30-25
(10)
2
6. Remove thermal insulation covers (4) to (6) 13. Disconnect radiator outlet hose (17) on the radi-
from the turbocharger and exhaust manifold. ator side.
7. Remove thermal insulation cover (7) from the
exhaust pipe.
14. Remove 2 fan guards (18).
8. Remove exhaust pipe (8) between the turbo-

charger and exhaust muffler.
9. Separate exhaust brake linkage (9) on the tur-
bocharger side, and remove bracket (10).
a Before the separation, measure the installed
dimensions.
15. Remove radiator fan (19).

a Put the fan away on the radiator side.
10. Disconnect after-cooler tube and hose (11) and

(12).
11. Disconnect air hose (13) between the air
cleaner and turbocharger.
12. Disconnect radiator inlet hose (14), aeration
hose (15) and coolant hose (16) on the radiator
side.
30-26 HM300-1
(10)
2
16. Disconnect centralized connectors of engine 18. Disconnect fuel supply hose (30) and fuel return
(EG4) (20) and (EG5) (21). hoses (31) and (32) from the left side of engine.
a Before disconnecting the hoses, turn the

fuel valve to the CLOSE side.
17. Remove the air conditioner compressor in the

following manner.
1) Disconnect grounding wire (22) and wiring
connector (COMP) (23). 19. Disconnect the following tubes and wiring from
the right side of engine.
2) Remove cover (24).
1) Separate E terminal (E1) (30), R terminal
3) Loosen air conditioner compressor mount- (CN-80) (31) and B terminal (32) from the
ing bolt (25) as well as adjust-rod mounting alternator.
bolt and nut (26).
4) Loosen adjust-nut (27) and remove air con-
ditioner compressor belt (28).
5) Remove air conditioner compressor (29)
from the bracket.
a Push the air conditioner compressor
with the piping in place outward and fas-
ten it with a rope.
2) Disconnect engine grounding cable (33).

3) Separate wiring connector (CN-78) (34) and
B terminal (35) from the engine starting
motor.
HM300-1 30-27
(10)
2
4) Disconnect water connector (36) and water 22. Remove 4 engine mounting bolts (44).
hose (37). a Mounting bolts are on the upper side of the
engine mount and a mounting nuts are on
5) Disconnect heater hoses (38) and (39).
the underside.
20. Remove the following parts from the rear of the

23. Sling engine assembly (45) to remove.
engine.
a Check that there is no wiring or tube that is
1) Remove cover (40). still connected, and sling the engine assem-
2) Remove wiring clamps (41) at three points. bly slowly.
4 Engine assembly: 1,300kg
3) Disconnect hose (42) from the steering and

hoist pump.
21. Separate drive shaft (43) between the engine

and transmission at the engine side.
30-28 HM300-1
(10)
2
INSTALLATION
a When removing the engine assembly, trans-
mission and torque converter assembly or
removal.
drive shafts, carry out centering the engine
a When replacing an engine assembly or engine
controller assembly, refer to your Komatsu dis- and transmission in the left and right direc-
tributor for fuel injection amount adjustment tion in the following manner, using tool A4.
before starting the work. 1) Install tool A4 to the coupling on the engine
side and the coupling on the torque con-
verter side.
a Seal the mating part of the exhaust pipe
2) Put scale [1] to the left and right sides of tool
thermal insulation covers closely with an
A4.
accessory belt.
3) Measure the clearance between scale [1]
and tool A4 on the left side (a) and on the
a Install the exhaust brake linkage to the right side (b).
dimensions measured before the separa- a Check that the max. clearance remains
tion. below 3 mm both on the left and right
sides. (If both clearances are not in par-
allel, check that the clearance remains
a Two clamps are used. Install them in the less than 3 mm even at the widest point)
way that clamping position of one of the two a If the clearance exceeds 3 mm, make
is shifted by 180 degrees from that of the adjustment by shifting the position of
other and both can still be tightened from torque converter and transmission
the same direction. assembly mount.
3 After-cooler hose clamp:

9.8 ± 0.5 Nm {100 ± 5 kgm}
3 Air hose clamp:

8.8 ± 0.5 Nm {90 ± 5 kgm}
a Two clamps are used. Install them in the

is shifted by 180 degrees from that of the
other and both can still be tightened from a When installing the drive shaft, check that
the same direction. the keyway of spider cap fully engage with
that of the corresponding yoke, and then
tighten the mounting bolt.
2 Mounting bolt
a For adjustment of the air conditioner com-
pressor belt tension, refer to the section of
"TESTING AND ADJUSTING AIR CONDI- : Liquid adhesive compound (LT-2)
TIONER COMPRESSOR BELT TENSION" 3 Mounting bolt for drive shaft
in the chapter of INSPECTION AND between engine and transmission:
ADJUSTMENT. 98 - 123 Nm {10 - 12.5 kgm}
[Target value: 113 Nm {11.5 kgm}]
3 Fuel hose joint bolt:

14.8 - 19.6 Nm {1.51 - 2.0 kgm}
3 Clamp mounting bolt:

58.8 - 73.5 Nm {6 - 7.5 kgm}
HM300-1 30-29
(10)
2
DISASSEMBLY AND ASSEMBLY RADIATOR ASSEMBLY
a When measuring dimension "a" between REMOVAL AND

the flywheel housing and the coupling tip,
while drive shaft (43) between the engine INSTALLATION OF
and transmission is in place, and if this RADIATOR ASSEMBLY
dimension "a" falls out of the value shown
below, make adjustment by shifting the posi- REMOVAL
k
tion of engine assembly mount or transmis-
Disconnect the negative (-) terminal of battery
sion and front differential assembly mount
beforehand.
so that the dimension falls within the speci-
fied value.
wooden blocks behind the wheels.
Dimension "a" between flywheel housing
and coupling tip: 161.2 -30 mm
2. Remove the engine undercover.
3. Drain engine coolant from the engine as well as
steering and torque converter oil cooler.
4. Disconnect after-cooler air hose and tube (1)
and (2).
5. Disconnect the following hoses from the upper
part of radiator.
• (3) Radiator inlet hose
• (4) Coolant hose
• (5) Aeration hose
• (6) Reservoir tank hose
3 Engine mount bolt:

662 - 829 Nm {67.5 - 84.5 kgm}
• Refilling with water

Refill with water through the water filler port up
to the specified level, start the engine to raise
the coolant temperature, and then check the
coolant level again.
30-30 HM300-1
(10)
2
6. Disconnect radiator outlet hose (7) from the bot- 9. Remove 4 mounting bolts, and put air condi-
tom of radiator. tioner condenser (10) away toward the machine
front.
★ Do not disconnect the air conditioner tubes.
7. Remove 2 fan guards (8).
10. Remove pedal assembly (11) for releasing the

engine hood lock.
11. Remove two radiator stays (12) on the left and
right sides.
★ Before the removal, measure the installed
dimensions.
8. Remove radiator fan (9).

★ Put the fan away toward the radiator and
fasten it with a rope.
12. Remove 4 radiator mounting bolts (13).
HM300-1 30-31
2
(9)
13. Sling radiator and after-cooler assembly (14) to • Refilling with water
remove, using eyebolt [1]. Refill with water through the water filler port up
4
to the specified level, start the engine to raise
Radiator and after-cooler assembly
the coolant temperature, and then check the
: 165kg coolant level again.
14. Separate radiator assembly (15) from after-

cooler assembly (16).
4 After-cooler assembly: 30kg
INSTALLATION
removal.

both can still be tightened from the same
direction.
3 After-cooler hose clamp:
9.8 ± 0.5 Nm {100 ± 5 kgm}

both can still be tightened from the same
direction.
30-32 HM300-1
(9)
2
DISASSEMBLY AND ASSEMBLY OUTPUT SHAFT ASSEMBLY
REMOVAL AND k Check that the lock lever (2-1) closes and
the operator cab assembly (3) is held
INSTALLATION OF securely in position by the lock bar (2).
OUTPUT SHAFT ASSEMBLY
SPECIAL TOOL
Disti
Neces Ske-
sity
n*
792-220-1110 Centering tool t 2
A4
01050-61225 Bolt t 8
V 792-454-1100 Pump assembly q 1 N
REMOVAL
level ground.
knob.
the wheels.
k Set the lock bar to the frame and lock front
and rear frame.
• For detailed procedures of removing and
• Precautions in tilting cab installing the operator's cab, refer to the
k When tilting the cab, check that the lock lever section of "METHOD OF TILTING CAB UP"
is fixed securely. in TESTING AND ADJUSTING.
k Do not start the engine while the cab is tilted. 4. Disconnect the following 5 hoses from steering
k When it is obliged to start the engine for test- and hoist pump (1).
ing etc., check that there is nobody under the • (2), (3), (4) and (5): Discharging hoses
cab. • (6): Suction hose
lever.
k Loosen the hydraulic oil filler cap to release

the remaining pressure in the hydraulic tank.
k Disconnect the cable from the negative (–)
terminal of the battery.

cab with a tilt cylinder or with a crane.
2. Tilt the operator's cab with a crane or with a tilt-
up cylinder and tool V.
care the direction of the lock bar (2).
HM300-1 30-33
(10)
2
5. Sling steering and hoist pump assembly (1) to a When replacing oil seal (10), remove oil seal
remove. cage (9) first, using forcing screws [1], and
4
then take out the oil seal from the cage.
Steering and hoist pump assembly
: 50kg
8. Remove cover plate assembly (10).

6. Sling drive shaft (7) between the engine and
transmission to remove.
9. Remove plate (12) from cover (11).

a A seal is provided between cover (11) and
7. Remove coupling (8).
plate (12).
30-34 HM300-1
(10)
2
10. Sling output shaft assembly (13) to remove,

using guide bolts [2]. a When installing the oil seal, press-fit it until
4
"f" dimension from the edge of oil seal cage
Output shaft assembly: 50kg
is reached.
• Oil seal press-fitting dimension f
: 1 ± 0.5mm
a When installing the oil seal, fill "G" clear-
ance between the main lip and dust trap
with G2-LI grease or extreme-pressure
grease containing lithium type molybdenum
disulfide.
a When installing the oil seal cage, fill "T" part
with 100 cc of lithium type extreme-pressure
grease containing molybdenum disulfide.
2 Lithium type extreme-pressure grease
containing molybdenum disulfide:
INSTALLATION • Molylex No. 2 of Kyodo Yushi or
equivalent
• Installation is carried out in the reverse order to • Retinax AM of Showa Shell
removal. Sekiyu or equivalent
• Molynoc No. 2 of Nippon
Mitsubishi Oil or equivalent
a Install the drive shaft between the engine
and transmission, referring to the section of
"REMOVAL AND INSTALLATION OF
ENGINE ASSEMBLY".
a Install the coupling after filling "S" part with

20 cc of extreme-pressure grease contain-
ing lithium type molybdenum disulfide.
2 Extreme-pressure grease containing
lithium type molybdenum disulfide:
• Molylex No.2 of Kyodo Yushi or
equivalent
• Retinax AM of Showa Shell
Sekiyu or equivalent
• Molynoc No. 2 of Nippon
a Coat the spline portion of coupling with dry-
ing type lubricant of molybdenum disulfide
and install after the lubricant dries up in a
few minutes.
2 Drying type lubricant of molybdenum
disulfide:
3 Oil seal cage mounting bolt

Rocol Dry Spray of Sumico Lubricant
or equivalent
: 58.8 - 73.5 Nm {6 - 7.5 kgm}
HM300-1 30-35
(10)
2
2 Portion between cover and flywheel

housing:
Gasket sealant No. 1207B of Three Bond or
equivalent
3 Cover and plate assembly mounting
bolt
: 58.8 - 73.5 Nm {6 - 7.5 kgm}
2 Seal cover and contact face

: Adhesive compound
(No. 1521 of Three Bond or equivalent)
2 Seal inside perimeter contact face
: Grease (G2-LI)
3 Plate mounting bolt
: 27.44 - 34.3 Nm {2.8 - 3.5 kgm}
2 Mounting bolt
: Liquid adhesive compound (LT-2)
3 Output shaft assembly mounting bolt
: 58.8 - 73.5 Nm {6 - 7.5 kgm}
30-35-1 HM300-1
2(10)
ASSEMBLY AND DISASSEMBLY OF
ASSEMBLY AND 2. Outer body
DISASSEMBLY OF 1) Set outer body (5) on wooden blocks [2],

keeping it off the ground.
OUTPUT SHAFT ASSEMBLY 2) Separate outer body (5) from inner body (6),
hitting the inner body with push tool [3].
DISASSEMBLY
★ In order not to lose the original balance of the
output shaft assembly due to disassembly, mark
a setting position on the flange and outer body
before disassembling.
1. Inner flange
1) Remove 12 flange mounting bolts (1).
2) Remove snap ring (2).
3. Rubber
Remove 4 large pieces of rubber (7) and 4 small
pieces of rubber (8).
3) Remove inside flange (3), using forcing

screws [1].
4. Outside flange and inner body

1) Reverse outside flange and inner body
assembly (9).
4) Remove bearing (4) from inside flange (3).
30-36 HM300-1
2
3) Push inner body (11) out of outer flange (12) ASSEMBLY

with a press, using push tool [4]. 1. Outside flange and inner body
1) Press-fit bearing (13) into outside flange
(12).
★ Fill the inside and outside of bearing
balls completely with lithium type
extreme-pressure grease containing
molybdenum disulfide.
2 Lithium type extreme-pressure
grease containing molybdenum
sulfide:
• Molylex No. 2 of Kyodo Yushi or
equivalent
• Retinax AM of Showa Shell
Sekiyu or equivalent
• Molynoc No.2 of Nippon
2 Bearing outside contact face and
periphery
: Loctite 601 or equivalent
4) Remove bearing (13) from outside flange

(12).
HM300-1 30-37
2
(9)
2) Set outside flange (12) on inner body (11), 3. Rubber

and then press-fit, using push tool [5]. Install 4 large pieces of rubber (7) and 4 small
2
pieces of rubber (8).
Bearing inside contact face and
★ Set the rubber pieces as shown in the photo
perimeter
below.
: Loctite 601 or equivalent
2 When installing the rubber pieces, coat
all over the rubber, inner body periph-
ery and outer body periphery with
grease (G2-LI).
2 After installing the rubber pieces, fill
each "P" portion (4 points) between the
rubber and inner body evenly with
1,500 cc of grease (G2-LI).
3) Install snap ring (10).
2. Outer body
1) Reverse outside flange and inner body
assembly (9).
2) Press-fit outer body (5) into outside flange
and inner body assembly (9).
2 Mating face
30-38 HM300-1
2
REMOVAL AND INSTALLATION OF TRANSMISSION AND
DISASSEMBLY AND ASSEMBLY FRONT DIFFERENTIAL ASSEMBLY
REMOVAL AND 6. Remove the operator's cab assembly in the fol-

lowing order.
INSTALLATION OF
TRANSMISSION AND
FRONT DIFFERENTIAL
ASSEMBLY
SPECIAL TOOL
Mark Part No. Part Name Neces Q'ty Distin Ske-
sity ction* tch
799-703-1200 Service Tool Kit ■ 1
Vacuum Pump
799-703-1100 ■ 1
(100 V)
Vacuum Pump
X 799-703-1110 ■ 1
(200 V) 1) Disconnect 11 wiring connectors (1) to (11)
Vacuum Pump from "A" part.
799-703-1120 ■ 1
(240 V)
• (1) : J08
799-703-1400 Gas leak tester ■ 1
• (2) : J09
*Distinction of new part and improved part • (3) : J02
• (4) : J04
REMOVAL • (5) : J05
• (6) : J06
k Disconnect the negative (-) terminal of battery • (7) : J07
beforehand. • (8) : J10
k Turn the parking brake switch on and put • (9) : J11
wooden blocks behind the wheels. • (10) : J01
1. Drain hydraulic oil. • (11) : (Spare)
6 Hydraulic tank: 120l
2. Drain oil from the transmission and brake oil
tank.
6 Transmission case and brake oil tank:
77.5l
3. Drain engine coolant from the radiator as well
as steering and torque converter (brake) oil
cooler.
6 Radiator, steering and torque con-
verter (brake) oil cooler: 51l
cab with a crane or using a built-in tilt-up cylin-
der.
k Fasten the operator's cab securely with a
bar.
• For procedures of removing and installing the
operator's cab, refer to the section of
"METHOD OF TILTING CAB UP" in TEST-
ING AND ADJUSTING.
5. Remove the engine undercover.
HM300-1 30-39
2
(9)
2) Disconnect 5 brake valve hoses (12) to (16) 4) Disconnect air conditioner hoses (23) and
from "B" part and remove clamp (17) at 2 (24) as well as heater hoses (25) and (26)
points. from "D" part.
k In disconnecting the air conditioner
★ In order to make no mistake about the
installing position, either mark each
hoses, it is a dangerous practice to dis-
hose or attach an identification tag.
connect the hoses without first releas-
• (12) : A port hose
ing pressure inside the cooling system.
• (13) : B port hose
For this reason, evacuate the air condi-
• (14) : PB port hose
tioner gas before the work, using tool
• (15) : T port hose
X.
• (16) : PA port hose
★ When the heater hose is disconnected,
coolant leaks out, so prepare for a blind
plug.
3) Disconnect 5 hoses (18) to (22) from "C"

part.
★ The ports listed hereunder stands for a
5) Remove head pin (28) from cab lift cylinder
port in the steering valve.
(27) in "E" part.
• (18) : LS port hose
★ After removing the head pin, retract the
• (19) : R port hose
lift cylinder to its stroke end.
• (20) : L port hose
★ Shims are provided, so check their
• (21) : T port hose thickness, number in use and installed
• (22) : P port hose position beforehand.
30-40 HM300-1
2
(9)
6) Lower the tilted operator's cab assembly 7. Sling vertical member (31) to remove.
4
with a crane.
Vertical member: 35 kg
★ Lower the operator's cab after checking
that no wiring or piping gets pinched.
7) Lift the operator's cab and remove mounting
pins (29) from the left and right of the
machine rear.
★ Shims are installed, so check their thick-
ness, number in use and installed loca-
tion beforehand.
8. Separate the following parts from the transmis-

sion upper front side.
1) Disconnect 5 hoses (33) to (37) from steer-
ing and hoist pump assembly (32).
• (33), (34), (35) and (36): Discharging hose
(37): Suction hose
8) Sling operator's cab assembly (30) to

remove.
4 Operator's cab assembly: 1,200 kg
2) Sling steering and hoist pump assembly

(32) to remove.
4 Steering and hoist pump assembly
: 50 kg
HM300-1 30-41
2
(5)
3) Remove upper and lower drive shaft guards 8) Disconnect grounding wire (42) at the front
(33), and then remove drive shaft (34) left side.
between the engine and transmission.
4) Remove coupling (35) on the output shaft

side.
9. Separate the following parts from the transmis-

sion upper rear side.
1) Disconnect grease hose (43) at the chassis
side on the right side of the transmission.
5) Disconnect transmission lubrication circuit
inlet hoses (36) and (37).
6) Disconnect front differential breather hose
(38).
7) Disconnect 3 discharging hoses (39), (40)
and (41) from the rear brake cooling and
brake actuating pump assembly.
2) Disconnect torque converter outlet hoses

(44), (45) and (46) and return hose (47).
30-42 HM300-1
2
(9)
(5)
10. Separate the following parts from the rear of the

transmission.
1) Disconnect grease hose (47).
2) Disconnect return hoses (48) and (49) as
well as breather hose (50) from the oil sup-
ply piping.
11. Disconnect left and right drive shafts (57) from

the underside of the transmission.
★ Disconnect them at the front differential
side.
3) Remove cover (51), and then remove cou-

pling (52) between the sub-tank and oil sup-
ply piping.
4) Remove the mounting bolts of oil supply
connector (53).
5) Disconnect oil supply piping (54).
6) Disconnect transmission output shaft revo-
lution sensor (N3) (55).
12. Remove the mounting bolts for front differential

mount (58) and transmission mounts (59) and
(60). (4 bolts for each)
★ Remove the mounting bolts of front dif-
ferential mount (58) from the machine's
underside.
★ Shims are installed, so check their thick-
ness, number in use and installed loca-
tion beforehand.
7) Remove drive shaft (56) between the trans-

mission and hitch frame.
4 Drive shaft between transmission
and hitch frame: 30 kg
HM300-1 30-43
2
(9)
13. Sling the transmission and front differential INSTALLATION

assembly to remove. • Installation is carried out in the reverse order to
1) Sling the transmission and front differential removal.
assembly until the transmission front mount
(59) gets clear of the floor, and remove left
and right mount brackets (61).
★ Install hoses in the air conditioner circuit

carefully so that no dirt, dust, moisture, etc.
will get in them.
★ Install the hoses so that they will not be
twisted, bent forcibly or slackened in a
harmful way.
★ Check that an O-ring is properly provided at
hose connecting parts and then install.
★ Make sure that O-rings are free of damage
or deterioration.
★ Coat the spigot of refrigerant hoses with
compressor oil (ND-OIL8) before connect-
2) Sling transmission and front differential ing them, and then tighten with a double
assembly (62) slowly and remove it. spanner.
3 Hose spigot (M16 x 1.5)
★ Make sure that no hose or wiring is left
still connected.
: 12 - 15 Nm {1.2 - 1.5 kgm}
3 Hose spigot (M24 x 1.5)
In particular, take good care to avoid
interference between the torque con-
verter outlet tube on the front side and : 30 - 35 Nm {3.0 - 3.5 kgm}
the output shaft oil seal as well as inter-
ference between the rear left mount and
the hoist valve.
4 Transmission and front differential ★ Adjust the clearance between operator's
assembly: 1,450 kg cab (62) and mount (63) with shims in order
to attain clearance dimension "a" both at left
and right.
• Standard clearance "a"
: 0.2 mm (on one side)
• Kind of shim thickness
: 0.5 mm, 1.0 mm and 2.3 mm
30-44 HM300-1
2
(9)
3 Mounting bolt for front differential

mount
★ Install the drive shaft between the engine
: 1,150 - 1,440 Nm {118 - 147 kgm}
3 Mounting bolt for front transmission
and transmission, referring to the section of
"REMOVAL AND INSTALLATION OF
ENGINE ASSEMBLY". mount
: 153 - 190 Nm {15.5 - 19.5 kgm}
3 Mounting bolt for rear transmission
mount
★ Coat the coupling spline with dry type lubri- : 171.5 - 214.5 Nm {17.5 - 21.9 kgm}
cant of molybdenum disulfide, and install
after it dries up in a few minutes.
2 Dry type lubricant of molybdenum
disulfide: ★ Install the transmission front mount, keeping
Rocol Dry Spray of Sumico Lubricant it clear of the floor.
or equivalent 3 Mounting bolt for rear transmission
mount
: 171.5 - 214.5 Nm {17.5 - 21.9 kgm}
• Oil supply (hydraulic tank)
★ When installing the drive shaft between the
Refill with oil through the oil filler port up to the
transmission and hitch frame, turn it to face
specified level, then start the engine to let oil cir-
in the same direction as the yoke of the
culate in the piping and check the oil level
drive shaft between the hitch frame and again.
5 Hydraulic tank :120l (EO10-CD)
center differential.
★ When installing drive shafts, check that the
spider cap keyway fully engages with the • Oil supply (transmission case and brake oil
keyway of the counter yoke, and then tank)
tighten the mounting bolts. Refill with oil through the oil filler port up to the
★ Install the drive shaft between the transmis- specified level, then start the engine and run at
low idle, and check the oil level again.
5 Transmission and brake oil tank
sion and hitch frame only after confirming
that it faces in the same direction as the
yoke of the drive shaft between the hitch : 77.5l (EO10-CD)
frame and center differential does.
• Water supply
2 Mounting bolt Refill with water through water filler port up to
: Liquid adhesive compound (LT-2) the specified level, then start the engine to raise
3 Mounting bolt for drive shaft between
the coolant temperature, and check the coolant
level again.
transmission and hitch frame and
k
mounting bolt for left and right drive
Air bleeding (brake)
shaft
:98 - 123 Nm {10 - 12.5 kgm} After finishing the installation, bleed air from the
[Target value: 113 Nm {11.5 kgm}] brake circuit, referring to the section of "BLEED-
ING AIR FROM BRAKE CIRCUIT" in TESTING
AND ADJUSTING.
★ Install shims both for the front differential

mount and for the transmission rear mount.
Do not make a mistake about their right
location for installation.
• Standard shim thickness: 2 mm
• Kind of shim thickness:
0.5 mm (for front differential mount)
1.0 mm (for transmission rear mount)
HM300-1 30-45
2
(9)
CONNECTION AND DISCONNECTION OF FRONT DIFFERENTIAL
DISASSEMBLY AND ASSEMBLY ASSEMBLY AND TRANSMISSION ASSEMBLY
CONNECTION AND
DISCONNECTION OF FRONT
DIFFERENTIAL ASSEMBLY
AND TRANSMISSION
ASSEMBLY
DISCONNECTION
1. Remove pipes (1), (2) and (3), and disconnect
hose (4) at the pump side.
4. Remove mount bracket (7).

5. Sling transmission assembly (8) and front differ-
ential assembly (9), and support front differen-
tial assembly (9) with hydraulic jack [1].
6. Remove the front differential assembly mount-
ing bolts, tighten left and right forcing screws [2]
evenly and separate the front differential
assembly.
7. Pull out front differential assembly (9) with hoist

and a hydraulic jack [1] and remove.
2. Remove the rear brake cooling and brake actu- 4 Front differential assembly: 340 kg
ating pump (5).
4 Rear brake cooling and brake actuat-
ing pump: 30 kg
3. Remove the torque converter, transmission and
front brake cooling pump (6).
4 Torque converter, transmission and
front brake cooling pump: 25 kg
30-46 HM300-1
2
(9)
CONNECTION AND DISCONNECTION OF FRONT DIFFERENTIAL
DISASSEMBLY AND ASSEMBLY ASSEMBLY AND TRANSMISSION ASSEMBLY
CONNECTION
• Carry out connection in the reverse order to
disconnection.
2 Mount bracket mounting bolt

3 Mount bracket mounting bolt
: 455 - 565 Nm {46.5 - 58 kgm}
2 Front differential mounting bolt

3 Front differential mounting bolt
: 245 - 309 Nm {25 - 31.5 kgm}
HM300-1 30-47
2
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF
TORQUE CONVERTER
ASSEMBLY
SPECIAL TOOL
Dis-
Mark Part No. Part Name Neces- Q'ty tinc- Ske-
sity tion*
tch
790-501-5000 Unit Repair Stand ● 1

1 790-901-2110 Bracket ● 1
C
792T-213-1210 Plate ● 1 N c
2 792-213-1110 Wrench ■ 1
2) Turbine
Reverse the drive case, then remove the
*Distinction of new part and improved part mounting bolts, and remove turbine (7).
DISASSEMBLY
1. Turbine and clutch disassembly
1) Set the torque converter assembly on tool
C1.
2) Remove mounting bolt (1) at the pump side.
3) Remove turbine and clutch assembly (4),
using eyebolts [1].
3) Drive case
Remove the mounting bolts and then drive
case (8) from clutch housing assembly (9).
4) Disc
Remove disc (10) from clutch housing
assembly (9).
2. Further disassembly of turbine and clutch

assembly
1) Input shaft
i) Remove input shaft (5), using forcing
screws [2].
ii) Remove bearing (6), using puller [3].
30-48 HM300-1
2
5) Plate and snap ring 8) Bearing, seal ring and pin

Reverse the clutch housing, then remove i) Remove bearing (16) from the clutch
snap ring (11), and remove plate (12). housing, using push tool [5].
ii) Remove seal ring (17).
6) Shaft and piston

Remove shaft (13) from clutch housing 3. Stator assembly
assembly (9), using push tool [4], and then Pull up stator assembly (18) to remove.
remove piston (14).
4. Further disassembly of stator assembly

7) Seal ring 1) Stator
Remove seal rings (15) from piston (14). Remove snap ring (40) and then remove
stator (41).
HM300-1 30-49
2
2) Bushing
Remove bushings (20) and (21) from race
(19).
★ Be careful not to lose ball (50).
3) Race and one-way clutch
Remove one-way clutch (23) from race (19).
5. Further disassembly of pump and stator

shaft assembly
1) Nut
Remove nut (24), using tool C2.
4) Seal ring and bearing inner race

Remove seal ring (31) and bearing inner
race (32) from stator shaft (30).
2) Remove the pump and stator shaft assem-

bly from tool C1.
3) Stator shaft assembly and bearing inner
race
Remove stator shaft assembly (28) and
bearing inner race (29) from pump assem-
bly (27) by pushing stator shaft assembly
(28).
30-50 HM300-1
2
5) Retainer ASSEMBLY
Remove mounting bolts (33) and then
1. Subassembly of pump and stator shaft
remove retainer (35) from pump (34). assembly
1) Bearing and guide
Install bearing (36) to guide (37), and then
install the combination to pump (34).
★ Bearing (36) is a set part, so install it
after checking that its manufacturing No.
and counter mark (A) on the edge are
the same as those of a counter bearing.
6) Bearing and guide

i) Remove guide (37) from pump (34).
ii) Remove bearing (36) from guide (37).
2) Retainer
Install retainer (35) on pump (34) and fasten
with mounting bolts (33).
2 Retainer mounting bolt
: 58.8 - 73.5 Nm {6 - 7.5 kgm}
HM300-1 30-51
2
3) Bearing inner race and seal ring

Press-fit bearing inner race (32) into stator
shaft (30), using push tool [6], and install
seal ring (31).
★ Bearing inner race (32) is a set part, so
install it after checking that its manufac-
turing No. and counter mark (A) on the
edge are the same as those of a counter
bearing.
2 Seal ring periphery
: Grease (G2-LI)
iii) Drip approx. 6 cc of engine oil (EO10-

CD or EO30-CD) on the bearing and
rotate it by 10 turns.
5) Set pump and stator shaft assembly on tool
C1.
6) Nut
Install nut (24), using tool C2.
2 Nut thread portion
3 Nut
4) Stator shaft assembly and bearing inner : 441.3 - 490.3 Nm {45 - 50 kgm}
race
i) Press-fit stator shaft assembly (28) into
pump assembly (27).
2. Subassembly of stator assembly

1) One-way clutch and race
ii) Press-fit bearing inner race (29) into sta- Install one- way clutch (23) to race (19).
tor shaft (30), using push tool [7]. ★ Install the one-way clutch so that an
★ Bearing inner race (29) is a set part, arrow shown on the cage edge faces
so install it after checking that its the input side, and check the stator rota-
manufacturing No. and counter tion direction as viewed from the input
mark (A) on the edge are the same side.
as those of a counter bearing. Clockwise: No load
Counter-clockwise: Lock
2 Sliding surface
: Engine oil (EO10-CD or EO30-CD)
30-52 HM300-1
2
2) Bushing 4. Subassembly of turbine and clutch assembly

Expansion-fit bushings (20) and (21) with 1) Bearing, seal ring and pin
ball (50) into race (19). i) Install bearing (16), using push tool [8]
2 Sliding surface ii) Install seal ring (17).
: Engine oil (EO10-CD or EO30-CD) 2 Seal ring periphery
: Grease (G2-LI)
★ Drip approx. 6 cc of engine oil (EO10-
CD or EO30-CD) on the bearing (16)
and rotate it by 10 turns.
3) Stator
Install stator (41) with snap rings (40).
2) Seal ring, piston and shaft

i) Install seal rings (15) to piston (14).
★ Do not make a mistake about the direc-
tion of installation, referring to the figure
below.
3. Stator assembly
Install stator assembly (18).
HM300-1 30-53
2
ii) Install piston (14) to the clutch housing 4) Disc

assembly. Install disc (10) to clutch housing assembly
2 Seal ring periphery (9).
: Grease (G2-LI) 2 Sliding surface
: Engine oil (EO10-CD or EO30-CD)
5) Drive case
Install drive case (8) to clutch housing
assembly (9).
2 Mounting bolt
3 Mounting bolt
: 58.8 - 73.5 Nm {6.0 - 7.5 kgm}
iii) Press-fit shaft (13) into clutch housing

assembly (9), using push tool [9].
6) Turbine
Install turbine (7).
2 Mounting bolt
3) Plate, snap ring 3 Mounting bolt
Install plate (12) to the shaft and then install : 58.8 - 73.5 Nm {6.0 - 7.5 kgm}
snap ring (11).
30-54 HM300-1
2
(9)
7) Input shaft
i) Install bearing (6), using push tool [10].
★ Drip approx. 6 cc of engine oil (EO10-
CD or EO30-CD) on the bearing (6) and
rotate it by 10 turns.
ii) Install input shaft assembly (5) to the
clutch housing.
2 Mounting bolt
3 Mounting bolt
: 58.8 - 73.5 Nm {6.0 - 7.5 kgm}
5. Turbine and clutch assembly

1) Install turbine and clutch assembly (4),
using eyebolts [1].
2) Tighten 40 mounting bolts (1).
2 Mounting bolt
3 Mounting bolt
: 27 - 34 Nm {2.8 - 3.5 kgm}
HM300-1 30-55
2

C1 Plate
30-56 HM300-1
2
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF
TRANSMISSION ASSEMBLY
SPECIAL TOOL
Neces- Dis- Ske-
Mark Part No. Part Name Q'ty tinc-
sity tch
tion*
1 790-102-1871 Nut Wrench ■ 1
2 796-465-1120 Push Tool ■ 1
3 792T-423-1110 Push Tool ■ 1 c
792T-213-1220 Push Tool ■ 1 N c
4 790-101-5421 Grip ■ 1
01010-81240 Bolt ■ 1
D 792T-213-1230 Push Tool ■ 1 N c
5 790-101-5421 Grip ■ 1
01010-81240 Bolt ■ 1
6 790-201-2730 Spacer ■ 1
7 792T-413-1120 Push Tool ■ 1 c
8 792T-215-1120 Push Tool ■ 1 N c
9 799-301-1500 Oil Leak Tester Kit ■ 1
DISASSEMBLY
1. Trunnion
1) Remove plate (300) and then remove trun-
nions (1) and (2).
2) Remove bushing (301) from trunnion (1).
2. Wiring harness, sensor and piping
Disconnect wiring harness assembly (3), hose
(4), intermediate shaft rotation sensor (5), out-
put shaft F rotation sensor (6), output shaft R
rotation sensor (7) and tubes (8), (9) and (10).
3. Relief valve assembly

1) Remove torque converter oil temperature
sensor (11) and then remove block (12)
HM300-1 30-57
2
2) Remove relief valve assembly (13) and dis-

connect piping (14).
4. Strainer (left and right)

Remove cover (15) and then remove strainer
(16) and block (17).
6. Main relief valve assembly, valve flow

assembly and sensor
Remove main relief valve assembly (22), valve
flow assembly (23), input shaft rotation sensor
(24), torque converter intermediate pressure oil
pressure sensor (25) and torque converter out-
5. Transmission control valve assembly
let oil temperature sensor (26).
★ Seal the oil holes on the installing face with
★ Seal the oil holes on the installing face with
tape or the like so that no foreign objects tape or the like so that no foreign objects
enter them.
enter them.
1) Disconnect tubes (18), (19) and (20).
2) Remove transmission control valve assem-
bly (21) and valve seat (302) together.
3) Remove each transmission control valve
and filter assembly (303) from the valve
seat.
30-58 HM300-1
2
7. Coupling 2) Remove cover (305).

1) Remove input coupling (27) and output cou- 3) Remove cage (30), using forcing screws [1].
pling (28). ★ Check the thickness of shims and their
number in use beforehand.
2) Remove cover (304) from output coupling

(28). 4) Remove outer race (31) from cage (30).
8. Cover and cage (R clutch and 2nd clutch 9. Retainer and cage (differential lock clutch
side) rear output side)
1) Sling the transmission assembly and set it 1) Screw forcing screws in holes A and remove
on the block so that the transmission case retainer (32).
faces up.
2) Screw forcing screws in holes B and remove
cage (33).
HM300-1 30-59
2
(9)
3) Remove dust seal (34) and oil seal (35)

from retainer (32).
4) Remove outer race (36) from cage (33).
10. Rear transmission case assembly

Separate rear transmission case assembly (29)
from the front side, using forcing screws [2] at 3
points.
k If the transmission is not placed with the
torque converter side down, it cannot be
disassembled. Be sure to set it with the
torque converter side down.
★ If the transmission is disassembled with
the torque converter side up, its inside will 12. Seal ring
be broken. Accordingly, be sure to disas- Remove seal rings (44), (45) and (46).
semble the transmission with the torque
converter side down.
11. Further disassembly of rear transmission

case assembly
1) Remove holder (37) to remove bearing (39),
then remove gear (38), bearing (40) and col-
lar (41).
2) Remove outer races (320) and (321) from
gear (38).
3) Remove bearings (42) and (43).
30-60 HM300-1
2
(5)
13. Clutch assembly 5) Sling FL and R clutch assembly (49) to

★ Sling [53] is shown just as an example. remove.
1) Take out idler gear (138) of FH and 1st ★ For details on the further disassembly of
clutch assembly (47) together with inner the FL and R clutch assembly, refer to
race (137), using puller [18]. the sections of 23 and 24.
2) Sling 2nd and 3rd clutch assembly (48) to

remove.
★ For details on the further disassembly of
the 2nd and 3rd clutch assembly, refer
to the sections of 19 and 20.
3) Sling differential clutch assembly (401)
together with shroud (400) to remove.
★ Shroud (400) cannot be removed inde-
pendently, when the differential lock
clutch assembly is still installed.
★ For details on the further disassembly of
differential lock clutch assembly, refer to
the section of 18. 14. Further disassembly of front transmission
4) Sling FH and 1st clutch assembly (47) to case assembly
remove. 1) Remove bearing (50) and outer races (51)
★ For details on the further disassembly of and (52).
the FH and 1st clutch assembly, refer to
the sections of 21 and 22.
2) Reverse the case and remove cage (53),

using forcing screws [3].
HM300-1 30-61
2
(9)
15. PTO case assembly

Separate PTO case assembly (54) from the
front transmission case to remove, using forcing
screws [4].
★ Before removing, loosen nut (55) before-
hand, using tool D1. (Refer to the section of
16.)
★ Use the input coupling as a lock.
2) Remove retainer (64), using forcing screws

[5].
3) Remove outer race (331) from the PTO
case.
16. Further disassembly of PTO case assembly

1) Disassemble PTO gears at 3 locations fur-
ther in the following steps.
i) Remove nuts (55), using tool D1.
4) Remove dust seal (65) and oil seal (66)

from retainer (64).
ii) Remove snap ring (56) and spacer (57).

iii) Remove PTO gear (61) together with
spacer (59) and bearing (60) by pushing
the shaft portion.
★ When the PTO gear is disengaged,
the bearing (58) goes off, too.
iv) Remove spacer (59) and bearing (60)
from PTO gear (61).
v) Remove outer races (62) and (63) as
well as spacer (330) from the PTO case.
30-62 HM300-1
2
17. Torque converter assembly 2) Separate rear housing (70) from the output
Remove mounting bolts (67) connecting the gear, using forcing screws [6].
torque converter assembly with front transmis-
sion case, and then remove torque converter 3) Sling rear housing (70) together with bear-
assembly (68). ing (71) and rear output shaft (72), using
a For disassembly of the torque converter tool [54] and remove.
assembly, refer to the section of "DISAS-
SEMBLY AND ASSEMBLY OF TORQUE
CONVERTER".
4) Disassemble the rear output shaft, rear

housing and ring gear further in the follow-
ing steps.
i) Using push tool (D8) (inside diameter
must be 115 mm or larger), take out the
bearing and ring gear plate (73) together
from the rear output shaft. (Never press
the snap ring.)
18. Further disassembly of differential lock

clutch assembly
1) Remove gear (69).
a Be careful not to lose a ball between the
gear and the shaft. ii) Screw bolt [7] into the tapped hole for
slinging and raise ring gear (74) to
remove.
HM300-1 30-63
(10)
2
iii) Remove snap ring from shaft.

iv) Remove bearing (71) and (77) from rear
housing (70).
5) Remove plate (79).
6) Remove carrier assembly (80).

a For further disassembly of the carrier
assembly, refer to the section 15).
30-64 HM300-1
2(10)
7) Remove snap rings (81) and (82). 9) Remove clutch hub (85).
10) Compress the spring by pushing plate (87),
using tools [27], and remove snap ring (86).
8) Remove sun gear (84) together with inner

race (83), using puller [9].
11) Remove 6 plates (87), 5 discs (88) and 5
springs (89).
12) Remove piston (90).

★ Use the tapped holes for slinging.
HM300-1 30-65
2
13) Remove seal ring (91) from piston (90). iv) Reverse the front output shaft and hous-
ing assembly, and separate front output
shaft (95) from front housing (96), using
puller [11].
14) Disassemble the front output shaft, front

housing and output gear further in the fol-
lowing steps. v) Remover seal rings (306) from front out-
i) Separate front output shaft and housing put shaft (95) and seal ring (307) from
assembly (92) from output gear (93), front housing (96).
using forcing screws [10], and sling to
remove.
vi) Remove snap ring (97) and spacer (98),

and then remove bearing (99) from the
ii) Remove seal rings (94). front output shaft.
iii) Remove snap ring (308).
30-66 HM300-1
2
(9)
vii) Remove bearing (100) from the front

output shaft.
viii) Remove bearing (101) from the front

housing.
19. Further disassembly of 2nd and 3rd clutch

assembly (2nd clutch side)
1) Set the clutch assembly to tool [12].
15) Disassemble the carrier assembly further in 2) Remove 2nd gear (112) together with bear-
the following steps. ing (109), plate (110) and thrust washer
i) Remove snap ring (102) and then bear- (111), using forcing screws [13].
ing (103).
ii) Hammer out shaft (104) to ball (105)

side, and remove shaft (104), ball (105),
thrust washer (106), planetary gear
(107) and bearing (108).
★ Be careful not to lose ball (105) dur-
ing the work.
HM300-1 30-67
2
(9)
3) Remove bearing (113) from 2nd gear (112). 6) Remove 10 plates (116), 9 discs (117) and 9
springs (118).
4) Compress the spring by pushing end plate

(114), using tool [14], and remove snap ring
(115).
★ Fit the tool to the gear, using tapped
holes for slinging provided on the gear,
then insert a spacer of appropriate thick-
ness in between the tool and end plate
(114), and compress the spring.
5) Remove end plate (114).
30-68 HM300-1
2
7) Remove thrust washer (119) and piston

(120).
★ For removing the piston, use provided
tapped holes.
5) Remove bearing (127) from 3rd gear (126).
8) Remove seal rings (121) and (122) from pis-

ton (120).

(128) with a C clamp, and remove snap ring
(129).
7) Remove end plate (128), 10 plates (130), 9
discs (131) and 9 springs (132).
20. Further disassembly of 2nd and 3rd clutch
assembly (3rd clutch side) 8) Remove thrust washer (133) and piston
1) Set the clutch assembly to tool [15]. (134).
2) Hook the claw of puller [16] to the underside

of plate (123), and remove bearing (124)
together with plate (123).
3) Remove thrust washer (125).
4) Remove 3rd gear (126).
HM300-1 30-69
2
9) Remove seal rings (135) and (136) from pis- 5) Compress the spring by pushing end plate
ton (134). (143), using tool [19], and remove snap ring
(144).
21. Further disassembly of FH and 1st clutch

assembly (1st clutch side)
1) Set the clutch assembly to a cylinder-like 7) Remove 12 plates (145), 11 discs (146) and
tool. 11 springs (147).
2) Remove snap ring (139) and thrust washer
(140).
3) Remove 1st gear (141).

(149).
4) Remove bearing (142) from 1st gear (141).
30-70 HM300-1
2
9) Remove seal rings (150) and (151) from pis- 3) Remove bearing (156) from FH gear (155).
ton (149).

22. Further disassembly of FH and 1st clutch (157), using a C clamp, and remove snap
assembly (FH clutch side) ring (158).
1) Set the clutch assembly to tool [20]. ★ The spring can also be compressed by
fitting the tool to tapped holes A on the
2) Remove FH gear (155) together with bear- FH and 1st cylinder and idler gear, and
ing (152), plate (153) and thrust washer then inserting a spacer of appropriate
(154). thickness in between the tool and end
plate.
5) Remove end plate (157), 11 plates (159), 10
discs (160) and 10 springs (161).
(162).
HM300-1 30-71
2
7) Remove seal rings (163) and (164) from pis- 4) Remove bearing (169) from R gear (168).
ton (162).

23. Further disassembly of FL and R clutch (170) with a C clamp, and remove snap ring
assembly (R clutch side) (171).
1) Set the clutch assembly to a cylinder-like 6) Remove end plate (170), 11 plates (172), 10
tool. discs (173) and 10 springs (174).
2) Hook the claw of puller [22] to the underside 7) Remove thrust washer (175) and thrust
of plate (166), and remove inner race (165) bearing (176).
and plate (166).
8) Remove piston (177).
3) Remove thrust washer (167) and then R
gear (168).

ton (177).
30-72 HM300-1
2
24. Further disassembly of FL and R clutch 4) Remove bearings (184) from FL gear (183).
assembly (FL clutch side)
1) Set the clutch assembly to tool [23].
2) Remove idler gear (181) together with inner
race (180), using puller [24].

(185), using tool [25], and remove snap ring
(186).
3) Remove thrust washer (182) and then FL 7) Remove 11 plates (187), 10 discs (188) and
gear (183). 10 springs (189).
HM300-1 30-73
2
8) Remove thrust washers (190) and thrust ASSEMBLY

bearing (191). ★ Clean each of the parts thoroughly and
9) Remove piston (192). check that it is free of dust, damage, etc.
before assembling.
★ Coat the sliding surface of each of the parts
with engine oil before assembling.
★ Immerse discs in clean engine oil (EO-
10CD) for more than 2 minutes before
assembling.
★ Assemble each seal ring (a) for pistons of
the clutch assembly with its pressure-
receiving side (b side) facing housing (c) as
shown in the figure below.

ton (192).
1. Subassembly of FL and R clutch assembly

(FL clutch side)
1) Install seal rings (193) and (194) to piston
(192).
★ Install the seal ring with its pressure-
receiving side facing the housing side.
30-74 HM300-1
2
2) Install piston (192). 6) Install bearings (184) to FL gear (183).

2 Seal ring periphery and sliding sur-
face: Engine oil (EO-10CD)
3) Install thrust washer (190) and thrust bear-
ing (191).
7) Install FL gear (183) to the clutch assembly

temporarily, and match grooves of the discs.
★ Turn the gear to the left and right, while
pressing it down, and push the gear in
gradually, avoiding interfering with the
4) Install each of 11 plates (187), 10 discs disc mountains.
(188) and 10 springs (189) alternately from 8) Remove FL gear (183) once.
the bottom to the top.
★ Immerse the discs in clean engine oil 9) Compress the spring by pushing end plate
(EO-10CD) for more than 2 minutes (185), using tool [25], and install snap ring
before assembling. (186).
★ Take care so that the plate will not get
caught in the snap ring groove.
★ Make sure that the snap ring settles in
the groove completely.
5) Install end plate (185).
HM300-1 30-75
2
10) Install FL gear (183) and thrust washer 2. Subassembly of FL and R clutch assembly
(182). (R clutch side)
★ If it is found difficult to assemble the FL 1) Install seal rings (178) and (179) to piston
gear in, start the work all again from the (177).
step 7) above. ★ Install the seal ring with its pressure-
receiving side facing the housing.
11) Install idler gear (181) and shrink-fit inner

race (180). 2) Install piston (177).
: For 30 minutes at approx. 120fC

2
• Shrink-fit temperature
Seal ring periphery and sliding sur-
face
12) Apply a dial gauge to the edge surface of : Engine oil (EO-10CD)
idler gear (181), move the idler gear in the
3) Install thrust washer (175) and thrust bear-
thrust direction and check that clearance "a"
ing (176).
remains within the range of 0.28 and 1.10
mm. 4) Install each of 11 plates (172), 10 discs
(173) and 10 springs (174) alternately from
★ Immerse the discs in clean engine oil
(EO-10CD) for more than 2 minutes
before assembling.
30-76 HM300-1
2
6) Install bearing (169) to R gear (168). 10) Install R gear (168) and thrust washer (167).
★ If it is found difficult to assemble the R
gear in, start the work all again from the
step 7) above.
11) Install plate (166) and shrink-fit inner race
(165).

12) Apply a dial gauge to the edge surface of R

gear (168), move the R gear in the thrust
direction and check that clearance "b"
remains within the range of 0.08 and 0.90
mm.
7) Install R gear (168) to the clutch assembly
temporarily, and match disc grooves.
gradually, avoiding interference with the
disc mountains.
8) Remove R gear (168) once.
(170) with a C clamp, and then install snap
ring (171).
★ Make sure that the snap ring settles in 3. Actuation test of FL and R clutch assembly
the groove completely. Blow air into the shaft oil hole, using tool D9,
and check that each clutch is actuated.
★ If the gear on the air-blown side is fixed, the
clutch is in normal operation.
HM300-1 30-77
2
4. Subassembly of FH and 1st clutch assembly 6) Install bearing (156) to FH gear (155).
(FH clutch side)
(162).
★ Install the seal rings with their pressure-
7) Install FH gear (155) to the clutch assembly,

and match disc grooves.
2) Install piston (162). disc mountains.
2 Seal ring periphery and sliding sur- 8) Remove FH gear (155) once.
face: Engine oil (EO-10CD) 9) Compress the spring by pushing end plate
3) Install thrust washer (210). (157) with a C clamp, and install snap ring
(158).
4) Install each of 11 plates (159), 10 discs
(160) and 10 springs (161) alternately from caught in the snap ring groove.
the bottom to the top. ★ Make sure that the snap ring settles in
★ Immerse the discs in clean engine oil the groove completely.
before assembling.
30-78 HM300-1
2
10) Install FH gear (155). 2) Install piston (149).

2
★ If it is found difficult to assemble the FH
Seal ring periphery and sliding sur-
gear in, start the work all again from the
step 7) above.
3) Install thrust washer (148).
11) Install thrust washer (154) and plate (153).
12) Shrink-fit bearing (152).

• Shrink fit temperature
13) Apply a dial gauge to the edge surface of

FH gear (155), move the FH gear in the
thrust direction and check that clearance "c"
remains within the range of 0.07 to 0.93
mm.
4) Install each of 12 plates (145), 11 discs

(146) and 11 springs (147) alternately from
before assembling.
5. Subassembly of FH and 1st clutch assembly

(1st clutch side)
(149).
★ Install seal rings with their pressure-
HM300-1 30-79
2
6) Install bearing (142) to 1st gear (141). 10) Install 1st gear (141).
★ If it is found difficult to assemble in the
1st gear, start the work all again from
the step 7) above.
11) Install thrust washer (140) and snap ring
(139).
7) Install 1st gear (141) to the clutch assembly

disc mountains.
12) Install idler gear (138) and shrink-fit inner
8) Remove 1st gear (141) once. race (137).

9) Compress the spring by pushing end plate • Shrink fit temperature
(143), using tool [19], and install snap ring
(144).
13) Apply a dial gauge to the edge surface of

1st gear (141), move the 1st gear in the
thrust direction and check that clearance "d"
remains within the range of 0.23 to 1.37
mm.
30-80 HM300-1
2
6. Actuation test of FH and 1st clutch assembly 2) Install piston (134).

1) Blow air into the shaft oil hole, using tool D9, 2 Seal ring periphery and sliding sur-
and check that each clutch is actuated. face: Engine oil (EO-10CD)
★ If the gear on the air-blown side is fixed,
the clutch is in normal operation. 3) Install thrust washer (133).
4) Install each of 10 plates (130), 9 discs (131)
and 9 springs (132) alternately from the bot-
tom to the top.
before assembling.
2) Remove idler gear (138) and inner race

(137) once, referring to the step 13 of the
section 2) "DISASSEMBLY".
★ Installation is to be made in the step 15.
7. Subassembly of 2nd and 3rd clutch assem-
bly (3rd clutch side)
(134). 6) Install bearing (127) to 3rd gear (126).
HM300-1 30-81
2
7) Install 3rd gear (126) to the clutch assembly 13) Apply a dial gauge to the edge surface of
temporarily, and match grooves of the discs. 3rd gear (126), move the 3rd gear in the
★ Turn the gear to the left and right, while thrust direction and check that clearance "e"
pressing it down, and push the gear in remains within the range of 0.07 to 0.93
gradually, avoiding interference with the mm.
disc mountains.
8) Remove 3rd gear (126) once.
(128) with a C clamp, and then install snap
ring (129).
10) Install 3rd gear (126).
★ If it is found difficult to assemble in the
3rd gear, start the work all again from
the step 7) above. 8. Subassembly of 2nd and 3rd clutch assem-
11) Install thrust washer (125) and plate (123). bly (2nd clutch side)
(120).
12) Press-fit bearing (124), using tool D2. (Or

shrink-fit the bearing)

2) Install piston (120).

2 Seal ring periphery and sliding sur-
3) Install thrust washer (119).
30-82 HM300-1
2
4) Install each of 10 plates (116), 9 discs (117) 6) Install bearing (113) to 2nd gear (112).
and 9 springs (118) alternately from the bot-
tom to the top.
before assembling.
7) Install 2nd gear (112) to the clutch assembly

disc mountains.
8) Remove 2nd gear (112) once.
(114), using tool [14], and then install snap
ring (115).
HM300-1 30-83
2
10) Install 2nd gear (112). 13) Apply a dial gauge to the edge surface of
★ If it is found difficult to assemble the 2nd 2nd gear (112), move the 2nd gear in the
gear in, start the work all again from the thrust direction and check that clearance "f"
step 7) above. remains within the range of 0.07 to 0.93
11) Install thrust washer (111) and plate (110). mm.
12) Press-fit bearing (109), using tool D3. (Or 9. Actuation test of 2nd and 3rd clutch assem-
shrink-fit the bearing.) bly

• Shrink fit temperature Blow air into the shaft oil hole, using tool D9,
and check that each clutch is actuated.
★ If the gear on the air-blown side is fixed, the
clutch is in normal operation.
30-84 HM300-1
2
10. Subassembly of differential lock clutch iv) Install bearing (103) and then snap ring
assembly (102).
1) Carry out subassembly of the carrier
assembly in the following steps.
i) Assemble bearing (108) in planetary
gear (107).
ii) Set planetary gear (107) to the carrier
with thrust washers (106) installed to the
top and bottom.
iii) Hammer shaft (104) in to the midway,
then assemble ball (105) in the shaft,
and hammer the shaft in until it is flush
with the carrier edge surface.
★ Hammer the shaft in after aligning the
shaft ball hole and the hole on the car-
rier side. 2) Carry out subassembly of the front output
★ Before hammering, make sure that the shaft, front housing and output gear in the
alignment is correct so that the thrust following steps.
washers are not damaged. i) Shrink-fit bearing (101) to the front
housing.

ii) Expansion-fit bearing (100) to the front

output shaft.
HM300-1 30-85
2
iii) Shrink-fit bearing (99) to the front output vii) Install snap ring (308), and then install
shaft. seal rings (94) to the front output shaft.

iv) Install spacer (98) and snap ring (97).
viii) Sling front output shaft and housing

assembly (92) and install output gear
(93).
v) Install seal rings (306) to front output 2 Housing mounting bolt
shaft (95) and seal ring (307) to front : Liquid adhesive compound (LT-2)
housing (96).
★ Install seal ring (307) with its pres- 3 Housing mounting bolt
sure-receiving side facing the bear- : 59 - 74 Nm {6 - 7.5 kgm}
ing in the housing.
: Grease (G2-LI)
vi) Install front output shaft (95) to front
housing (96) with the shaft front facing
up (the side of shorter shaft from the
bearing), using tool [26].
★ Be careful not to damage the seal
ring.
30-86 HM300-1
2
(9)
3) Set the front output shaft-housing-output 7) Install each of 6 plates (87), 5 discs (88) and
gear assembly with the rear output shaft 5 springs (89) alternately from the bottom to
connecting side facing up. the top.
4) Install seal ring (91) to piston (90).
(EO-10CD or EO-30CD) for more than 2
★ Install the seal ring with its pressure-
minutes before assembling.
: Grease (G2-LI)
8) Compress the spring by pushing plate (87),

using tool [27], and install snap ring (86).
5) Install piston (90).
9) Install sun gear (84), snap ring (82), inner

race (83) and snap ring (81).
6) Install clutch hub (85).
HM300-1 30-87
2
(9)
10) Install carrier assembly (80) to the front out- i) Shrink-fit bearing (71) to rear housing
put shaft-housing-output gear assembly. (70).
• Shrink-fit temperature of bearing
(71)
: For 30 minutes at approx. 120°C
11) Install plate (79).

2 Plate mounting bolt
: Liquid adhesive compound (LT-2) ii) Install snap ring (73), ring gear (74) and
3
spacer (76) to the rear shaft.
Plate mounting bolt
iii) Press fit the rear housing assembly to
: 59 - 74 Nm {6 - 7.5 kgm}
the rear shaft assembly.
(Before press fitting, check that snap
ring (73) and (75) are installed.)
12) Carry out subassembly of the rear output

shaft, rear housing and ring gear in the fol-
lowing steps.
30-88 HM300-1
2(10)
13) Set the front output shaft and housing

assembly on a pair of blocks with the output
gear facing up.
14) Install rear output shaft-housing-ring gear
assembly (309), using tool [54].
2 Rear housing mounting bolt
3 Rear housing mounting bolt
: 59 - 74 Nm {6 - 7.5 kgm}
15) Install coupling (69).

a Do not forget to assemble a ball in
between the gear and shaft.
HM300-1 30-89
(10)
2
11. Torque converter assembly 2) Install retainer (64) to the PTO case.
Install torque converter assembly (68) in the
front transmission case and tighten bolt (67).
★ For assembling the torque converter, refer
to the section of "DISASSEMBLY AND
ASSEMLY OF TORQUE CONVERTER".
3) Carry out subassembly of PTO gears at 3

locations in the following steps.
i) Install to the PTO case in the order of
outer race (63), spacer (330) and outer
race (62).
12. Subassembly of PTO case assembly

1) Install dust seal (65) and oil seal (66) to
retainer (64), using tools D4 and D5.
2 Seal lip face and clearance
between dust seal and oil seal
: Silicone grease (Three Bond 1855)
2 Periphery of press-fitted face on
retainer side
: Gasket sealant (Three Bond 1110B)
★ After press-fitting, wipe out oozed gas-
ket sealant completely.
30-90 HM300-1
2
ii) Press-fit bearing (60) into PTO gear 13. PTO case assembly
(61), using tool D6.
1) Install guide bolt [27] to the front transmis-
★ Check that a manufacturing No. and
sion case, and install PTO case assembly
a counter mark on inner ring (58)
(54) to the front transmission case.
and outer ring (60) match, i.e. match
A and A, as well as B and B.
(This means that they are to be
used as a set part.)
2) Tighten nut (55) of the PTO gear, using tool

D1.
★ Install the nut with its chamfered side
iii) Install spacer (59) to the shaft of PTO facing inward.
gear (61), and assemble in the PTO ★ Install the input coupling and use it as a
case. lock.
2
iv) Press-fit bearing (58) and install spacer Nut: Grease (G2-LI)
(57) and snap ring (56).
3 Nut: 314 - 392 Nm {32 - 40 kgm}
3) Coat the bearing with 6cc of engine oil
(EO10-CD or EO30-CD), rotate the bearing
by 10 turns and check the nut tightening
torque again.
14. Subassembly of front transmission case

assembly
1) Install cage (53).
HM300-1 30-91
2
2) Reverse the case and install bearing (50)

and outer races (51) and (52).
16. Seal ring

Install seal rings (44), (45) and (46).
15. Clutch assembly 2 Seal ring: Grease (G2-LI)
★ Tool [53] is shown just as an example.
1) Install FL and R clutch assembly (49).
★ Check that the seal ring on the FL clutch
side has not enlarged at the abutment.
17. Subassembly of rear transmission case

assembly
1) Install collar (41).
★ Be careful of the installing direction.
2) Install FH and 1st clutch assembly (47). (Refer to the figure below.)
★ Install this assembly with idler gear
2) Press-fit bearing (40), using tool D7.
(138) and inner race (137) as removed.
3) Sling differential lock clutch assembly (401)
set shroud (400) to its setting position.
★ The shroud cannot be installed after the
differential lock clutch assembly is
installed.
4) Install differential lock clutch assembly (401)
after it is lowered.
5) Put shroud (400) to the differential clutch
assembly and tighten the mounting bolts in
a position 1 mm away from the assembly.
6) Install 2nd and 3rd clutch assembly (48).
7) Install idler gear (138) to FH and 1st clutch
assembly (47), and shrink-fit inner race
(137).

30-92 HM300-1
2
3) Shrink-fit outer races (320) and (321) to

gear (38).
4) Install gear (38) and press-fit bearing (39).
★ Before installing, make sure that a man-
ufacturing No. and counter mark on
inner ring (39) and outer ring (40) match
with each other. (This means that they
are to be used as a set part.)
5) Install holder (37) and tighten the mounting
bolt.
2 Holder mounting bolt
: Grease (G2-LI)
3
2) Install guide bolt [28] to rear transmission
Holder mounting bolt case assembly (29) and install the assem-
: 245 - 309 Nm {25 - 31.5 kgm}
bly.
6) Install bearings (42) and (43). ★ When installing, be careful of interfer-
ence with the clutch assembly as well as
displacement of the seal ring.
3 Rear transmission case assembly
mounting bolt
: 98 - 122.5 Nm {10 - 12.5 kgm}
18. Rear transmission case assembly

1) Coat the case mating faces (both on the
front side and on the rear side) with gasket
sealant, referring to the drawing below.
★ "a" mark stands for a tapped hole.
★ "I" mark indicates the inside while "O"
mark indicates the outside.
★ Coat so that area of the cross section of
the coated gasket sealant (B x H) is 2 to
5 mm2.
2 Case mating face
HM300-1 30-93
2
(9)
19. Subassembly of retainer and cage (differen-

tial lock clutch rear output side)
1) Install outer race (36) to cage (33).
20. Shrink-fit outer race (31) to cage (30) on the 2nd

clutch side.
2) Shrink-fit oil seal (35) and dust seal (34) to

retainer (32), using push tool [29].
★ Oil seal press- fit dimension "a"
: 11.5 ± 0.2 mm.
★ Press-fit dust seal (34) in the direction
shown in the figure.
★ Dust seal press- fit dimension "b"
: 2.5 ± 0.2 mm
★ Wipe out oozed gasket sealant com-
pletely after press-fitting.
2 Seal lip face and clearance
between dust seal and oil seal
: Silicone grease (Three Bond 1855)
2 Press-fitted surface of periphery on
cover side
30-94 HM300-1
2
21. Shim adjustment of taper roller bearing (2nd 8) Tighten cage (30) mounting bolts.
3
clutch side and differential lock clutch side)
Mounting bolt
1) Install cages (30) and (33) without shims to : 98 - 122 Nm {10 - 12.5 kgm}
the rear transmission case.
9) Activate the differential lock clutch to mea-
3 Mounting bolts of cages (30) and sure rotation torque of output shaft (200),
(33) and check that increment from the value of
: 8.8 - 10.8 Nm {0.9 - 1.1 kgm}
rotation torque obtained in the step 5
2) Blow air into oil passage A through oil hole remains within the following range of values.
B for the differential lock clutch to operate ★ Rotation torque increment
this clutch, using tool D9, and rotate output : 4.9 - 12.8 Nm {0.5 - 1.3 kgm}
shaft (200) by 20 turns. 10) Measure clearance "b" between cage (33)
points of periphery (120w apart) and calcu-

and the rear transmission case at three
late the average value.

★ If fluctuation of the values measured at
three points does not fall within 0.15
mm, check whether the bearing is cor-
rectly installed, or there is any other
cause. Take a corrective action as the
case may be, and measure again.
11) Assemble shims (202) having thickness of
average value of "b" obtained in the step 10
above minus the following dimensions.
3) Check that there is no change in the tighten- ★ Thickness decrement: 0.20 - 0.25 mm
★ Shim thickness tolerance (for refer-
ing torque of cages (30) and (33) mounting
ence): 1.5 - 2.9 mm
bolts. If any, repeat the steps 1) and 2).
12) Tighten cage (33) mounting bolts.
4) Loosen cages (30) and (33) mounting bolts.
3 Mounting bolt
5) Measure rotation torque of output shaft
: 98 - 122 Nm {10 - 12.5 kgm}
(200).
★ Rotation torque 13) Measure rotation torque of output shaft
: 11.8 - 17.6 Nm {1.2 - 1.8 kgm} (200), and check that increment from the
value of rotation torque obtained in the step
6) Measure clearance "a" between cage (30)
9) remains within the following range of val-
and the rear transmission case at three
ues. (See a note below.)
points of periphery (120 degrees apart) and
★ Rotation torque increment
calculate the average value.
: 1.9 - 9.8 Nm {0.2 - 1.0 kgm}
★ If fluctuation of the values measured at
Note: Only with the 2nd clutch, this measure-
three points does not fall within 0.15 ment is to be taken at the time of shim
mm, check whether the bearing is cor- adjustment.
rectly installed, or there is any other
cause. Take a corrective action as the
case may be, and measure again.
7) Assemble shims (201) having thickness of
average value of "a" obtained in the step 6
above minus the following dimensions.
★ Thickness decrement: 0.15 - 0.20 mm
★ Shim thickness tolerance (for refer-
ence): 1.2 - 2.1 mm
HM300-1 30-95
2
(9)
24. Sling the transmission assembly and put it on

blocks as horizontally as if mounted on a truck.
25. Coupling
1) Press-fit cover (304) into output coupling
(28), using tool D8.
2) Install output coupling (28) and input cou-

pling (27) together with the holder.
2 Output coupling mounting bolt
3 Output coupling mounting bolt
22. Install retainer (32). : 662 - 829 Nm {67.5 - 84.5 kgm}
2 Input coupling mounting bolt
3 Input coupling mounting bolt
: 245 - 309 Nm {25 - 31.5 kgm}
23. Install cover (305).

2 Mounting bolt
3 Mounting bolt
: 59 - 74 Nm {6 - 7.5 kgm}
30-96 HM300-1
2
26. Main relief valve assembly, valve flow 27. Transmission control valve assembly
assembly and each sensor
1) Install filter assembly (303) to valve seat
Install main relief valve assembly (22), valve
(302).
flow assembly (23), input shaft rotation sensor
★ When case (310) and plug (311) have
(24), torque converter intermediate pressure oil been removed from the filter assembly,
pressure sensor (25) and torque converter out- tighten each of them to the following
let oil temperature sensor (26). torque.
★ Degrease the grounding wire mounting part
on the main relief valve assembly thor- 3 Case
oughly. : 34.3 - 44.1 Nm {3.5 - 4.5 kgm}
★ When installing the input shaft rotation sen- 3 Plug
sor, refer to the section of "ADJUSTING : 15.7 - 19.2 Nm {1.6 - 2.0 kgm}
TRANSMISSION SPEED SENSOR" in
2) Install each transmission control valve to
valve seat (302).
3
3
Main relief valve assembly mount-
Mounting bolt
ing bolt
: 8 - 10 Nm {0.8 - 1.0 kgm}
: 44.1 - 53.9 Nm {4.5 - 5.5 kgm}
3
3) Install transmission control valve assembly
Valve flow assembly mounting bolt
(21) together with the valve seat in the rear
: 29.4 - 39.2 Nm {3 - 4 kgm}
transmission case after installing O-rings to
2 Torque converter intermediate the case.
pressure oil pressure sensor
4) Install tubes (18), (19) and (20).
thread: Gasket sealant (LG-5)
3 Torque converter intermediate
pressure oil pressure sensor
: 9.8 - 19.6 Nm {0.15 - 0.20 kgm}
2 Torque converter output oil temper-
ature sensor thread
3 Torque converter output oil temper-
ature sensor
: 29.4 - 49 Nm {3 - 5 kgm}
HM300-1 30-97
2
(9)
28. Strainer (left and right) 30. Wiring harness, each sensor and piping
Install block (17) and then strainer (16) and
1) Install tubes (8), (9) and (10).
cover (15).
2) Tighten the mounting bolts of block (12)
which were temporarily tightened in the step
29.
3) Install output shaft R rotation sensor (7),
output shaft F rotation sensor (6) and inter-
mediate shaft rotation sensor (5).
a When installing them, refer to the sec-
tion of "ADJUSTING TRANSMISSION
SPEED SENSOR" in INSPECTION
AND ADJUSTMENT.
4) Install hose (4) and wiring harness assem-
bly (3).
29. Relief valve assembly
1) Install in the order of piping (14) and relief
valve assembly (13).
2) Install block (12).

a Tighten the mounting bolt temporarily.
(Refer to the step 30 when tightening for
the last time.)
3) Install torque converter oil temperature sen-
sor (11).
2 sensor thread
3 Torque converter oil temperature
sensor: 29.4 - 49 Nm {3 - 5 kgm}
30-98 HM300-1
2(10)
31. Trunnion
1) Install bushing (301) to trunnion (1) in the
following steps.
i) Remove smudges and oil inside the
trunnion with detergent.
ii) Ingrain primer for hard-to-stick applica-
tion adhesive compound of Loctite
Prism in cloth and clean the mating sur-
face on the bushing side.
iii) Coat the trunnion mating surfaces with
411 instant adhesive compound of Loc-
tite Prism (or equivalent). Approx. 3g a
bushing is a benchmark for the adhesive
compound to coat.
iv) Press-fit the bushing into the trunnion.
★ Press-fit within 5 minutes after coat-
ing the hard-to-stick application
adhesive compound of Loctite
Prism.
★ Do not mix the primer with the adhe-
sive compound.
2) Install trunnions (1) and (2).
HM300-1 30-99
2

D3 Push Tool
D4 Push Tool
30-100 HM300-1
2
D5 Push Tool
D7 Push Tool
HM300-1 30-101
2
D8 Push Tool
30-102 HM300-1
2
DISASSEMBLY AND 4. Coupling

Remove holder (4) and coupling (5).
ASSEMBLY OF
FRONT DIFFERENTIAL
ASSEMBLY
SPECIAL TOOL
Dis-
sity tion*
tch
1 792T-227-1110 Push Tool ■ 1 N c

792T-423-1130 Push Tool ■ 1 c
H 2 • 790-101-5421 • Grip ■ 1
• 01010-51240 • Bolt ■ 1
3 790-201-2840 Spacer ■ 1
5. Removal of bevel pinion and cage assembly
*Distinction of new part and improved part Remove bevel opinion and cage assembly (6),
using forcing screws [1].
DISASSEMBLY ★ Shims are provided, so check their thick-
1. Drive shaft cover ness, number in use and installed locations
Remove drive shaft covers (1) at left and right. beforehand.
2. Upper cover
Remove upper cover (2).
6. Further disassembly of bevel pinion and

cage assembly
3. Bevel gear fall-proof bolt 1) Remove bevel pinion assembly (8) from
Remove bevel gear fall-proof bolt (3). cage assembly (7), using push tool [2].
HM300-1 30-103
2
2) Remove spacer (10) and bearing (11) from 8. Side carrier and shaft assembly and differ-
bevel pinion (9). ential gear assembly
1) Sling differential gear assembly (22), and
remove side carrier assemblies (23) and
(24), using forcing screws [3].
thickness, number in use and installed
locations beforehand.
2) Remove differential gear assembly (22)
from differential housing (25).
3) Remove oil seals (13) and (14) from cage

(12).
4) Remove bearing (15) and outer races (16)
and (17).
9. Further disassembly of side carrier and

shaft assembly
1) Remove shaft and bearing assembly (27)
from side carrier assembly (26), using push
tool [4].
7. Left and right output shaft couplings

Remove holder (18) and then remove output
shaft couplings (19).
★ Shims (56) are provided, so check their
thickness, number in use and installed loca-
tions beforehand.
30-104 HM300-1
2
2) Remove bearing (29) from shaft (28). 2) Remove bearing (38) from case (37).
3) Remove oil seal (31) from carrier (30). 3) Remove washer (39).
4) Remove bearing (32) and outer races (33),
(34) and (35).
4) Remove 3 plates (40) and 3 discs (41).
10. Further disassembly of differential gear

assembly
1) Remove case and bearing assembly (36).
HM300-1 30-105
2
5) Remove pressure ring (42). 8) Remove 4 pinion gears (46) and 4 bushings
★ Put fingers into a hole on the case side (47) from shaft (45).
and lift.
9) Remove differential side gear (48).

10) Remove pressure ring (49).

7) Remove pinion gear assembly (44) in one
piece.
30-106 HM300-1
2
11) Remove discs (50) and plates (51), 3 for 2) Install bevel gear (53) to case (54).
each. ★ Install according to the counter marks
which were left at the time of removing.
12) Remove washer (52).
2 Mounting bolt
3 Mounting bolt
: 157 - 196 Nm {16 - 20kgm}
13) Reverse the case and bevel gear assembly.

14) Remove bevel gear (53) from case (54).
★ Leave a counter mark both on the bevel
gear and on the case before removing.
3) Reverse the bevel gear and case assembly.
15) Remove bearing (55).
4) Put washers (52) in the case, and assemble
plates (51) and discs (50) 3 for each.
★ Immerse the discs and plates in the fol-
lowing oil before assembling.
2 Disc and plate
: DONAX TD of Showa Shell
ASSEMBLY
★ Clean each of the parts thoroughly and check
that it is free of dust or damage. Coat the sliding
surface with axle oil and then assemble.
1. Subassembly of differential gear assembly
1) Shrink-fit bearing (55) to case (54).
• Shrink- fit temperature: For 30 minutes
at approx. 120fC.
★ Drip axle oil (SHELL DONAX TD) on the
bearing after installing.
HM300-1 30-107
2
5) Install pressure ring (49) to the case. 7) Install bushings (47) and pinion gears (46) 4
pieces for each to shaft (45).
6) Install differential side gear (48).

8) Install pinion gear assembly (44) in one
piece.
★ Match a cutout portion on disc (50) (at 4

points) with a groove on differential side
gear (48) (at 4 points).
30-108 HM300-1
2
10) Install pressure ring (42).
13) Install washer (39).

11) Assemble discs (41) and plates (40) 3 for
each.
lowing oil before assembling.
2 Disc and plate

• Bearing shrink fit temperature
: For 30 minutes at 120fC
12) Adjust the clearance between case (37) and

plate (40).
i) Measure dimension "a" from case (54)
to plate (40).
ii) Measure thickness "b" of case (37).
iii) Calculate value "d" of dimension "a"
minus dimension "b".
(Dimension of clearance between case
(37) and plate (40))
iv) Select suitable ones out of plates (40)
and install them so that clearance "d" is
0.2 - 0.75 mm.
★ The total thickness of 3 plates on either
side must be identical.
• Kind of plate (40) thickness
: 3.0 mm and 3.1 mm
HM300-1 30-109
2
15) Install case and bearing assembly (36).

3 Mounting bolt
: 98 - 123 Nm {10.0 - 12.5 kgm}
2) Press-fit bearing (29) into shaft (28), using

tool H1.
16) Adjust the clearance between washers (39)

and (52) and cases (37) and (54) in the fol-
lowing manner.
i) Measure dimension "e" from the left and
right shaft holes on the differential gear
assembly to the case and washer.
ii) Select suitable ones out of washers (39)
and (52) and install them so that clear-
ance "e" is 0.15 to 0.35 mm on either
side.
• Kind of washer thickness
: 4.0 mm and 4.1 mm
3) Put side carrier assembly (28) on shaft and
bearing assembly (27).
4) Assemble bearing (32) in.
5) Install output shaft coupling (19) and holder
(18), and then press-fit bearing (32), using
push tool [5].
2. Subassembly of side carrier and shaft

assembly
1) Install outer races (35), (34) and (33) to car-
rier (30).
30-110 HM300-1
2
3. Adjustment of pre-load on shaft bearing

1) Drip axle oil (SHELL DONAX TD) on the
bearing and rotate it.
2) Measure dimension "b" between the end
surface of shaft (28) and the end surface of
output shaft coupling.
3) Select shims which attain the dimension of
b + (0 to 0.05 mm).
4) Assemble the selected shims (56) in and
then install output shaft coupling (19) and
holder (18).
3 Mounting bolt
: 490 - 608 Nm {50 - 62 kgm}
5) Hook a push-pull scale on to the bolthole
(208 mm in dia.) on side carrier assembly
(28), and measure start torque.
• Standard value for start torque
: Min. 14.7 N {1.5 kg)
★ If the start torque exceeds the above
standard value, increase or decrease
the number of shims for adjustment and
measure again.
6) Remove holder (18) and output shaft cou-
4. Differential gear assembly and side carrier
pling (19).
and shaft assembly
1) Sling differential gear assembly (22) and
keep the gear on the mounting position of
differential case (25).
2) Assemble shims (57) whose thickness,
number in use and location were confirmed
at the time of disassembling, and then install
side carrier and shaft assemblies (23) and
(24).
: 0.05 mm, 0.2 mm, 0.3 mm and 0.8 mm
3 Mounting bolt
7) Press-fit oil seal (31) into carrier (30), using : 157 - 196 Nm {16 - 20 kgm}
tool H2.
★ Keep press-fitting until distance "a"
between the oil seal periphery surface
and carrier end surface becomes 4.6 ±
0.2 mm.
2 Oil seal periphery surface
: Seal End 242 or equivalent
2 Oil seal lip face and oil seal inside
(to be filled completely)
: Grease (G2-LI)
HM300-1 30-111
2
(9)
5. Adjustment of pre-load on side bearing 7. Subassembly of bevel pinion and cage

★ Drip axle oil (SHELL DONAX TD) on the assembly
bearing thoroughly. 1) Install outer races (17) and (16) to cage
1) Measure start torque of bevel gear (53) at (12).
the addendums (in the tangential direction),
using push scale [5].
: 7.2 - 32.4 N {0.74 - 3.3 kg}
2) If the start torque exceeds the standard
value, decrease thickness of the shims and
measure again.
★ Do not change the total thickness of left
and right shims, even if swapping them
between the left and right for adjusting
tooth contact or backlash.
★ After adjusting the pre-load, be sure to
tighten the mounting bolts to the torque
2) Press-fit bearing (11) into bevel pinion (9),
specified in the step 2).
using tool H3.
bearing after assembling.
3) Install spacer (10).
6. Left and right output shaft couplings

1) Assemble shims (56) selected in the step 3,
and install output shaft coupling (19) and
holder (18).
2 Mounting bolt
3 Mounting bolt
: 490 - 608 Nm {50 - 62 kgm}
30-112 HM300-1
2
4) Put cage assembly (7) and bearing (11) on 6) Press-fit oil seal (13), using tool [8].
bevel pinion assembly (8), and press-fit ★ Keep press-fitting until the oil seal
bearing (11) into the cage assembly, while periphery surface is flush with the cage
turning the cage assembly, using coupling (12) end surface.
(5), holder (4) and push tool [6]. 2 Oil seal periphery surface
★ Drip axle oil (SHELL DONAX TD) on the : Seal End 242 or equivalent
2
bearing (11).
★ Remove holder (4) and coupling (5) Oil seal lip face and between lips
after press- fitting. : Grease (G2-LI)
5) Press-fit oil seal (14), using tool [7]. 8. Installation of bevel pinion and cage assem-
★ Keep press-fitting until distance "d" bly
between periphery surface of the oil seal Assemble the shims whose thickness, number
and end surface of cage (12) is 26 ± 0.5 in use and location were confirmed at the time
mm. disassembling, and then install bevel pinion
2
cage assembly (6).
Oil seal periphery surface ★ Tighten with 3 mounting bolts.
: Seal End 242 or equivalent ★ Tighten all the mounting bolts after adjusting
2 Oil seal lip face and between lips tooth contact.
3
: Grease (G2-LI) Mounting bolt
: 157 - 196 Nm {16 - 18 kgm}
9. Input shaft coupling and holder
1) Install coupling (5) and holder (4).
2 Mounting bolt
3 Mounting bolt
: 490 - 608 Nm {50 - 62 kgm}
HM300-1 30-113
2
(9)
10. Adjustment of tooth contact and backlash iv) If the backlash is found to fall out of the
• Adjust backlash and adjust tooth contact at standard value as a result of the mea-
the same time. surement, make adjustment in the fol-
lowing manner.
1) Adjustment of backlash
• When there is a small backlash:
i) To shift the bevel gear for the adjust-
Decrease the shims on the right side of
ment, change shims (57) between differ-
ential case (25) and side carrier chassis and add as many shims to the
assembly (23) or (24). In that case, do left side (i.e. shifting the bevel gear in
not change the total thickness of left and direction A).
right shims (57) in order not to change
the pre-load given to the bearing.
• When there is a big backlash:

Decrease the shims on the left side of
ii) Apply the probe of dial gauge [9] per- chassis and add as many shims to the
pendicularly to the tip of bevel gear. right side (i.e. shifting the bevel gear in
iii) Read out the dial when moving the direction B).
bevel gear back and forth (in the direc-
tion of rotation), while fixing the bevel
pinion.
• Standard value for backlash
In the circumferential direction of the
gear : 0.36 - 0.55 mm
In the perpendicular direction to the gear
: 0.25 - 0.38 mm
★ Make this adjustment at 3 points and
keep the fluctuation of backlash less
than 0.1 mm.
(The bevel gear in the photo below slightly
differs from the one for HM300-1)
30-114 HM300-1
2
2) Adjustment of tooth contact

To shift the bevel pinion for the adjustment,
increase or decrease shims (58) between
differential case (25) and cage (12).
: 0.15 mm, 0.2 mm, 0.3 mm and 1.0 mm
Adjusting
• If no right pattern of tooth contact is
obtained as a result of inspection, make
readjustment in the following manner.
★ When adjusting shims for the side car-
rier assemblies, do not change the total
Inspection thickness of left and right shims in order
not to change the pre-load given to the
i) Coat the bevel gear tooth surface thinly bearing.
with minium or red lead, then rotate the i) When the bevel pinion is too far away
bevel gear back and forth to check the from the bevel gear centerline, a tooth
tooth contact pattern on the bevel gear. contact pattern shows the contact of the
ii) The center of tooth contact must come small end tooth face of the bevel gear
in the middle of tooth height. Moreover, tooth face curved outward with the big
it must be approx. 33% away from the end tooth face of the bevel gear tooth
small end along the tooth length (x), and face curved inward.
the contact width must cover 45% to • Make adjustment in the following man-
55% of the tooth length (y). Meanwhile, ner.
make sure that there is no excessively Shift the bevel pinion in direction A by
strong tooth contact at any point of adjusting the shims on the bevel pinion
addendum A, dedendum B, small end C
side.
and big end D.
In addition, shift the bevel gear in direc-
★ If the adjustment is made this way,
right tooth contact is ensured, when tion B and check the tooth contact pat-
load is applied. tern and backlash again.
HM300-1 30-115
2
(9)
ii) When the bevel pinion is too close to the

bevel gear centerline, a tooth contact
pattern shows the contact of the big end
tooth face of the bevel gear tooth face
curved outward with the small end tooth
face of the bevel gear tooth face curved
inward.
• Make adjustment in the following man-
ner.
Shift the bevel pinion in direction A by
adjusting the shims on the bevel pinion
side.
tion B and check the tooth contact pat- 12. Upper cover
tern and backlash again. Install upper cover (2).
★ Pick out bolt A out of the 15 mounting bolts
and coat it with gasket sealant and install.
2 Cover mating surface
: Gasket sealant (Loctite LT-515
or equivalent)
2 Bolt A
: Gasket sealant (LG-5 or equivalent)
3 Mounting bolt
: 157 - 196 Nm {16 - 20 kgm}
13. Drive shaft cover
Install left and right drive shaft covers (1).
3) After adjusting tooth contact, tighten the
mounting bolts for the bevel pinion cage and
side carriers to the specified torque.
3 Bevel pinion cage mounting bolt
: 157 - 196 Nm {16 - 20 kgm}
3 Side carrier mounting bolt
: 157 - 196 Nm {16 - 20 kgm}
11. Bevel gear fall-proof bolt
Install bevel gear fall-proof bolt (3).
★ Screw the bolt in until it contacts the bevel
gear backside, then loosen by a 1/2 turn
and fasten with a lock nut.
2 Mounting bolt
3 Mounting bolt
: 196 - 245 Nm {20 - 25 kgm}
30-116 HM300-1
(9)
2

H1 Push Tool
H2 Push Tool
HM300-1 30-117
2
DISASSEMBLY AND ASSEMBLY CENTER DIFFERENTIAL ASSEMBLY
REMOVAL AND 2) Sling carrier assembly (1) to remove.
4 Carrier assembly: 40kg (one side)

INSTALLATION OF
CENTER DIFFERENTIAL
ASSEMBLY
SPECIAL TOOL
Disti
Mark Part No. Part Name Neces Q'ty nctio Ske-
sity tch
n*
790-101-5401 Push Tool Kit ■ 1
• 790-101-5441 • Plate ■ 1
4
H • 790-101-5421 • Grip ■ 1
• 01010-51240 • Bolt ■ 1
5 790-201-2770 Spacer ■ 1
3) Sling sun gear and drive shaft assembly (3)
REMOVAL to remove.
k Turn the parking brake switch on and put 4 Sun gear and drive shaft assembly
wooden blocks behind the wheels. : 25kg (one side)
k Raise the body assembly fully and insert a
safety pin.
1. Drain oil from the center differential case and

center final drive case.
6 Center differential case: 25l
6 Center final drive case: 4l (one side)
2. Remove the left and right drive shafts in the fol-
lowing steps.
1) Remove the mounting bolts of carrier
assembly (1), and pull out of the final drive
assembly, using forcing screws [1] and
3. Remove drive shaft guard (4).
guide bolts [2].
4. Sling drive shaft (5) between the hitch frame
and center differential temporarily, and discon-
nect it at the center differential side.
30-118 HM300-1
2
(9)
5. Sling drive shaft (6) between the center differen- 8. Remove coupling (13).
tial and rear differential and disconnect it at the
center differential side.
6. Remove the mounting bolts of coupling (7) on
the transfer output side and remove the cou-
pling.
9. Disconnect 2 brake cooling hoses (10).

10. Disconnect 2 brake cooling tubes (11).
★ Remove the U clamp and tube mounting
bolts from the left and right brakes.
7. Remove the mounting bolts of bearing cage

assembly (9) and remove the bearing cage
assembly together with transfer output shaft (8)
for, using forcing screw [3].
★ Do not remove 2 mounting bolts (b), but
remove only 6 mounting bolts (a).
11. Sling center differential assembly (12) and

remove the mounting bolts; separate the center
differential assembly from the axle case, using
forcing screw [2], and remove.
4 Center differential assembly: 300kg
HM300-1 30-119
2
(9)
INSTALLATION
★ When installing the drive shaft between
hitch frame and center differential, let it face
removal.
in the same direction as that of the yoke of
drive shaft between the transmission and
★ Install the carrier assembly in the following hitch frame.
steps. ★ When installing, the yoke of drive shaft
1) Insert the carrier assembly into the cen- between the hitch frame and center differen-
ter axle assembly up to the intermediate tial and the yoke of drive shaft between cen-
point of sun gear and drive shaft assem- ter differential and rear differential must be
bly (3). shifted from each other by 45f ± 6f.
2) Assemble the sun gear portion of sun ★ When installing the drive shafts, check that
gear and drive shaft assembly (3) in the keyway of spider cap completely
lifted carrier assembly (2). engages with that of counter yoke, and then
3) In that condition, match the carrier tighten the mounting bolts.
2
assembly with guide bolt [3], then match
the ring gear of the final drive assembly Mounting bolt
with the planetary gear of the carrier : Liquid adhesive compound (LT-2)
assembly, and push them in. 3 Mounting bolts for drive shaft between
3 Carrier assembly mounting bolt transmission and hitch frame and
: 157 - 196 Nm {16 - 20 kgm} drive shaft between center differential
[Target value: 177 Nm {18 kgm}] and rear differential
: 98 - 123 Nm {10 - 12.5 kgm}
★ Install as shifted from the coupling on the

input side of center differential by 45f ± 6f.
2 Mating faces between coupling and
bearing
: Lubricant containing molybdenum
disulfide (LM-P)
2 Coupling mounting bolt
: 455 - 565 Nm {46.5 - 57.5 kgm}
30-120 HM300-1
2
(9)
2 Transfer output shaft spline portion

: Extreme-pressure grease containing
molybdenum disulfide
3 Bearing cage assembly mounting bolt
: 98 - 123 Nm {10 - 12.5 kgm}
★ When disassembling the bearing cage
assembly, press-fit oil seal (13) and side
seal (14) into cage (15) in the following
manner.
i) Press-fit oil seal (13) into cage (15),
using tool H4.
★ Keep press-fitting until the oil seal
3 Center differential mounting bolt

periphery surface is flush with the cage
end surface.
2 Oil seal periphery : 157 - 196 Nm {16 - 20 kgm}
: Seal end 242 or equivalent [Target value: 177 Nm {18 kgm}]
2 Oil seal lip face: Grease (G2-LI) • Refilling with oil (center differential case and
center final drive case)
Refill with oil through the oil filler ports of the
center differential case and left and right final
drive cases up to the specified level.
5 Center differential case
:25l (SHELL DONAX TD)
5 Center final drive case
:4l (one side) (SHELL DONAX TD)
ii) Press-fit side seal (14) into cage (15),

using tool H5.
★ Keep press-fitting until the side seal
periphery surface is flush with the cage
end face.
2 Side seal periphery
: Seal end 242
2 Side seal lip face: Grease (G2-LI)
HM300-1 30-121
2
(9)
DISASSEMBLY AND 3. Cover

Remove cover (3).
ASSEMBLY OF
CENTER DIFFERENTIAL
ASSEMBLY
SPECIAL TOOL
Dis-
Mar Neces- tinc- Ske
Part No. Part Name Q'ty
k sity tion -tch
*
792T-423-1130 Push Tool ■ 1 c
2 • 790-101-5421 • Grip ■ 1
• 01010-51240 • Bolt ■ 1
790-501-5000 Unit Repair Stand ■ 1

(AC100V) 4. Input shaft cage
Unit Repair Stand
6 790-501-5200 (AC110V, AC220V) ■ 1 1) Remove input shaft cage assembly (4),
790-901-2110 Bracket ■ 1 using forcing screws [1].
H
792T-222-1210 Plate ■ 1 N c ★ Shims are provided, so check their
7 792-103-0901 Wrench ■ 1 thickness, number in use and installed
8 792T-223-1120 Push Tool ■ 1 N c locations beforehand.
792T-423-1140 Push Tool ■ 1 c
9 • 790-101-5421 • Grip ■ 1
• 01010-51240 • Bolt ■ 1
10 792T-223-1110 • Grip ■ 1 N c
DISASSEMBLY
1. Setting center differential assembly to tool
Set the center differential assembly to tool H6.
2) Remove side seal (6) and oil seal (7) from

cage (5).
3) Remove outer race (64).
2. Transfer input coupling and holder

Remove holder (1) and then remove coupling
(2).
30-122 HM300-1
2
5. Transfer input shaft and gear assembly

1) Remove transfer input shaft and gear
assembly (8).
7. Transfer case
1) Sling transfer case assembly (17) to
remove, using forcing screws [2].
2) Remove bearings (10) and (11), 2 spacers
(12) and gear (13) from transfer input shaft
(9).
2) Remove bearing (19) and outer races (20)

and (21) from transfer case (18).
6. Input shaft holder

★ Before removing the holder, put wooden
blocks or the like under the bevel pinion so
as not to let it fall.
1) Remove holder (14).
2) Remove holder (15) and key (16).
HM300-1 30-123
2
(9)
8. Spacer and input gear 10. Bevel pinion and bearing assembly
1) Remove spacer (22). 1) Remove bevel pinion and bearing assembly
2) Remover spacer cover (23) and then (28).
remove input gear (24).
2) Remove bearing (30) from bevel pinion (29).

9. Cage assembly
1) Remove cage assembly (25), using forcing
screws [3].
2) Remove outer race (27) from cage (26).
30-124 HM300-1
2
11. Removal of differential gear assembly 2) Remove bearing (41) from case (40).
1) Reverse tool H6.
2) Remove locks (32) and (33) together with
cover (31).
3) Loosen adjusting nuts (34) and (35) using
tool H7 until they can be loosened manually.
4) Sling the differential gear assembly and
remove bearing caps (36) and (37) as well
as adjusting nuts (34) and (35).
5) Sling differential gear assembly (38) to
remove.
★ Be careful then not to let fall the bearing
outer race. 3) Remove washer (42).
12. Further disassembly of differential gear 4) Remove 3 plates (43) and 3 discs (44).
assembly
1) Remove case and bearing assembly (39).
HM300-1 30-125
2
(9)
5) Remove pressure ring (45). 8) Remove pinion gears (49) and bushings
★ Lift the ring with a finger inserted into the (50) 4 for each from shaft (48).
case side hole.


7) Remove pinion gear assembly (47) in one
piece.
30-126 HM300-1
2
11) Remove discs (53) and plates (54) 3 for 2) Install bevel gear (56) to case (57).
each. ★ Install the gear, matching the counter
marks which were put when removing.
2 Mounting bolt
3 Mounting bolt
: 157 - 196 Nm {16 - 20 kgm}
13) Reverse the bevel gear assembly.

★ Before removing, put a counter mark
both on the bevel gear and on the case.
4) Put washers (55) in the case and assemble
in plates (54) and discs (53) 3 for each.
lowing oil before installing.
2 Disc and plate
ASSEMBLY
★ Clean each of the parts and check that it is free
of dust or damage, then coat the sliding surface
with axle oil and assemble.

★ After press- fitting, drip axle oil (SHELL
DONAX TD) on the bearing.
HM300-1 30-127
2
(9)
5) Install pressure ring (52) to the case. 7) Install bushings (50) and pinion gears (49) 4
for each to shaft (48).

piece.
★ Match the cutout portion on disc (53) (at

4 points) with grooves on differential
side gear (51) (at 4 points).
30-128 HM300-1
2

each.
2 Disc and plate

• Bearing shrink- fit temperature
12) Adjust the clearance between case (40) and

plate (43).
to plate (43).
ii) Measure thickness "b" of case (40).
iii) Calculate difference "d" between dimen-
sions "a" and "b".
(This is the clearance dimension
between case (40) and plate (43))
iv) Select appropriate ones out of plates
(43) and install them so that the clear-
ance dimension "d" is 0.2 to 0.75 mm.
★ Make sure that the total thickness of 3
plates is identical on the left and right
sides.
: 3.0 mm and 3.1 mm
HM300-1 30-129
2

3 Mounting bolt
: 98 - 123 Nm {10.0 - 12.5 kgm}
3) Install bearing caps (37) and (36) and

tighten the mounting bolts.
2 Mounting bolt
16) Adjust clearance between washer (42) and : Liquid adhesive compound (LT-2)
3
case (40) and clearance between washer
Mounting bolt
(55) and case (57) in the following manner.
: 824 - 1,030 Nm {84 - 105kgm}
i) Measure clearance "e" between the
case and washer through the left and
right shaft holes of differential gear
assembly.
ii) Select appropriate ones out of washers
(42) and (55) and install them so that the
clearance "e" is 0.15 to 0.35 mm both on
the left and right sides.
: 4.0 mm and 4.1 mm
2. Installation of differential gear assembly

1) Sling differential gear assembly (38) and
keep it above the installing position of differ-
ential case (60).
★ Keep the differential gear assembly in
loose contact with the differential case.
2) Install an outer race to the bearing, and
tighten adjusting nuts (34) and (35) to the
differential case temporarily.
30-130 HM300-1
2
3. Adjustment of bearing pre-load 4. Subassembly of transfer input shaft

1) Tighten adjusting nuts (34) and (35), using 1) Install gear (13) and 2 spacers (12) to trans-
tool H7. fer input shaft (9).
2
Spline portion of inserted gear
bearing thoroughly.
★ Rap the bevel gear with a copper ham-
mer, while rotating the bearing, so that
the bearing sits well with other parts in 2) Press-fit bearing (11), using tool H8.
contact. ★ Press-fit bearing (10) in the same man-
ner, too.
2) Measure start torque in the tangential direc-

tion at the peripheral addendums of bevel 5. Subassembly of transfer input shaft cage
gear (56), using push-pull scale [4]. 1) Install outer race (64) to cage (5).
• Standard value for start torque 2) Press-fit oil seal (7), using tool H9.
: 7.1 - 19.6 N (0.73 - 2.0 kg) ★ Keep press-fitting until distance "f "
★ If the start torque is lower than the stan- between the oil seal periphery surface
dard value, tighten the adjusting nuts, and end surface of cage (12) is 10 ± 0.5
and if it is higher, loosen the nuts. mm.
2
★ When the adjusting nut is loosened on
one side, tighten the nut on the other as Oil seal periphery surface
much. : Seal End 242 or equivalent
2 Oil seal lip face and inside of oil
seal (to be filled completely)
: Grease (G2-LI)
HM300-1 30-131
2
3) Press-fit side seal (6), using tool H2. 2) Measure the endplay with dial gauge [5]
★ Keep press-fitting until the side seal while lifting and lowering input shaft and
periphery surface is flush with cage (12) gear assembly (8) with a crane.
end surface.
3) Adjust thickness of shims (61) so that the
2 Side seal periphery surface endplay may reach the standard value.
: Seal End 242 or equivalent • Standard value for endplay: 0 - 0.05 mm
2 Side seal lip face and inside of side • Shim adjustment allowance
seal (to be filled completely) : 0.8 - 1.7 mm
: Grease (G2-LI) • Kind of shim thickness
: 0.15 mm, 0.18 mm, 0.2 mm,
0.3 mm and 0.8 mm
4) After adjusting the shim thickness, once
remove transfer input shaft and gear
assembly (8) and input shaft cage assembly
(4).
6. Transfer case
Install outer races (20) and (21) to transfer case
(18).
8. Bevel pinion and bearing assembly

1) Install bearing (30) to bevel pinion (29).
★ Shrink-fit bearing (30), or press-fit, using
push tool H10.
7. Adjustment of pre-load on transfer input

shaft
1) Support transfer case assembly (17) with
wooden blocks, then assemble transfer
input shaft and gear assembly (8), and
install input shaft cage assembly (4).
★ Assemble the standard shims (having
thickness checked at the time of disas-
sembling) and install the input shaft
cage assembly.
★ Keep tightening the mounting bolts,
while rotating the bearing, until the bear-
ing is steadied.
3 Mounting bolt
: 157 - 196 Nm {16 - 20 kgm}
30-132 HM300-1
2
(9)
Table 1
MD Shim Letter
Dimension of
Thickness Spacer Part No. Notched on Spacer Width
Range Spacer
1.07 - 1.16 56D-23-16900 A 24.765 ± 0.025
1.17 - 1.26 56D-23-16910 B 24.665 ± 0.025
1.27 - 1.36 56D-23-16920 C 24.565 ± 0.025
1.37 - 1.46 56D-23-16930 D 24.465 ± 0.025
1.47 - 1.56 56D-23-16940 E 24.365 ± 0.025
1.57 - 1.66 56D-23-16950 F 24.265 ± 0.025
1.67 - 1.76 56D-23-16960 G 24.165 ± 0.025
1.77 - 1.86 56D-23-16970 H 24.065 ± 0.025
1.87 - 1.96 56D-23-16980 I 23.965 ± 0.025
1.97 - 2.06 56D-23-16990 J 23.865 ± 0.025
2) Install bevel pinion and bearing assembly
(28).
10. Spacer and input gear

9. Cage assembly 1) Assemble in input gear (24).
1) Install outer race (27) to cage (26). 2) Install cover (23).
3 Mounting bolt
: 98 -123 Nm {10 - 12.5 kgm}
3) Assemble spacer (22) in.
★ When changing thickness of the shims
as a result of carrying out "Tooth contact
and backlash adjustment" in the subse-
quent section of 12, change the spac-
ers, too, in reference to Table 1 above.
2) Install cage assembly (25).

★ Assemble shims (62), whose thickness,
number in use and installed location
were confirmed at the time of disassem-
bling, in cage assembly (25), and install
the cage assembly.
★ Determine thickness and number in use
of shims after carrying out "Tooth con-
tact and backlash adjustment" in the
subsequent section of 12.
3 Mounting bolt
: 157 - 196 mm {16 - 20 kgm}
HM300-1 30-133
2
4) Sling transfer case assembly (17) to install. 4) Measure start torque of the input shaft at the
2
holder mounting bolt, using torque wrench
Case mating face
: Gasket sealant (LT-515 or equivalent) [6].
• Start torque: 4.1 - 9.0 N {0.42 - 0.92 kg}
3 Mounting bolt ★ If the measured start torque falls out of
: 98 - 123 Nm {10 - 12.5 kgm} the standard value, either increase or
decrease the shim thickness and mea-
sure again.
11. Bearing
12. Tooth contact and backlash adjustment
2) Press-fit bearing (19) using push tool [5]. • Adjust backlash and at the same time,
adjust tooth contact.
i) To shift the bevel gear, use adjusting
nuts (36) and (37). In that case, if loos-
ening the adjusting nut on one side,
tighten the adjusting nut on the other as
much, in order not to change the pre-
load given to the bearing.
3) Install holder (14) after being fitted with

holder (15) and key (16).
★ Assemble the shims whose thickness,
number in use and installed location
were confirmed at the time of disassem-
bling.
: 0.15 mm, 0.18 mm, 0.2 mm and 0.5 mm
• Shim adjustment allowance
: 0.36 - 1.74 mm
2 Mounting bolt
3 Mounting bolt
: 824 - 1,030 Nm {84 - 105 kgm}
30-134 HM300-1
2
ii) Apply the probe of dial gauge [7] per- • When there is big backlash:
pendicularly to the addendums of bevel Loosen the adjusting nut on the left side
gear. of chassis and tighten the adjusting nut
iii) Fix the bevel pinion and shift the bevel on the right side as much (shift the bevel
gear back and forth (in the direction of gear in direction B).
rotation), then read out the dial.
• Standard value for backlash:
gear: 0.36 - 0.55 mm
In the perpendicular direction to the
gear: 0.25 - 0.38 mm
★ Make this adjustment at 3 points. Keep
fluctuation of the backlash below 0.1
mm.

• To shift the bevel pinion, increase or
decrease the number of shims (62) between
differential case (60) and cage (26).
iv) If the measured value of backlash falls

out of the standard value as a result of
the measurement, make adjustment in
the following manner.
• When there is small backlash:
Loosen the adjusting nut on the right
side of chassis and tighten the adjusting
nut on the left side as much (shift the
bevel gear in direction A).
HM300-1 30-135
2
INSPECTION i) When the bevel pinion is too far away

i) Coat the tooth surface of bevel gear with from the bevel gear centerline, a tooth
minium or red lead thinly, and check a contact pattern shows the contact of the
tooth contact pattern on the bevel gear small end tooth face of the bevel gear
after moving the bevel gear back and tooth face curved outward with the big
forth. end tooth face of the bevel gear tooth
ii) The center of tooth contact must come face curved inward.
in the middle of tooth height. Moreover, • Make adjustment in the following man-
it must be approx. 33% away from the ner.
small end along the tooth length (x), and Shift the bevel pinion in direction A by
the contact width must cover 45% to adjusting the shims on the bevel pinion
55% of the tooth length (y). Meanwhile, side.
make sure that there is no excessively
strong tooth contact at any point of
tion B and check the tooth contact pat-
tern and backlash again.
and big end D.
right tooth contact is ensured, when
load is applied.

inward.
ner.
side.
ADJUSTMENT
obtained as a result of inspection, make
★ To shift the bevel gear, use the left and
right adjusting nuts. In that case, if loos-
ening the adjusting nut on one side,
tighten the adjusting nut on the other as
much, in order not to change the pre-
load given to the bearing.
30-136 HM300-1
2
3) After adjusting the tooth contact, tighten the 15. Cover

bevel pinion cage mounting bolts. Install cover (3).
3 Mounting bolt 2 Cover mating part
: 157 - 196 Nm {16 - 20kgm} : Gasket sealant (LT-515)
13. Lock and cover 3 Mounting bolt
Install locks (32) and (33) for the left and right : 98 - 123 Nm {10 - 12.5 kgm}
adjusting nuts and cover (31).
16. Transfer input coupling and holder
3 Mounting bolt Install an O-ring and coupling (2), then install
: 157 - 196 Nm {16 - 20 kgm} holder (1).
2 Mating part g of bearing and coupling
disulfide (LM-P)
2 Mounting bolt
3 Mounting bolt
: 490 - 608 Nm {50 - 62 kgm}
14. Transfer input shaft

1) Assemble transfer input shaft and gear
assembly (8).
2 Input shaft spline (both sides)
2) Assemble shims (61) selected in the forego-
ing step 7, then install an O-ring and install
input shaft cage assembly (4).
3 Mounting bolt
: 157 - 196 Nm {16 - 20 kgm}
HM300-1 30-137
2

★ Tighten the bolt until it touches the backside
of bevel gear, then loosen by a 1/2 turn and
fix with a lock nut.
2 Mounting bolt: Gasket sealant (LG-5)
3 Mounting bolt
: 196 - 245 Nm {20 - 25 kgm}
30-138 HM300-1
2

H2 Push Tool
H6 Plate
HM300-1 30-139
2
H8 Push Tool
H9 Push Tool
30-140 HM300-1
2
H10 Push Tool
HM300-1 30-141
2
DISASSEMBLY AND ASSEMBLY REAR DIFFERENTIAL ASSEMBLY
REMOVAL AND 2) Sling carrier assembly (1) to remove.
INSTALLATION OF
REAR DIFFERENTIAL 4 Carrier assembly: 40 kg (one side)
ASSEMBLY
REMOVAL
1. Remove the body assembly, referring to the

section of "REMOVAL AND INSTALLATION OF
BODY ASSEMBLY.
2. Drain oil from the rear differential case and rear
final drive case.
6 Rear differential case: 25l 3) Sling sun gear and drive shaft assembly (3)
6
to remove.
4 Sun gear and drive shaft assembly
Rear final drive case: 5l (one side)
3. Remove the left and right drive shafts in the fol-
: 25 kg (one side)
lowing manner.
1) Remove the mounting bolts of carrier
assembly (1), and pull it out of the final drive
assembly, using forcing screws [1] and
guide bolts [2].
4. Sling drive shaft (6) between the center differen-

tial and rear differential and disconnect at the
rear differential side.
30-142 HM300-1
(9)
5. Remove the rear differential assembly. 3) Push the carrier assembly in along
guide bolts [3], matching the ring gear of
1) Remove the mounting bolts of rear differen-
the final drive assembly with the plane-
tial assembly (7) and separate it from the
tary gear of the carrier assembly.
3 Carrier assembly mounting bolt
axle case, using forcing screw bolts [3].
: 157 - 196 Nm {16 - 20 kgm}

[Target value: 177 Nm {18 kgm}]
2) Sling rear differential assembly (7) to

remove, using eyebolts [5] and guide bolts
[4]. ★ Install after confirming that the yoke of drive
4 Rear differential assembly: 200 kg

shaft between the hitch frame and center
differential is shifted from the yoke of drive
shaft between center differential and rear
differential by 45f ± 6f.
★ When installing the drive shafts, tighten the
mounting bolts only after confirming that
keyway in the spider cap completely
engages with that of the counter yoke.
2 Mounting bolt
3 Mounting bolt for drive shaft between
center differential and rear differential
: 98 - 123 Nm {10 - 12.5 kgm}
INSTALLATION
removal.
★ Install the carrier assembly in the following

steps.
1) Insert the carrier assembly into the cen-
ter axle assembly up to the middle point
of sun gear and drive shaft assembly
(3).
2) Assemble the sun gear portion of sun
gear and drive shaft assembly (3) in
lifted carrier assembly (2).
HM300-1 30-143
2
(9)
DISASSEMBLY AND
3 Rear differential mounting bolt
: 157 - 196 Nm {16 - 20 kgm}
ASSEMBLY OF
[Target value: 177 Nm {18 kgm}] REAR DIFFERENTIAL
• Refilling with oil (rear differential case and ASSEMBLY
rear final drive case)
Refill with oil through the oil filler port of rear dif- SPECIAL TOOL
ferential case and through oil filler ports of the
Dis-
left and right rear final drives up to the specified Mark Part No. Part Name Neces- Q'ty tinc- Ske-
sity tch
level. tion*
5 790-501-5000 Unit Repair ■ 1

Center differential case Stand (AC100V)
: 25l (SHELL DONAX TD) Unit Repair
■
5
6 790-501-5200 Stand (AC110V 1
Center final drive case and AC220V)
H
: 5l (one side) (SHELL DONAX TD) 790-901-2110 Bracket ■ 1
792T-222-1210 Plate ■ 1 N c
7 792-103-0901 Wrench ■ 1
10 792T-223-1110 • Grip ■ 1 N c
DISASSEMBLY
1. Setting rear differential assembly to tool H6
Set the rear differential assembly to tool H6.
2. Input coupling and holder
Remove holder (1) and then remove coupling
(2).
30-144 HM300-1
2
3. Pinion and cage assembly 4) Further disassembly of pinion assembly

1) Remove pinion and cage assembly (3), Remove spacer (10) and bearing (11) from
using forcing screws [1]. pinion (9).
location beforehand.
5) Further disassembly of cage assembly

Remove bearing (13) and bearing outer
races (14) and (15) from cage (12).
2) Remove side seal (5) and oil seal (6) from ★ Bearing (13) has already been removed
the pinion and cage assembly. in the step 3).
3) Remove pinion assembly (7) from cage

assembly (8), using push tool [2].
HM300-1 30-145
2
4. Removal of differential gear assembly 5. Further disassembly of differential gear

assembly
1) Reverse tool H6.
2) Remove locks (16) and (17) together with 1) Remove case and bearing assembly (23).
the cover.
3) Loosen adjusting nuts (18) and (19), using
tool H7, until they can be turned manually.
4) Sling the differential gear assembly and
remove bearing caps (20) and (21) as well
as adjusting nuts (18) and (19).
2) Remove bearing (25) from case (24).
5) Sling differential gear assembly (22) to

remove.
★ Be careful not to let fall the bearing outer
race.
30-146 HM300-1
2
(9)
4) Remove 3 plates (27) and 3 discs (28). 7) Remove pinion gear assembly (31) in one
piece.

★ Put your fingers in the side hole and 8) Remove pinion gears (33) and bushings
raise the ring. (34) 4 for each from shaft (32).
6) Remove differential side gear (30). 9) Remove differential side gear (35).
HM300-1 30-147
2
10) Remove pressure ring (36). ASSEMBLY

★ Clean each of the parts and check that it is free
of any dust and damage. Coat the sliding sur-
faces with axle oil before assembling.
★ After installing, drip axle oil (SHELL
DONAX TD) on the bearing.
2) Install bevel gear (40) to case (41).
★ Install matching the counter marks
which were put at the time of disassem-
11) Remove discs (37) and plates (38) 3 for bling.
2
each.
Mounting bolt
12) Remove washer (39). : Liquid adhesive compound (LT-2)
3 Mounting bolt
: 157 - 196 Nm {16 - 20 kgm}

★ Before removing, put a counter mark
both on the bevel gear and on the case.
30-148 HM300-1
2
3) Reverse the case and bevel gear case ★ Match the cutout portions on disc (37)
assembly. (at 4 points) with the groove portions of
differential side gear (35) (at 4 points).
4) Put washer (39) in the case and assemble
plates (38) and discs (37) 3 for each.
2 Disc and plate
: SHELL DONAX TD
7) Install bushings (34) and pinion gears (33) 4

for each to shaft (32).
5) Install pressure ring (36) to the case.

piece.
HM300-1 30-149
2
(9)
9) Install differential gear (30). 12) Adjust the clearance between case (24) and
plate (27).
to plate (27).
ii) Measure thickness dimension "b" of
case (24).
iii) Calculate dimension "d" from dimension
"a" minus dimension "b".
(Clearance dimension between case
(24) and plate (27))
iv) Select appropriate ones from plates (27)
and install them so that the clearance
dimension "d" is 0.2 - 0.75 mm.
★ Make sure that the total thickness of 3
plates is identical both on the left and
right sides.
: 3.0 mm and 3.1 mm

each.
2 Disc and plate
: SHELL DONAX TD
30-150 HM300-1
2
(9)

2. Installation of differential gear assembly

1) Sling differential gear assembly (22) on the
installing position of differential case (43).
★ Do not fix it to the differential case yet.

3 Mounting bolt
: 98 - 123 Nm {10.0 - 12.5 kgm}
2) Install an outer race to the bearing and

tighten adjusting nut (19) to the differential
case temporarily.
★ Install an outer race and tighten the
adjusting nut in the same manner on the
16) Adjust the clearance between washer (26)
other side, too.
and case (24) and the clearance between
washer (39) and case (41) in the following
manner.
i) Measure clearance dimension "e"
between the case and the washer
through the left and right shaft holes on
the differential gear assembly.
ii) Select appropriate ones from washers
(26) and (39) and install them so that
clearance "e" is 0.15 - 0.35 mm both on
the left and right sides alike.
: 4.0 mm and 4.1 mm
HM300-1 30-151
2
3) Install bearing caps (21) and (20), and ★ If the measured start torque is lower
tighten the mounting bolts. than the standard value, tighten the
★ Install the caps in the same manner on adjusting nut. If it is higher than the stan-
the other side, too. dard value, loosen the adjusting nut.
2
★ When tightening the adjusting nut on
Mounting bolt
one side, loosen the adjusting nut on the
: Liquid adhesive compound (LT-2) other as much.
3 Mounting bolt
: 824 - 1,030 Nm {84 - 105 kgm}
4. Subassembly of bevel pinion and cage

assembly
3. Adjustment of bearing pre-load
1) Subassembly of cage assembly
1) Tighten adjusting nuts (19) and (18), using Install outer races (15) and (14) to cage
tool H7. (12).
★ Drip an ample amount of axle oil
(SHELL DONAX TD) on the bearing.
★ Rap the bevel gear with a copper ham-
mer, while rotating the bearing, so that
the bearing can have a good contact
with other parts.
2) Measure start torque in the tangential direc-

tion at the peripheral addendums of bevel
gear (40), using push-pull scale [3].
: 7.2 - 19.6 N (0.73 - 2.0 kg)
30-152 HM300-1
2
2) Subassembly of bevel pinion assembly 4) Mount cage assembly (8) on bevel pinion
Install bearing (11) to bevel pinion (9). assembly (7).
★ When installing the bearing, either
shrink-fit or press-fit it using push tool
H10. 6) Press-fit bearing (13), while turning case
assembly (8), using coupling (2), holder (1)
and push tool [4].
★ Drip axle oil (SHELL DONAX TD) on
bearing (13).
★ Remove holder (1) and coupling (2)
after press-fitting.
7) Press-fit oil seal (6), using tool [5].

★ Keep press-fitting until distance "f"
between the peripheral surface of oil
seal and the end surface of cage (12) is
10 ± 0.5 mm.
2 Oil seal peripheral surface
3) Install spacer (10) to bevel pinion (9).
: Grease (G2-LI)
HM300-1 30-153
2
8) Press-fit side seal (5), using tool [6]. 6. Input coupling and holder
★ Press-fit so that the peripheral surface Remove coupling (2) and holder (1) with the O-
of the side seal is flush with the end sur- ring.
face of cage (12).
2 Mounting bolt
2 Side seal peripheral surface
: Seal End 242 or equivalent : Liquid adhesive compound (LT-2)
2 Side seal lip face and inside of side 3 Mounting bolt
seal (to be filled completely): : 455 - 565 Nm {46.5 - 58 kgm}
Grease (G2-LI)
7. Adjustment of tooth contact and backlash

• Adjust the backlash and also the tooth con-
5. Installation of bevel pinion and cage tact at the same time.
assembly
Assemble shims (4) whose thickness, number i) When shifting the bevel gear, do so with
in use and installed location were confirmed at adjusting nuts (18) and (19). In that case,
the time of disassembling, then sling bevel pin- tighten the adjusting-nut on one side,
ion and cage assembly (3) to install. while loosening the adjusting-nut on the
• Kind of shim thickness other that much in order not to change
: 0.15 mm, 0.2 mm, 0.3 mm and 1.0 mm the preload given on the bearing.
3 Mounting bolt
: 157 - 196 Nm {16 - 20 kgm}
★ Determine the thickness and number of
shims to be used after carrying out the fol-
lowing "Adjustment of tooth contact and
backlash".
30-154 HM300-1
(9)
ii) Apply the probe of dial gauge [7] per- • When there are big backlash:
pendicularly to the addendums of bevel Loosen the adjusting nut on the left side
gear. of chassis and tighten the adjusting nut
iii) Read out the dial when moving the on the right side as much (i.e. shifting
bevel gear back and forth (in the direc- the bevel gear in direction B).
tion of rotation), while fixing the bevel
pinion.
• Standard value for backlash:
gear: 0.36 - 0.55 mm
In the perpendicular direction of the
gear: 0.25 - 0.38 mm
★ Make this adjustment at 3 points and
keep fluctuation of the measured back-
lash values less than 0.1 mm.

• Adjust the tooth contact of bevel pinion by
either increasing or decreasing the number
of shims (4) between differential case (41)
and cage (12).
iv) If the measured backlash is found to fall

out of the standard value as a result of
the measurement, make adjustment in
the following manner.
• When there is small backlash:
Loosen the adjusting nut on the right
side of chassis and tighten the adjusting
nut on the left side as much shift (i.e.
shifting the bevel gear in direction A).
HM300-1 30-155
2
INSPECTION • Make adjustment in the following man-

i) Coat the tooth surface of bevel gear with ner.
minium or red lead thinly, and check a Shift the bevel pinion in direction A by
tooth contact pattern on the bevel gear adjusting the shims on the bevel pinion
after moving the bevel gear back and side.
forth.
ii) The center of tooth contact must come
in the middle of tooth height. Moreover,
it must be approx. 33% away from the
small end along the tooth length (x), and
the contact width must cover 45% to
55% of the tooth length (y). Meanwhile,
make sure that there is no excessively
strong tooth contact at any point of
and big end D.
right tooth contact is ensured, when
load is applied.

inward.
ner.
side.
ADJUSTMENT
obtained as a result of the inspection, make
i) When the bevel pinion is too far away
from the bevel gear centerline, a tooth
contact pattern shows the contact of the
small end tooth face of the bevel gear
tooth face curved outward with the big
end tooth face of the bevel gear tooth
face curved inward.
30-156 HM300-1
2
3) After adjusting the tooth contact, tighten the

bevel pinion cage mounting bolts.
3 Tightening bolt
: 157 - 196 Nm {16 - 20kgm}
8. Lock and cover
Install adjusting nut locks (17) and (16) as well
as cover (44).
3 Mounting bolt
: 157 - 196 Nm {16 - 20 kgm}

★ Tighten the bolt until it touches the backside
of bevel gear, then loosen by a 1/2 turn and
fasten with the lock nut.
2 Mounting bolt: Gasket sealant (LG-5)
3 Mounting bolt
: 196 - 245 Nm {20 - 25 kgm}
HM300-1 30-157
2

H6 Plate
H10 Push Tool
30-158 HM300-1
2
REMOVAL AND INSTALLATION OF FRONT FINAL
DISASSEMBLY AND ASSEMBLY DRIVE AND BRAKE ASSEMBLY
REMOVAL AND 4) Sling front wheel (2) and remove the mount-
ing bolts.
4
INSTALLATION OF FRONT
Front wheel: 550 kg (one side)
FINAL DRIVE AND BRAKE
ASSEMBLY
REMOVAL
1. Drain oil from the front final drive case.

6 Front final drive case: 4.5l (one side)
2. Remove the front wheels.
1) Push up the underside of front axle on the
side of wheel to be removed, using hydrau- 3. Disconnect drive shaft (3) at the front differential
lic jacks [1]. side.
2) Support the front axle underside with a ped-
estal (frame) [2].
4. Remove cover (4).

5. Disconnect left and right brake actuating tubes
3) Sling left fender (1) to remove.
4 Left fender: 80 kg
(5).
6. Disconnect brake cooling tubes (6) and (7).
HM300-1 30-159
2
(9)
REMOVAL AND INSTALLATION OF FRONT FINAL
DISASSEMBLY AND ASSEMBLY DRIVE AND BRAKE ASSEMBLY
7. Disconnect wiring connectors (If equipped) (8). INSTALLATION

• Right final drive: B28
• Left final drive: B01
removal.
8. Remove brake wear sensor (If equipped) (9).
3 Front wheel mounting bolt

: 824 - 1,030 Nm {84 - 105 kgm}
★ When installing the drive shaft, check that

the keyway of spider cap completely
engages with that of the counter yoke, and
then tighten the mounting bolts.
2 Drive shaft mounting bolt
3
9. Sling final drive and brake assembly (10), and Drive shaft mounting bolt
remove the 14 mounting bolts and 8 mounting : 98 - 123 Nm {10 - 12.5 kgm}
nuts. [Target value: 113 Nm {11.5 kgm}]
4 Front final drive and brake assembly
(including drive shaft)
: 420 kg (one side) 2 Front final drive and brake assembly
mounting bolt

mounting bolt
: 490 - 680 Nm {50 - 62 kgm}
mounting nut
: 422 - 520 Nm {43 - 53 kgm}
30-160 HM300-1
2
DISASSEMBLY AND ASSEMBLY FRONT FINAL DRIVE AND BRAKE ASSEMBLY
• Refilling with oil (front final drive case)

DISASSEMBLY AND
Refill with oil through the oil filler port of front ASSEMBLY OF
final drive up to the specified level. FRONT FINAL DRIVE AND
5 Front final drive case BRAKE ASSEMBLY
: 4.5l (one side) (SHELL DONAX TD)
• Air bleeding (brake)

SPECIAL TOOL
After installing, bleed air from the brake circuit, Neces Distin Ske-
referring to the section of "BLEEDING AIR 792T-227-1120 Fixture ■ 3 N c
FROM BRAKE CIRCUIT". in INSPECTION 792T-223-1140 Plate ■ 3 N c
AND ADJUSTMENT. 01010-61240 Bolt ■ 3
1 01643-31232 Washer ■ 3
01580-01210 Nut ■ 3
01010-61245 Bolt ■ 3
01010-62440 Bolt ■ 3
2 792T-222-1220 Push Tool ■ 1 N c
J 792T-227-1130 Push Tool ■ 1 N c
3 790-101-5221 Grip ■ 1
01010-81225 Bolt ■ 1
4 791-580-1520 Installer ■ 1
5 791-580-1510 Installer ■ 1
793T-622-1110 Push Tool ■ 1 c
6 790-101-5421 Grip ■ 1
01010-81240 Bolt ■ 1
7 797T-622-1240 Push Tool ■ 1 c
DISASSEMBLY
1. Drive shaft
Remove drive shaft (1).
★ Take care so that the drive shaft cap (yoke)
will not slip off.
HM300-1 30-161
2
(9)
2. Removal of carrier assembly

1) Separate carrier assembly (2), using forcing
screws [1].
4. Sun gear and shaft

2) Remove sun gear (8) and collar (9).
2) Sling carrier assembly (2) to remove. ★ When removing the snap ring, be careful not
to expand it too widely. Moreover, if the snap
ring inner diameter is found to exceed 46.5
mm, or if there is a height difference of more
than 0.3 mm when it is put on a flat surface,
do not use it but replace with new one.
3. Further disassembly of carrier assembly

1) Drive spring pin (3) into shaft (4), using
round bar [2].
2) Drive out shaft (4) and remove bearing (5)
and gear (6).
3) Pull spring pin (3) out of shaft (4). 3) Remove shaft (10).
★ Drain oil remaining in the case.
30-162 HM300-1
2
(9)
5. Plate
1) Remove plate (11), using forcing screws [3].
9. Floating seal retainer and floating seal

1) Remove the assembly of floating seal
6. Retainer and shim retainer (19) and floating seal (20), using
1) Fix tools J1 at three points between the forcing screws [4].
outer gear and wheel hub (inner gear).
★ Be sure to fix tools J1 before removing
retainer (12) in order not to give damage
to the floating seal.
★ Fix tools J1 at an equal interval.
2) Remove retainer (12) and shims (13).
★ Check their thickness, number in use
and installed location beforehand.
7. Removal of ring gear
Remove ring gear (14).
10. Removal of brake assembly

1) Remove brake assembly (22) from shaft
(tube) (21).
★ Before removing, put a counter mark on
the assembly and shaft.
2) Remove tools J1 from the brake assembly.
8. Further disassembly of ring gear

1) Remove 6 plates (15).
2) Remove inner hub (17) from ring gear (16).
3) Remove bearing (18) from inner hub (17).
HM300-1 30-163
2
11. Separation of outer gear assembly and inner

gear assembly
1) Remove cylinder and piston assembly (23).
4) Sling outer gear and disc plate assembly

(28) to remove.
2) Remove piston (25) from cylinder (24).
12. Further disassembly of outer gear assembly

1) Remove dampers (30a) and (30b), 6 plates
3) Remove seal rings (26) and (27) from cylin- (31), 7 discs (32) and plate (33) from outer
gear (29).
der (24) and piston (25).
30-164 HM300-1
2
(9)
2) Remove plate (34) from outer gear (29) and 2) Remove oil seal (45) and bushing (46).
then remove oil seal (35).
3) Remove floating seal (36).
ASSEMBLY
13. Further disassembly of inner gear assembly ★ Before installing, clean each of the parts thor-
1) Remove floating seals (38) and (39) from oughly; also check that it is free of dust and
hub (inner gear) (37). damage and coat the sliding surface with axle
oil.
2) Remove outer races (40) and (41). ★ Precautions when installing floating seal
• When installing a brand-new oil seal, com-
pletely wipe out white dust on the O-ring
surface with alcohol.
• Degrease the mating face of O-ring before
installing.
• Install the O-ring with a push-in type special
tool.
• Coat sealing face A with engine oil. Also
check that the face is free of dust.
• Measure dimension "a" (at 4 points on the
circumference) that is the seal height
against the gear and hub as well as retainer.
14. Further disassembly of shaft assembly
1) Remove bearing (43) and retainer (44) from
shaft (tube) (42).
HM300-1 30-165
2
1. Subassembly of shaft assembly

1) Install retainer (44) to shaft (tube) (42).
2) Press-fit bearing (43), using tool J2.
3) Install floating seal (39) to hub (inner gear)

(37), using tool J4.
★ Refer to the section of "PRECAUTIONS
WHEN INSTALLING FLOATING SEAL".
3) Install bushing (46) to shaft (42).
• Install so that dimension "b" between
the shaft end surface and bushing end
surface is 5 ± 0.2 mm.
4) Install oil seal (45), using tool J3.
★ Install so that dimension "d" between the
shaft end surface and bushing end surface
is 33 ± 0.2 mm.
: Grease (G2-LI) 4) Install floating seal (38) to hub (inner gear)
2. Subassembly of inner gear assembly

1) Install outer races (41) and (40) to hub
(inner gear) (37).
2) Install sleeve (47) for the oil seal, using tool
[4].
30-166 HM300-1
2
3. Subassembly of outer gear assembly

1) Install floating seal (36) to outer gear (29),
using tool J5.

3 Mounting bolt
: 59 - 74 Nm {6 - 7.5 kgm}

using tool J6.
★ Install so that breather hole B on the oil
seal will come within the illustrated
range as against position C of the outer
gear.
★ Install so that dimension "e" between
the end surface of outer gear and the
end surface of oil seal is 7 ± 0.5 mm.
: Loctite #648 or equivalent
2
4. Brake assembly
Oil seal lip face and inside of oil
1) Install outer gear (29) to hub (inner gear)
(37).
: Grease (G2-LI)
★ When installing, take care so that the
floating seal will not be damaged or
turned up.
HM300-1 30-167
2
2) Install plate (33), 7 discs (32), 6 plates (31) 4) Install piston (25) to cylinder (24).
and dampers (30a) and (30b) to outer gear
(29).
surfaces of discs and plates are not
damaged.
5) Install cylinder and piston assembly (23).

6) Fix tool J1.
3) Install seal rings (26) and (27) to cylinder

(24) and piston (25) respectively.
7) Install brake assembly (22) to shaft (21).

★ When installing, match both counter
marks which were put at the time of dis-
assembling.
30-168 HM300-1
2
(9)

1) Install floating seal assembly (20) to floating
seal retainer (19), using tool J4.
2) Install the assembly of floating seal retainer

(19) and floating seal assembly (20), hold-
ing forcing screw [4].
7. Installation of ring gear assembly

Install ring gear assembly (14).
8. Adjustment of bearing pre-load
1) Install retainer (12) temporarily without
shims being assembled in.
2) Remove tools J1 (at 3 points).
6. Subassembly of ring gear assembly

1) Install ring gear (16) to inner hub (17).
2) Install 6 plates (15).
2 Mounting bolt
3 Mounting bolt
: 27.5 - 34.5 Nm {2.8 - 3.5 kgm}
3) Press-fit bearing (18) into inner hub (17),
using tool J7.
HM300-1 30-169
2
3) Fasten the ring gear assembly to the forks 6) Assemble retainer (12) shims (13) whose
of lift truck [5], and tighten every other hub thickness was determined in the foregoing
bolt (4 bolts in total) to the specified torque step, and install the retainer.
of 49 ± 4.9 Nm {5 ± 0.5 kgm}., while rotating ★ Tighten the mounting bolts evenly, rotat-
the hub (inner gear) (37) by 20 to 30 turns. ing hub (inner gear) (37), until an even
★ If the bolts are tightened without hub tightening torque is obtained for all the
(inner gear) (37) being rotated, the bear- bolts.
ing will not fit in well, thus giving no 2 Mounting bolt
appropriate pre-load. : Liquid adhesive compound (LT-2)
(The photo below differs a bit from the
actual ring gear in its outer gear configu- 3 Mounting bolt
ration.) : 98 - 123 Nm {10 - 12.5 kgm}
★ After finishing tightening, check that
there is nothing wrong with its rotation,
while actually rotating hub (inner gear)
(37).
4) Measure dimension "f" between the end

surface of shaft and the end surface of
retainer (12), using depth micrometer [6].
★ Take measurement at 2 points and
obtain the average value. 9. Plate
5) Remove retainer (12) and measure retainer Install plate (11).
thickness "g", then calculate difference
"h" (=f - g) and add 0.27 mm to it. That
value is the thickness of shim.
: 0.05 mm, 0.2 mm, 0.3 mm and 1.0 mm
30-170 HM300-1
2
10. Shaft
Install shaft (10).
13. Installation of carrier assembly

Sling carrier assembly (2) to install.
3
11. Collar and sun gear
Mounting bolt
1) Install collar (9) and sun gear (8). : 157 - 196 Nm {16 - 20 kgm}
2) Install snap ring (7). [Target value: 177 Nm {18 kgm}]
12. Subassembly of carrier assembly 14. Drive shaft

1) Set bearing (5) to gear (6) and install them Install drive shaft (1).
to the carrier. 2 Mounting bolt
2) Install shaft (4). : Liquid adhesive compound (LT-2)
★ When installing, pay attention to the 3 Mounting bolt
spring pinholes. : 98 - 123 Nm {10 - 12.5 kgm}
3) Install spring pin (3). [Target value: 113 Nm {11.5 kgm}]
HM300-1 30-171
2
(9)

J1 Fixture
J1 Plate
30-172 HM300-1
2
J2 Push Tool
J3 Push Tool
HM300-1 30-173
2
J6 Push Tool
J7 Push Tool
30-174 HM300-1
2
DISASSEMBLY AND ASSEMBLY CENTER FINAL DRIVE AND BRAKE ASSEMBLY
REMOVAL AND
INSTALLATION OF
CENTER FINAL DRIVE AND
BRAKE ASSEMBLY
REMOVAL
beforehand.
k Raise the body assembly to the maximum and
insert a safety pin.
1. Drain oil from the center differential case and

the center final drive case.
6 Center differential case: 25l
6 Center final drive case: 4l (one side)
2. Disconnect the center wheel.
1) Raise the underside of center axle on the
side of wheel to be removed, using hydrau-
lic jack [1].
4. Disconnect brake wearing switch connector (3)

(If equipped).
5. Disconnect wiring connectors (4) (If equipped).
• Final drive, right: B26

• Final drive, left: B02
6. Disconnect left and right brake actuating tubes
(5).
7. Disconnect brake cooling tubes (6) and (7).
2) Sling the center wheel (1) and remove the
mounting bolts.
4 Center wheel: 550kg (one side)
HM300-1 30-175
2
8. Remove carrier assembly (8) and the sun gear • Refilling with oil (center differential case and
and drive shaft assembly from the final drive center final drive case)
assembly, referring to the section of "REMOVAL Refill with oil through the oil filler ports of center
AND INSTALLATION OF CENTER DIFFEREN- differential case and left and right center final
TIAL ASSEMBLY". drive up to the specified level.
9. Sling final drive and brake assembly (9) and 5 Center differential case
remove the 23 mounting bolts. : 25l (SHELL DONAX TD)
5
4 Center final drive and brake assembly Center final drive case
: 4l (one side) (SHELL DONAX TD)
: 350kg (one side)
• Air bleeding
Bleed air from the brake circuit after finishing
installation, referring to the section of "BLEED-
ING AIR FROM BRAKE CIRCUIT" in INSPEC-
TION ANDADJUSTMENT.
INSTALLATION
removal.
3 Center wheel mounting bolt

: 824 - 1,030 Nm {84 - 105 kgm}
★ Install the sun gear and drive shaft assem-

bly and the carrier assembly, referring to the
section of "REMOVAL AND INSTALLA-
TION OF CENTER DIFFERENTIAL
ASSEMBLY".
2 Center final drive and brake assembly
mounting bolt
3 Center final drive and brake assembly
mounting bolt
: 490 - 680 Nm {50 - 62 kgm}
30-176 HM300-1
2
DISASSEMBLY AND
ASSEMBLY OF
CENTER FINAL DRIVE AND
BRAKE ASSEMBLY
SPECIAL TOOL
Dis-
sity tch
tion*
2 792T-222-1220 Push Tool ■ 1 N c
4 791-580-1520 Installer ■ 1
5 791-580-1510 Installer ■ 1
3. Further disassembly of ring gear assembly
793T-622-1110 Push Tool ■ 1 c
6 790-101-5421 Grip ■ 1 1) Remove 6 plates (4).
01010-81240 Bolt ■ 1 2) Remove inner hub (6) from ring gear (5).
7 797T-622-1240 Push Tool ■ 1 c
J 3) Remove bearing (7) from inner hub (6).
792T-223-1130 Fixture ■ 3 N c
792T-223-1140 Plate ■ 3 N c
01010-61240 Bolt ■ 3
8 01643-31232 Washer ■ 3
01580-01210 Nut ■ 3
01010-61245 Bolt ■ 3
01010-62440 Bolt ■ 3
DISASSEMBLY
1. Retainer and shim
1) Fix tools J8 at 3 points between the outer
gear and wheel hub (inner gear).
★ Be sure to fix tools J8 before removing 4. Floating seal retainer and floating seal
retainer (1) in order to protect the float- 1) Remove the assembly of floating seal
ing seal from damage. retainer (8) and floating seal assembly (9)
★ Fix tools J8 at an equal interval. by fitting forcing screws [1].
2) Remove retainer (1) and shim (2).
★ heck the thickness, number in use and
installed location of the shims before-
hand.
2. Removal of ring gear assembly
1) Remove ring gear assembly (3).
HM300-1 30-177
2
5. Removal of brake assembly 3) Remover seal rings (15) and (16) from cylin-
1) Remove brake assembly (11) from shaft der (13) and piston (14) respectively.
(tube) (10).
★ Before removing, put a counter mark on
both of them.
2) Remove tools J8 from the brake assembly.
6. Separation of outer gear assembly and inner

gear assembly
1) Remove cylinder and piston assembly (12).
4) Sling outer gear and disc plate assembly

(17) to remove.
2) Remove piston (14) from cylinder (13).
30-178 HM300-1
2
(9)
7. Further disassembly of outer gear assembly 9. Further disassembly of shaft assembly

Remove bearing (32) and retainer (33) from
1) Remove dampers (19a) and (19b), 8 plates
shaft (31).
(20), 9 discs (21) and plate (22) from outer
gear (18).
ASSEMBLY
2) Remove plate (23) from outer gear (18) and
then remove oil seal (24). ★ Before assembling, clean each of the parts thor-
oughly; check that it is free of dust and damage,
3) Remove floating seal (25). and coat the sliding surface with axle oil.
★ Precautions when installing floating seal
• When installing a brand-new O-ring, com-
pletely wipe out white dust on the O-ring
surface with alcohol.
• Degrease the mating surface of O-ring
before installing.
• Install an O-ring with a push-in type special
tool.
• Coat seal face A with engine oil, and check
that the seal is free of dust and damage.
• Measure dimension "a" (at 4 points on the
circumference) that is the seal height as
8. Further disassembly of inner gear assembly against the carrier and hub as well as
retainer.
1) Remove floating seals (27) and (28) from
hub (inner gear) (26).
2) Remove outer races (29) and (30).
HM300-1 30-179
2
(9)
1. Subassembly of shaft assembly

1) Install retainer (33) to shaft (31).
2) Press-fit bearing (32), using tool J2.

2. Subassembly of inner gear assembly
1) Install outer race (30), (29) to hub (inner
gear) (26).
2) Install sleeve for the oil seal (36), using tool
[2].
3. Subassembly of outer gear assembly

using tool J5.

30-180 HM300-1
2
2) Install oil seal (24) to outer gear (18), using 3) Install plate (23).
3
tool J6.
Mounting bolt
★ Install so that breather hole B on the oil : 59 - 74 Nm {6 - 7.5 kgm}
seal will come within the illustrated
range as against position C of the outer
gear.
★ Install so that dimension "e" between
the end surface of outer gear and the
end surface of oil seal is 7 ± 0.5 mm.
: Loctite #648 or equivalent
: Grease (G2-LI)
4. Brake assembly
1) Install outer gear (18) to hub (inner gear)
(26).
floating seal will not be damaged or
turned up.
2) Install plate (22), 9 discs (21), 8 plates (20)

and dampers (19a) and (19b) to outer gear
(18).
surfaces of discs and plates are not
damaged.
HM300-1 30-181
2
(9)
3) Install seal rings (15) and (16) to cylinder 5) Install cylinder and piston assembly (12).
(13) and piston (14) respectively.
6) Fix tool J8.
7) Install brake assembly (11) to shaft (tube)

(10).
★ When installing, pay attention to the
counter marks which were put at the
time of disassembly.
4) Install piston (14) to cylinder (13).

1) Install floating seal (9) to floating seal
retainer (8), using tool J4.
30-182 HM300-1
2
2) Install the assembly of floating seal cage (8) 7. Installation of ring gear assembly
and floating seal assembly (9), holding forc- Install ring gear assembly (3).
ing screw [1]. 8. Adjustment of bearing pre-load
1) Install retainer (1) temporarily without shim
(2) being assembled in.
2) Remove tools J8 (at 3 points).

1) Install ring gear (5) to inner hub (6).
2) Install 6 plates (4).
2 Mounting bolt 3) Fasten the ring gear assembly to the forks
: Liquid adhesive compound (LT-2) of lift truck [3], and tighten every other hub
3 Mounting bolt bolt (4 bolts in total) to the specified torque
: 27.5 - 34.5 Nm {2.8 - 3.5 kgm} of 49 ± 4.9 Nm {5 ± 0.5 kgm}, while rotating
[Target value: 31 Nm {3.2 kgm}] hub (inner gear) (26) by 20 to 30 turns.
★ If the bolts are tightened without hub
3) Press-fit bearing (7) to inner hub (6), using (inner gear) (26) being rotated, the bear-
tool J7. ing will not fit in well, thus giving no
appropriate pre-load.
(The photo below differs a bit from the
actual ring gear in its outer gear configu-
ration.)
HM300-1 30-183
2

surface of shaft and the end surface of
★ Take measurement at 2 points and
obtain the average value.
5) Remove retainer (1) and measure retainer
thickness "g", then calculate difference
"h" (= f - g) and add 0.27 mm to it. That
value is the thickness of shim.
: 0.05 mm, 0.2 mm, 0.3 mm and 1.0 mm
6) Assemble in retainer (1) shims (2) which

were selected in the foregoing step.
★ Tighten the mounting bolts evenly, while
rotating hub (inner gear) (26), until all
the mounting bolts are tightened to even
torque.
2 Mounting bolt
3 Mounting bolt
: 98 - 123 Nm {10 - 12.5 kgm}
★ After finishing installing, check that there
is nothing wrong with rotation, while
turning hub (inner gear) (26).
30-184 HM300-1
2

J2 Push Tool
J6 Push Tool
HM300-1 30-185
2
J7 Push Tool
J8 Fixture
30-186 HM300-1
2
J8 Plate
HM300-1 30-187
2
DISASSEMBLY AND ASSEMBLY REAR FINAL DRIVE ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF
REAR FINAL DRIVE
ASSEMBLY
SPECIAL TOOL
Neces Distin Ske-
2 792T-222-1220 Push Tool ■ 1 N c
J
7 797T-622-1240 Push Tool ■ 1 c
4. Removal of carrier assembly
DISASSEMBLY 1) Remove the mounting bolts, and pull carrier
k
assembly (2) out of the final drive assembly,
Turn the parking brake switch on and put using forcing screws [2] and guide bolt [3].
(Remove the carrier assembly without a
1. Body assembly
wheel unlike the photo below)
Remove the body assembly, referring to the
section of "REMOVAL OF BODY ASSEMBLY".
2. Draining oil
Drain oil from the rear differential case and the
rear final drive case.
6 Rear differential case: 25l
6 Rear final drive case: 5l (one side)
3. Rear wheel
1) Raise the underside of rear axle with
hydraulic jack [1].
2) Sling carrier assembly (2) to remove.
4 Carrier assembly: 40kg (one side)

(Remove the carrier assembly without
wheel unlike the photo below)
2) Sling rear wheel (1), then remove the

mounting bolts and remove the rear wheel.
4 Rear wheel: 550kg
30-188 HM300-1
2
(9)
5. Further disassembly of carrier assembly 2) Remove snap ring (9).

1) Drive spring pin (3) into shaft (4), using 3) Remove sun gear (11) and spacer (12) from
round bar [4]. drive shaft (10).
2) Pull out shaft (4) and then take out bearing
(5) and gear (6).
3) Pull spring pin (3) out of shaft (4) before-
hand.
7. Removal of ring gear assembly

1) Sling flywheel hub assembly (13).
2) Remove retainer (14).
6. Sun gear and drive shaft

1) Remove sun gear and drive shaft assembly
(8). 3) Remove ring gear (16).
HM300-1 30-189
2
8. Further disassembly of ring gear assembly 10. Retainer assembly

1) Remove 6 plates (17). 1) Remove retainer (27).
2) Remove inner hub (19) from ring gear (18). 2) Remove protector (28) from retainer (27).
3) Remove bearing (20) from inner hub (19).
9. Wheel hub assembly ASSEMBLY

1) Sling flywheel hub assembly (21) to remove. ★ Before assembling, clean each of the parts thor-
oughly, then check that it is free of dust and
damage and coat the sliding surface with axle
oil.
1. Retainer assembly
1) Install protector (28) to retainer (27), using
push tool [5].
★ Keep press-fitting until the protector is
flush with the retainer.
2) Install retainer (27) with an O-ring to the axle
housing.
2) Remove oil seal (23), bearing (24) and outer

races (25) and (26) from wheel hub (22).
30-190 HM300-1
2
(9)
2. Wheel hub assembly 4) Sling wheel hub assembly (21) and install it
1) Install outer races (25) and (26) to wheel to the axle housing.
hub (22). 5) Press-fit bearing (24), using tool J2.
bearing.
3) Press-fit oil seal (23), using push tool [6].
★ Keep press-fitting until the oil seal
comes into close contact with the wheel
hub.
: Grease (G2-LI)

1) Press-fit bearing (20) into inner hub (19),
using push tool J7.
bearing.
HM300-1 30-191
2
2) Assemble inner hub (19) in ring gear (18)

and install plate (17).
2 Mounting bolt
3 Mounting bolt
: 27.5 - 34.5 Nm {2.8 - 3.5 kgm}

surface of the shaft and the end surface of
★ Take measurement at 2 points and cal-
culate the average value.
4) Remove retainer (14) and measure thickness
"g" of the retainer. Add 0.27mm to difference
"h" of the measured values h (= f - g), and
3) Install ring gear assembly (16).
the shim thickness is obtained.
: 0.05 mm, 0.2 mm, 0.3 mm and 1.0 mm
4. Adjustment of pre-load on bearing

1) Install retainer (14) temporarily without
shims being assembled in.
2) Tighten every other mounting bolt (4 bolts in
total) evenly to the specified torque of 49 ±
4.9 Nm {5 ± 0.5 kgm}, while rotating ring
gear assembly (16) by 20 to 30 turns.
★ If the mounting bolts are tightened with-
out rotating the ring gear assembly (16),
the bearing will not sit in well and no
right preload is given to the bearing.
30-192 HM300-1
2
5) Assemble shims (15) having thickness 2) Install sun gear and drive shaft assembly
selected in the step 4) above in retainer (14) (8).
and install the retainer.
★ Tighten the mounting bolts evenly, while
rotating ring gear assembly (16), until
the tightening torque is equal for all the
bolts.
2 Mounting bolt
3 Mounting bolt
: 98 - 123 Nm {10 - 12.5 kgm}
[Target value: 11.3 Nm {11.5 kgm}]
★ After finishing tightening, check that
there is nothing wrong with rotation
when turning ring gear assembly (16). 6. Subassembly of carrier assembly
1) Set bearing (5) to gear (6) and assemble the
gear in the carrier.
2) Install shaft (4).
★ When installing the shaft, pay attention
to its pinhole for spring pin.
3) Install spring pin (3).
5. Sun gear and drive shaft

1) Assemble spacer (12) and sun gear (11) in
drive shaft (10) and install snap ring (9).
HM300-1 30-193
2
7. Installation of carrier assembly

1) Sling carrier assembly (2) after installing an
O-ring and install along guide bolt [3].
3 Mounting bolt
: 157 - 196 Nm {16 - 20 kgm}
8. Rear wheel assembly

Sling rear wheel (1) to install.
3 Mounting bolt
: 824 - 1,030 Nm {84 - 105 kgm}
• Refilling with oil (rear differential case and

rear final drive case)
Refill with oil through oil filler ports of rear differ-
ential case and left and right rear final drives up
to the specified level.
5 Rear differential case
: 25l (SHELL DONAX TD)
5 Rear final drive case
: 5l (one side) (SHELL DONAX TD)
30-194 HM300-1
2

J2 Push Tool
J7 Push Tool
HM300-1 30-195
2
DISASSEMBLY AND ASSEMBLY CENTER AXLE ASSEMBLY
REMOVAL AND 3. Separate drive shaft (2) between the hitch

frame and center differential and drive shaft (3)
INSTALLATION OF between the center differential and rear differen-
CENTER AXLE ASSEMBLY tial at the center differential side.
★ After slinging, separate by removing the
REMOVAL drive shaft mounting bolts.
k Disconnect the negative (-) terminal of battery.

k Evacuate nitrogen gas from the rear suspen-
sion cylinder, referring to the section of
"TESTING AND ADJUSTING SUSPENSION
CYLINDER" in the chapter of INSPECTION
AND ADJUSTMENT.
1. Raise the underside of center axle and rear axle

at the left and right sides, using hydraulic jacks 4. Remove cover (4).
[1].
5. Disconnect left and right wiring connectors (5).
• Final drive, right: B26
• Final drive, left: B02
2. Sling center wheel (1) to remove the mounting

bolts, and remove the left and right center
wheels.
4 Center wheel: 550 kg (one side)
30-196 HM300-1
2
(9)
DISASSEMBLY AND ASSEMBLY CENTER AXLE ASSEMBLY
6. Disconnect wiring connector (T14) (6). 11. Sling center axle and arm assembly (12).
7. Disconnect brake actuator hose (7) and discon-
nect 2 brake actuator tubes (8).
8. Disconnect 2 brake cooling hoses (9).
12. Remove left and right caps (13) at a pin of the

arm mounting base, and take down center axle
and arm assembly (12) to remove.
4 Center axle and arm assembly
9. Remove the mounting bolts for center lateral
: 1,600 kg
rod (10) and sling the rod to remove.
4 Center lateral rod: 40 kg
INSTALLATION
10. Remove the mounting bolts for equalizer bar • Installation is carried out in the reverse order to
spring (11) and separate the spring. removal.

: 824 - 1,030 Nm {84 - 105 kgm}
★ Install the center axle assembly after con-

firming that the yoke of drive shaft between
the hitch frame and center differential and
the yoke of drive shaft between center dif-
ferential and rear differential are shifted
from each other at 45f ± 6f.
HM300-1 30-197
2
(9)
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
★ When installing the drive shafts, check that REMOVAL AND

the spider cap keyway engages completely
with that of the counter yoke, and then INSTALLATION OF
tighten the mounting bolts. REAR AXLE ASSEMBLY
: Liquid adhesive compound (LT-2) REMOVAL
3 Drive shaft mounting bolt k Turn the parking brake switch on and put
: 98 - 123 Nm {10 - 12.5 kgm} wooden blocks behind wheels.
[Target value: 113 Nm {11.5 kgm}] k Evacuate nitrogen gas from the rear suspen-
★ When installing bearing (B) to center lateral rod "TESTING AND ADJUSTING SUSPENSION
(A), align tapped hole "c" with centerline "d" of CYLINDER" in the chapter of INSPECTION
bearing (B). AND ADJUSTMENT.
1. Remove the body assembly, referring to the

section of "REMOVAL AND INSTALLATION OF
BODY ASSEMBLY".
2. Raise the underside of center axle and rear axle
at the left and right sides, with hydraulic jacks
[1].
3 Cap mounting bolt

: 455 - 565 Nm {46.5 - 58 kgm}
★ Adjust the suspension cylinder stroke, referring

to the section of "TESTING AND ADJUSTING
SUSPENSION CYLINDER" in the chapter of
INSPECTION AND ADJUSTMENT.
3. Sling rear wheel (1) to remove the mounting
• Refilling with oil (transmission case and bolts and then remove the left and right rear
wheels.
4 Rear wheel: 550 kg (one side)
brake oil tank)
specified level, then start the engine and run at
low idle, and check the oil level again.
• Air Bleeding (brake)

After finishing the installation, bleed air from the
brake circuit , referring to the section of
"BLEEDING AIR FROM BRAKE CIRCUIT" in
INSPECTION AND ADJUSTMENT.
30-198 HM300-1
2
(9)
4. Separate drive shaft (2) between the center dif- 7. Remove left bracket (5).
ferential and rear differential at the rear differen-
8. Remove rear suspension pins (6) of both left
tial side.
and right sides at their head side.
★ After slinging, remove the drive shaft mount-
ing bolts and separate the shaft.
9. Remove left and right caps (7) at a pin of the

arm mounting base, and take down rear axle
5. Remove the mounting bolts of rear lateral rod arm (4) to remove.
4
(3) and sling the rod to remove.
4
Rear axle and arm assembly: 1,100kg
Rear lateral rod: 50 kg
6. Sling rear axle and arm assembly (4).
HM300-1 30-199
2
(9)
INSTALLATION
removal.
3 Rear wheel mounting bolt

: 824 - 1,030 Nm {84 - 105 kgm}
★ When installing the drive shafts, check that

the spider cap keyway engages completely
with that of the counter yoke, and then
: 98 - 123 Nm {10 - 12.5 kgm}
★ When installing bearing (B) to rear lateral

rod (A), align tapped hole "c" with centerline
"d" of bearing (B).
3 Bracket mounting bolt

: 455 - 565 Nm {46.5 - 58 kgm}
3 Cap mounting bolt

: 455 - 565 Nm {46.5 - 58 kgm}
★ Adjust the suspender cylinder stroke, referring
to the section of "TESTING AND ADJUSTING
SUSPENION CYLINDER" in the chapter of
INSPECTION AND MAINTENANCE.
30-200 HM300-1
2
(9)
DISASSEMBLY AND ASSEMBLY FRONT SUSPENSION CYLINDER ASSEMBLY
REMOVAL AND 4) Sling front wheel (2), and remove the

mounting bolts to remove the wheel.
INSTALLATION OF
FRONT SUSPENSION 4 Front wheel: 550 kg (one side)
CYLINDER ASSEMBLY
REMOVAL
k Evacuate nitrogen gas from the front suspen-
AND ADJUSTMENT.
1. Remove the front wheel.

1) Raise the underside of front axle on the side 2. Remove 3 covers (3).
of wheel to be removed with hydraulic jack
[1].
2) Support the front frame underside with ped-
estal (frame) [2].
4. Remove bracket (5).

5. Disconnect grease hose (6) from the head pin.
3) Sling left fender (1) to remove.
4 Left fender: 80kg
HM300-1 30-201
2
(9)
DISASSEMBLY AND ASSEMBLY FRONT SUSPENSION CYLINDER ASSEMBLY
6. Disconnect grease tube (7) from the bottom pin. INSTALLATION

removal.

: 824 - 1,030 Nm {84 - 105 kgm}
3 Cover clamp
: 6.31 - 7.29 Nm {64 - 74 kgm}
[Target value: 6.8 Nm {69 kgm}]
7. Sling the front suspension cylinder assembly.
8. Remove head pin (8) and bottom pin (9), and
sling front suspension cylinder (10) to remove. 3 Bracket mounting bolt
: 69 - 74 Nm {6 - 7.5 kgm}
4 Front cylinder suspension assembly [Target value: 66.5 Nm {6.75 kgm}]
: 75 kg
3 Pin mounting bolt

: 98 - 123 Nm {10 - 12.5 kgm}
[Target value: 110.5 Nm {11.3 kgm}]
• Refilling with nitrogen gas and adjusting cyl-

inder stroke
Refill with nitrogen gas and adjust the cylinder
stroke, referring to the section of "TESTING
AND ADJUSTING SUSPENSION CYLINDER"
in the chapter of INSPECTION AND ADJUST-
MENT.
30-202 HM300-1
(9)
2
INSTALLATION AND REMOVAL OF
DISASSEMBLY AND ASSEMBLY REAR SUSPENSION CYLINDER ASSEMBLY
INSTALLATION AND INSTALLATION

REMOVAL OF removal.
REAR SUSPENSION
CYLINDER ASSEMBLY ★ Install bearing (B) to rear lateral rod (A) and
align tapped hole "c" with centerline "d" of bear-
REMOVAL ing (B).
k Evacuate nitrogen gas from the rear suspen-
AND ADJUSTMENT.
1. Raise the underside of rear axle and equalizer

bar (underside of rear frame) with hydraulic
jacks [1] and [2].
2. Support rear lateral rod (1) with a hydraulic jack
and remove.
4 Rear lateral rod: 50 kg 3 Bracket mounting bolt
: 455 - 565 Nm {46.5 - 58 kgm}
3. Remove left bracket (2).
• Refilling with nitrogen gas and adjusting cyl-
inder stroke
Refill with nitrogen gas and adjust the cylinder
stroke, referring to the section of "TESTING
AND ADJUSTING SUSPENSION CYLINDER"
in the chapter of INSPECTION AND ADJUST-
MENT.
4. Sling rear suspension cylinder assembly (3)

with balance bar [3].
5. Remove pin (4) on the head side and pin (5) on
the bottom side, and sling rear suspension cyl-
inder assembly (4) to remove.
HM300-1 30-203
(9)
2
DISASSEMBLY AND
ASSEMBLY OF FRONT AND
REAR SUSPENSION
CYLINDER ASSEMBLY
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
792-201-3141 Push tool t 1
Q 1 790-101-5221 Grip t 1 4. Flange
1) Remove retainer (8) and flange (9) from
01010-51225 Bolt t 1
rod assembly (7).
2) Remove U-packing (11), backup ring, and
Disassembly buffer ring (12), and O-ring (13) from
flange (9).
1. Cover 3) Remove the bushing (17) from flange (9).
Hanging the cylinder assembly, loosen band (1) 4) Remove seal (14) and bushing from
and remove the button, then remove cover (2). retainer (8).
2. Intake valve and oil level valve

1) Remove the protector, them remove intake
valve (3) and oil level valve (4).
2) Drain oil from the cylinder.
5. Wear ring
Remove wear ring (15) from rod (16).
3. Cylinder rod assembly

Place the cylinder assembly on its end, upside
down.
1) Remove flange mounting bolt (5).
2) Slowly hang cylinder rod assembly (7) with
a crane to remove it from cylinder (10),
without removing retainer (8) and flange
(9).
30-203-1
30-204 HM300-1
2(14)
Assembly 5. Intake valve and oil level valve

Adjust the oil level. For details, see Testing and
1. Wear ring adjusting, "Testing and adjusting suspension
Install wear ring (15) to rode (16). cylinder".
2. Flange 6. Cover
1) Install the bushing (17) to flange (9) with 1) Install cover (2) and tighten band (1).
tool Q1. 2) Install the protector of the intake valve and
2) Install U-packing (11) to flange (9). oil level valve.
3) Install backup ring and buffer ring (12) and
O-ring (13) to flange (9).
3. Retainer
1) Install the bushing (18) to retainer (8) with
tool Q1.
2) Install seal (14) to retainer (8).
4. Cylinder rod assembly

1) Erect cylinder (10) by using a block.
2) Hang cylinder rod assembly (7) and install
it to cylinder (10).
3) Install plate (6), retainer (8), and flange (9)
3 Mounting bolt:
together with mounting bolts (5).
58.8 - 73.5 Nm {6.0 - 7.5 kgm}
HM300-1 30-205
30-203-2
(14)
2
DISASSEMBLY AND ASSEMBLY EQUALIZER BAR
REMOVAL AND 3. Remove bottom pin (3) of rear suspension cylin-

der assembly (2).
INSTALLATION OF ★ Tilt back the rear suspension cylinder
EQUALIZER BAR toward the rear and secure it.
REMOVAL
k Evacuate nitrogen gas in the rear suspension
cylinder, referring to the section of "TESTING
AND ADJUSTING SUSPENSION CYLIN-
DER" in the chapter of INSPECTION AND
ADJUSTMENT.
1. Raise the center axle, rear axle and rear frame 4. Separate equalizer spring (4) after removing its
on the side of equalizer bar to be removed, mounting bolts.
using 3 hydraulic jacks [1].
5. Sling the equalizer bar.

2. Sling center wheel (1), and remove its mounting
bolts to remove. 6. Remove plate (5) in the center of equalizer bar.
4 Center wheel: 550 kg (one side)
30-204 HM300-1
2
(9)
DISASSEMBLY AND ASSEMBLY EQUALIZER BAR
7. Remove bushing (6), using 3 forcing screws [2] INSTALLATION

and tool [3].
removal.

: 824 - 1,030 Nm {84 - 105 kgm}
★ Tighten 3 cover bolts (M24) after confirming

the following installing dimensions.
• Check that when dimension "x" between
upper and lower pins of rear suspension
8. Sling equalizer bar (7) to remove. cylinder is 518 mm (x = 518 mm),
4
dimension "a" between the bottom pin
Equalizer bar: 200kg
center of rear suspension cylinder and
the rear frame upper face is 17 mm and
dimension "b" between the equalizer
upper face and the rear frame upper
face is 162 mm.
3 Cover mounting bolt (M14)
: 157 - 196 Nm {16 - 20 kgm}
3 Cover mounting bolt (M24)
: 824 - 1,030 Nm {84 - 105 kgm}
HM300-1 30-205
2
(9)
DISASSEMBLY AND ASSEMBLY HITCH FRAME ASSEMBLY
REMOVAL AND 4. Remove drive shaft (3) between the transmis-

sion and hitch frame.
4
INSTALLATION OF
Drive shaft between transmission and
HITCH FRAME ASSEMBLY hitch frame: 30 kg
SPECIAL TOOL
Part Necess Distinc Ske-
Mark Part No. Name ity Q'ty tion* tch
1 792T-246-1130 Plate ■ 1 N c
K
2 792T-246-1140 Plate ■ 1 N c
REMOVAL
beforehand.
k
5. Sling exhaust box (4) to remove.
4
Raise the body assembly to the maximum and
insert a safety pin. Exhaust box: 35 kg
6. Remove guard (5).
1. Unscrew the cap on the hydraulic tank.
7. Remove hose covers (6) and (7).
2. Remove drive shaft guard (1).
3. Sling drive shaft (2) between the hitch frame
and center differential to remove.
4 Drive shaft between hitch frame and
center differential: 45 kg
30-206 HM300-1
2
(9)
8. Gradually loosen hoist cylinder hoses (8) and 11. Disconnect the following wiring connectors and
(9) between the front frame and rear frame as terminal from the rear frame front side.
well as brake cooling hoses (10) and (11) and • (15): J15
evacuate oil. • (16): J13
6
• (17): Grounding terminal (ER)
Hydraulic oil [hose (8) and (9)]
: Approx. 50l
6 Transmission and brake cooling oil
[hose (10) and (11)]: Approx. 15l
9. Disconnect the following hoses between the
front frame and rear frame.
★ Either put an identification tag or put a
counter mark on the piping in order to make
no mistake about the installing position later.
★ Disconnect the parking brake hose at the
rear frame side.
• Hoist cylinder hoses (8) and (9)
• Brake cooling hoses (10) and (11)
12. Disconnect the following wiring connectors and
• Parking brake hose (12) terminal from the front frame rear side.
• Brake hose (13) • (18): J14
• (19): J12
• (20): Grounding terminal (ER)
10. Disconnect connector (14) (If equipped) for a

rearview camera at the machine rear.
HM300-1 30-207
2
13. Sling exhaust duct assembly (21) to remove. 2) Support the body underside at the machine
4 Exhaust duct assembly: 40 kg rear with block [2].
14. Remove brackets (22) and (23).
3) Support the front frame underside at the

rear and the rear frame underside at the
15. Remove left and right steering cylinder head front with block [3] and pedestal [4] to
pins (29). ensure safety in the work.
4) Align the hinge pinhole centers by raising
and lowering the front frame and rear frame
with hydraulic jacks [5] and [6].
16. Support the chassis front and rear in the follow-

ing manner.
1) Lift the chassis front part with sling [1], using
a crane. 17. Remove the upper hinge pin and bushing in the
following manner.
1) Remove retainer (30).
30-208 HM300-1
2
(9)
2) If it is difficult to remove upper hinge pin

(31), set puller [7], plate [8] and 4 bolts
between retainer (30) and upper hinge pin
(31) and push down upper hinge pin (31) to
remove.
19. Check that there is clearance between the front

frame and hitch frame.
20. Push up lower bushing (35) on the upper pin
side toward the hitch frame (36) side by approx.
1 mm in order to avoid a step of the front frame
3) Hook puller [10] to a step inside the bush- (37).
ing, and take out bushing (32) upward by
pushing up the claw of puller [10], using
push tool [11] and puller [12].
21. While keeping the front portion of frame assem-

bly lifted with a crane, move the assembly a bit
forward, using a lift truck, and separate front
18. Remove the lower hinge pin in the following frame assembly (38) from hitch frame assembly
manner. (39).
1) Remove the mounting bolts for the lower k Before separating, carefully check level-
hinge pin. ness of the front frame and hitch frame and
2) Remove the mounting bolts and nuts, and also check that there is clearance between
then remove 2 O-rings (33). the two frames.
3) Put hydraulic jack [13] to lower hinge pin

(34) and take the pin out by pushing
upward.
• If the truck body is lifted with the lower
hinge pin and the pin cannot be pulled
out, hit the frame around the pin from
above in that lifted condition and strike
the pin out downward.
HM300-1 30-209
2
22. Remove cover (40). 26. Sling parking brake disc (43) to remove.
4
23. Turn parking brake releasing bolt (41) counter-
clockwise to release the parking brake. Parking brake disc: 30 kg
24. Sling parking brake caliper assembly (42) and 27. Sling bracket (44) to remove, using eyebolts
remove brackets (43) for expanding the pads [14].
and bracket (44). 4 Bracket: 30 kg
25. Sling parking brake caliper assembly (42) to
remove.
4 Parking brake caliper assembly: 45 kg
28. Remove coupling (45).
30-210 HM300-1
2
(9)
29. Remove retainer (46), using forcing screws [15].
32. Remove retainer (50) and dust seal (51) from

the rear frame.
30. Remove retainer (47), using forcing screws [16].
★ Shims are provided, so check their thick-

ness, number in use and installed locations
beforehand.
INSTALLATION
removal.
31. Sling hitch frame assembly (48) to remove. ★ Before installing, check that the yoke of drive
shaft between the hitch frame and center dif-
★ Bearing (49) may fall off from the rear frame, ferential and the yoke of drive shaft between
shifted from each other by 45f ± 6f.

so secure it to prevent fall-off. center differential and rear differential are
★ When installing the drive shafts, check that

the spider cap keyway completely engages
with that of the counter yoke, and then
: 98 - 123 Nm {10 - 12.5 kgm}
HM300-1 30-211
2
(9)
10) Install a combination of the selected shims

k When aligning the pinholes, never put a to retainer (30) and tighten retainer mount-
finger into the hole. ing bolts (52) and (53).
★ Install the hinge pin in the following steps.
1) Set bushing (35) to the hitch frame and
: 225 - 309 Nm {25.0 - 31.5 kgm}
match the articulation center (position of
center pin) by moving the front frame
assembly to the rear.
2) Insert lower hinge pin (34) from above.
2 Dust seal lip face
: Grease (G2-LI)
2 Bearing inside perimeter
disulfide (LM-P)
3) Install 2 O-rings (33).
2 O-ring: Grease (G2-LI)
4) Measure thickness "f" of retainer (30).
5) Insert upper hinge pin (31) from below.
2 Dust seal lip
: Grease (G2-LI)
2 Upper hinge pin outside perimeter
disulfide (LM-P)
6) Assemble bushing (32) in from above.
7) Press-fit retainer (30) by tightening the
mounting bolt (52).
: 225 - 309 Nm {25.0 - 31.5 kgm} ★ Check the parking brake pad wear amount
★ After confirming thorough running-in of and adjust the pad clearance, referring to
each contact surface, tighten mounting the section of "TESTING WEAR OF PARK-
bolt (52) again to the specified torque. ING BRAKE PAD" in INSPECTION AND
8) Measure dimension "g" of clearance ADJUSTMENT.
between retainer (30) and the front frame at 3 Pad expanding bracket mounting
3 points. bolt (43)
9) Select appropriate shims and assemble : 98 - 123 Nm {10 - 12.5 kgm}
them in so that the clearance has measured 2 Bracket mounting bolt (44)
dimension "g" less 0.08 to 0.18 mm. : Liquid adhesive compound (LT-2)
3
Bracket mounting bolt (44)
: 0.1 mm and 0.5 mm : 824 - 1,030 Nm {84 - 105 kgm}
• Standard shim thickness: 2 mm
30-212 HM300-1
2
2
★ Press-fit dust seal (55), using tool K2.
Parking brake disc mounting bolt
3 Parking brake disc mounting bolt
: 490 - 608 Nm {50.0 - 62.0 kgm}

: 157 - 196 Nm {16.0 - 20.0 kgm}

★ After installing the hitch frame assembly and
3 Coupling mounting bolt retainer (47), fill the space H - Q listed below
: 455 - 565 Nm {46.5 - 58.0 kgm} completely with hub grease.
2 H space: 350 g (inside of dust seal
★ When removing dust seal (54) from retainer and dust seal lip)
(46), press-fit dust seal (54), using tool K1. 2 J space: 620 g
2 K space: 1,030 g (inside of bearing)
2 L space: 2,400 g
2 M space: 2,085 g
2 N space: 680 g (inside of bearing)
2 P space: 530 g
2 Q space: 295 g (inside of dust seal
and dust seal lip)
★ *Select grease to be filled from among those
listed below.
No. Manufacturer Grease Brand
1 Nihon Ryuyu Hilex HD-2
2 SHELL OIL Super Duty Grease2
3 ESSO OIL RONEX MP
4 BP Energrease LS-EP2
HM300-1 30-213
2
5) Select appropriate shims so that the total

shim thickness is "u", i.e. the difference
★ Method for adjusting bearing at oscillating between dimensions "t" and "s" (u = t - s)
portion minus 0 to 0.15 mm.
1) Measure thickness "s" of retainer (47) at 2 • Standard thickness of shim: 3.0 mm
points. (Calculate the average value of the 2 • Kind of shim thickness
points.) : 0.2 mm, 0.3 mm and 1.0 mm
2) Tighten retainer (47) without shims with 3 6) Install a combination of selected shims (55)
mounting bolts (54). to retainer (47) and install the retainer with
3 Mounting bolt: 49 Nm {5 kgm} 12 mounting bolts (54).
2 Mounting bolt
3) In that condition, measure dimension "t"
with a micrometer. : Liquid adhesive compound (LT-2)
4) Rotate the hitch by 5 to 6 turns and repeat 3 Mounting bolt

: 245 - 309 Nm {25.0 - 31.5 kgm}
the steps 2) and 3) above.
★ Repeat the steps 2) to 4) until
dimension "t" is constant.
30-214 HM300-1
2

K1 Plate
K2 Plate
HM300-1 30-215
2
DISASSEMBLY AND 2) Remove ring (3), dust seal (4), grease fitting
(31), and nipple (32) from rear retainer (5).
ASSEMBLY OF a Grease fitting (31) and nipple (32) are
HITCH FRAME ASSEMBLY installed to serial No. 1054 and up.
SPECIAL TOOL
Neces- Dis- Ske-
Mark Part No. Part Name Q'ty tinc-
sity tch
tion*
3 792T-246-1110 Plate ■ 1 N !
790-101-5201 Push Tool Kit ■ 1
K • 790-101-5314 • Plate 1
4
• 790-101-5221 • Grip 1
• 01010-51225 • Bolt 1
DISASSEMBLY
3. Center shaft
1. Coupling 1) Remove center shaft and bearing assembly
Remove the mounting bolts and remove cou- (6) from hitch frame assembly (7).
pling (1).
2) Remove bearing (8) and bearing inner race

2. Rear retainer
(9) from center shaft (10).
1) Remove rear retainer assembly (2), using
forcing screws [1].
30-216 HM300-1
2
(7)
4. Further disassembly of hitch frame ASSEMBLY

1) Remove front cage assembly (11) from hitch ★ Clean each of the parts thoroughly and check
frame (12). that it is free of dust and damage.
★ When installing the seals, use a push tool of the
2) Remove ring (13), bearing (14) and rings size which corresponds with the seal diameter.
(15), (16). ★ Select grease to be filled from among those
3) Remove dust seal (17) from front cage (18). listed below.
No. Manufacturer Grease Brand
1 Nihon Ryuyu Hilex HD-2
2 SHELL OIL Super Duty Grease2
3 ESSO OIL RONEX MP
4 BP Energrease LS-EP2
1. Subassembly of upper and lower hinge pin

portions of hitch frame
★ Adjust shims in the following manner.
1) Install dust seals (30) and (29) to hitch
frame (12).
2) Install dust seals (28) and (27) to retainers
(22) and (21).
2
4) Remove bearing (19) and spacer (20) from
hitch frame (12). Dust seal lip: Grease (G2-LI)
3) Install bearing (25) and (26) to the hitch
frame.
★ Bearings (25) and (26) are a set part, so do
not change the combination of bearing and
spacer.
5) Remove retainers (21) and (22) and shims

(23) and (24) from the hinge portion, and
then remove bearings (25) and (26).
6) Remove dust seals (27), (28), (29) and (30)
from retainers (21) and (22) and hitch frame
(12) respectively.
HM300-1 30-217
2
4) Install retainers (21) and (22) after adjusting

the shims.
i) Measure respective thickness "a" and
"b" of retainers (21) and (22) of the hitch
frame.
ii) Install retainer (21) to the hitch frame
upper side with 5 mounting bolts.
: 58.8 Nm {6 kgm} ± 10%
iii) Install retainer (22) to the hitch frame
underside with 4 mounting bolts.
: 39.2 Nm {4 kgm} ± 10%
iv) Measure respective dimensions "d" and
"e" of clearance between retainer (21)
and the hinge plate, and retainer (22)
and the hinge plate.
v) Select and make a combination of the
shims so that the total shim thickness is
"f", i.e. the difference between "d" and
"a" dimensions (f = d - a) minus 0.02 to
0.12mm, and likewise "g", i.e. the differ-
ence between "e" and "b" dimensions (g
= e - d) minus 0.02 to 0.12 mm.
★ Kind of shim thickness
: 0.1 mm and 0.5 mm
★ Retainer (21) portion 2. Subassembly of hitch frame
: Standard shim thickness: 2 mm 1) Install spacer (20) to hitch frame (12).
★ Retainer (22) portion
2) Press-fit bearing (19), using tool K3.
: Standard shim thickness: 1 mm
vi) Install a combination of the shims to
retainers (21) and (22), and tighten all
the mounting bolts.
: 98 - 123 Nm {10.0 - 12.5 kgm}
30-218 HM300-1
2
★ Fill space A inside the bearing with grease 3. Center shaft

completely. 1) Press-fit bearing inner race (9) and bearing
2 Space A: 1,030 g (8) into center shaft (10), using a push tool.
★ Fill bearing space E with grease 40% as
completely.
2 Space E: 26 g
★ Be careful not to make a mistake about
the grease amount. Such a mistake will
likely cause the bearing to overheat.
3) Install rings (16) and (15) to hitch frame

(12).
★ Fill spaces B and C with grease 60% as
completely.
2 Space B: 29 g
2 Space C: 80 g
4) Install bearing (14) and spacer (13). 2) Insert center shaft and bearing assembly (6)
★ Fill space D inside the bearing with into hitch frame assembly (7).
grease 40% as completely. ★ Press-fit the portion of bearing outer
2
race of the center shaft and bearing
Space D: 14 g
assembly.
★ Be careful not to make a mistake about
HM300-1 30-219
2
4. Front cage assembly 6. Rear retainer

1) Install ring (13) to the hitch frame front side. 1) Using tool K4, press fit dust seal (4) to rear
2) Install dust seal (17) to the front cage. retainer (5).
a Supply grease of 25 g to the dust seal
a Coat the dust seal lip with grease and
lip and space H.
also fill space F inside with grease com-
pletely. 2 Dust seal lip and space H:
2 Space F: 25 g
Grease (G2-L1)
a If the quantity of the grease is improper,
a Be careful not to make a mistake about
the bearing will overheat. Accordingly,
take care extremely.
3) Fill space G with grease 60% completely. 2) Install ring (3) to rear retainer (5).
a Fill space J of the ring with grease of
2 Space G: 60 g 65 g.
2 Space J of ring: Grease (G2-L1)
a Be careful not to make a mistake about
a If the quantity of the grease is improper,
the bearing will overheat. Accordingly,
4) Install front cage assembly (11) to hitch take care extremely.
frame (12).
3) Install nipple (32) and grease fitting (31) to
rear retainer (5).
a Install nipple (32) and grease fitting (31)
to serial No. 1054 and up.
5. Coupling
Install coupling (1).
2 Coupling spline portion
: Lubricant containing
molybdenum disulfide (LM-G)
2 Mounting bolt
3 Mounting bolt
: 455 - 565 Nm {46.5 - 58 kgm}
30-220 HM300-1
2
(7)
4) Install rear retainer assembly (2).

2 Mounting bolt
3 Mounting bolt
: 59 - 74 Nm {6.0 - 7.5 kgm}
a Supply grease of 200 g to the retainer
through the grease fitting of serial No.
1054 and up.
2 Inside of retainer: Grease (G2-L1)
HM300-1 30-221
2
(7)

K3 Plate
30-222 HM300-1
2
DISASSEMBLY AND ASSEMBLY STEERING VALVE ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF
STEERING VALVE ASSEMBLY
Tools needed for disassmbluy and assembly

1) Torque wrench (torque capacity: 49Nm {5kg}) 7) Plastic hammer
2) 5/12 in - 12 point soket 8) Small amount of grease
3) Flat-headed screwdriver (large) 9) Vice
4) Flat-headed screwdriver (small) 10) Oil-based felt pen
5) Spring insertion tool (P/N: 600057) 11) Tweezers
6) 3/16 in hexagonal wrench
HM300-1 30-223
2
Part No. Part name Q‘ty Remarks
1 Screw 6
2 Retainer screw assembly 1
3 End cap 1
4 Gerotor 1
5 Spacer 1
6 Spacer (1)
7 Spacer plate 1
8 Drive 1
9 Housing 1
10 Sleeve 1
11 Spool 1
12 Pin 1
Centering spring 6 For standard input torque specification
13
Centering spring 4 For low input torque specification
14 Flat spring (2) Only for low input torque specification
15 Race bearing 1
16 Thrust needle 1
17 O-ring 1
18 Oil seal 1 X-ring or Teflon seal
19 Dust seal 1
20 Retaining ring 1
21 Seal gland bushing 1
22 O-ring 2 Part No.: 5776
23 O-ring 1 Part No.: BA0098A
24 Inlet check valve sub assembly 1 (Cannot be disassembled)
25 Valve seat 1 (Cannot be disassembled)
26 Poppet 1
27 Spring 1
28 Plug 1
29 O-ring 1
30 Retainer plug 2
31 Spring 2
32 Ball 2
33 Valve seat 2 (Cannot be disassembled)
34 Ball 2
35 Ball holder 2
36 Spring 2
37 Plug 2
38 O-ring 2
39 Adapter screw 1
40 Ball 1
41 Name plate 1
42 Rivet 2
Seal kit (X-ring) Part No.: BA0271A

Seal kit (Teflon seal) Part No.: BA0273A
30-224 HM300-1
2
DISASSEMBLY 2. Gerotor
1) Remove spacer (5) inside spline on inside of
★ When disassenbling the valve, cleanliness is star of Gerotor (4).
extremely important. Cary out the work in a
clean place. 2) Remove Gerotor (4).
★ In the following explanation diagrams, it is not ★ Be careful not to drop star from ring of
absolutely necessary to hold the unit in a vice, outer cicumference of Gerotor.
but it is recommended to use a vice as far as 3) Remove O-ring (22) from Gerotor.
possible.
★ Before removing the piping, remove all dirt and
dust from around the ports and joints on the out-
side circumferences of the motor.
k Be extremely careful not to injure yourself on
the edges of sleeves, spools, housing, and
other machined ports.
1. End cap
1) Put end cap (3) at the top, fit side face of
housing between copper sheets in vice [8].
★ Be careful not to tighten vice too
strongly.
3. Drive and Spacer plate

1) Remove drive (8), then remove spacer plate
(7).
2) Remove O-ring (23) from housing.
2) Remove 6 screws (1) and 1 retainer screw

(2), then remove end cap (3).
3) Remove O-ring (22) from end cap (3).
HM300-1 30-225
2
4. Ball
1) Using flat-headed screwdriver, remove
adapter screw (39).
2) Remove housing from vice, set upside
down, then remove ball (40).
★ Be careful not to drop or lose the ball.
3) Set housing on clean cloth with axial line of

valve horizontal.
4) Turn spool and sleeve assembly to set
sleeve pin in horizontal position, then push
out spool and sleeve assembly slightly, and
remove seal gland bushing (21) from hous-
5. Anti-cavitation check valve ing.
Set housing updise down, remove 2 springs
5) Remove oil seal and dust seal from gland
(31), 2 retainer lugs (30), and 2 balls (32).
★ Be careful not to drop or lose the parts. bushing.
★ When remove the seal, be careful not to
damage the seal gland bushing.
6. Seal gland bushing

1) Set on clean cloth with flange surface of
housing facing up to prevent damage to fin- 7. Race bearing and thrust needle
ished surface. Remove 2 race bearings (15) and thrust needle
(16).
2) Use flat-headed screwdriver to raise tip of
retaining ring (20), then remove from hous-
ing.
k The retaining ring may fly out from the
housing, so always wear protective
glasses.
30-226 HM300-1
2
8. Spool and sleeve 4) Rotate spool slowly and pull out spool (11)
1) Push spline portion inside spool with thumb from sleeve (10).
and remove spool and sleeve assembly 5) Remove O-ring from housing.
from opposite side of housing flange.
k Since center spring (13) may fly out of
the spool, be sure to put on protective
goggles..
★ When doing this, be careful not to let
outside diameter of sleeve get caught in
inside diameter of housing.
★ Depending on the assembly of sleeve
and spool, it may not work properly if it
is assembled 180° from the proper
direction so make marks to show the
position of spool and sleeve (43).
2) Remove pin (12)
9. Disassembly of steering relief valve
1) Using hexagonal wrench (width across flats:
3/16 inch), remove plug (28).
2) Remove O-ring (29) from plug.
3) Using tweezers, remove spring (27) and
poppet (26).
★ The valve seat is stuck to the housing
and cannot be removed.
3) Push out spool inside sleeve slightly, and

remove centering spring (13) carefully by
hand from spool.
HM300-1 30-227
2
(9)
10. Disassembly of overlord relief valve

1) Using hexagonal wrench (width across flats:
3/16 inch), remove plug (37)(2 places).
2) Remove O-ring (38) from plug.
3) Using tweezers, remove 2 springs (36), 2
ball holders (35), and 2 balls (34).
★ The valve seat is stuck to the housing
and cannot be removed.
2) Align 2 spring grooves st 180° in spool and

sleeve, then stand on a horizontal plate.
3) Insert spring insertion tool (Part No.: 60057)
in spring groove, then fit centering spring to
insertion tool so that notched portions at
both ends are at bottom.
★ When doing this, it is easier to insert if
spool is lifed up slightly from sleeve.
4) Hold centering spring at opposite end with a
ASSEMBLY finger and compress it to push it into spool
k
sleeve groove.
Be extremely careful not to injure yourself on
★ When doing this, slide insertion tool at
the edges of sleeves, spools, housing, and
other machined parts. same speed as pushing in spring.
★ After inserting, align end of spring with
★ Check all the joining parts.
outside diameter of sleeve.
Parts with gouges or burrs will cause leakage of
★ Insert sleeve pin into hole in sleeve, and
oil, so replace them with new parts.
align both ends of pin with outside diam-
Wash all metal parts with clean solvent and
eter of sleeve.
blow dry with compressed air. If they are wiped
with rags or paper, pieces of cloth or paper will
stick to the parts or get inside the valves. This housing, so always wear protective
will cause the hydraulic system to become dirty, glasses.
so do not wipe with cloth or paper.
Do not polish parts with sandpaper or modify
with a file.
★ As a basic rule, assemble new O-rings and seal
after disassembling. Coat the O-rings with a
small amount of clean grease before assem-
bling.
★ The O-rings in front of or behind the spacer
plate are of very similar sizes, so check the part
number before opening the seal kit, and be
extremely careful not to mix them.
1. Spool and sleeve
1) Turn spool (11) and insert slowly into sleeve
(10).
★ Grip spline portion of spool and check
that spool rotates smoothly inside
sleeve.
★ Align mark made when disassembling.
30-228 HM300-1
2
5) Set housing on clean cloth with axial line of 3. Seal gland bushing
valve horizontal. Insert spool and sleeve ★ There are two types of seal: Teflon seal and
assembly opposite end of housing to flange standard seal.
end. 1) Assemble dust seal (19) to seal gland bush-
★ In this condition, check that spool and ing (21).
sleeve assembly rotates smoothly inside ★ Assemble dust seal so that flat surface
housing. is at seal gland bushing end.
★ When inseting spool and sleeve assem-
2) Assemble oil seal (18) to seal gland bush-
bly, be careful not to insert it at an angle
and get it caught. ing.
★ Keep the pin at near the horizontal pos- ★ Assemble the oil seal carefully so that
tion, and rotate slightly to left and right to there is no twisting or deformation.
insert. ★ The diagram below is the Teflon seal
★ Insert so that the end face of the spool specification drawing; (44) is the distin-
and sleeve assembly is level with the guishing groove.
end face of the housing. If it is inserted
further, the pin will fall inside the hous-
ing, so stop inserting when the end face
is level.
★ The diagram below is the standard seal

specification drawing.
2. Race bearings and thrust needle

1) Place housing on clean flat surface, then
assemble O-ring (17).
2) Assemble 2 race bearings (15) and thrust
needle (16).
★ Always insert thrust needle between
race bearings.
HM300-1 30-229
2
3) After assembling seals, rotate seal gland 4. Assembly of steering relif valve
bushing (21) and insert to spool. 1) Assemble O-ring (29) to plug (28).
★ Tap with plastic hammer to insert to
2) Using tweezers, assemble spring (27) and
specified position.
popet (26) to housing.
4) Assemble retaining ring to housing (20).
3) Using hexagonal wrench (wrench (width
★ Push open with a flat-headed screw-
driver so that the whole circumference across flats: 3/16 inch), assemble plug (28)
of the retaining ring fits securely in the to housing.
groove in the housing.
housing, so always wear protective
glasses.
5. Assembly of overload relief valve

1) Assemble O-ring (38) to plug (37).
2) Fit grease to ball holder (35) and install ball
(34).
★ Seal assembly drawing
Screwdriver 9, dust seal (19), retaining ring 3) Using tweezers, assemble ball holder (35)
(20), seal gland bushing (21), oil seal (18), and spring (36) to housing.
O-ring (17) . 4) Using hexagonal wrench (width across flats:
3/16 inch), assemble plug (37) to housing.
★ The size of the overload valve ball and
the anti-cavitation check valve ball is dif-
ferent, so be careful not to mix them.
30-230 HM300-1
2
6. Assembly of anti-cavitation check valve 2) Of the 7 bolt holes in the end face of the
1) Grip the port surface and side surface of the housing, insert ball (40) in the holes shown
housing lightly in a vice. Fit copper sheets in in the drawing. Assemble adapter screw
the vice, and be careful not to tighten the (39) in holes in same drawing.
vice too strongly.
2) Of the 7 bolt holes in the end face of the
housing, insert 1 each of spring (31),
retainer plug (30), and ball (32) in the 2
holes shown in the drawing.
★ Be careful not to drop or lose the ball.
★ Be careful of the assembly direction of
the retainer plug.
3) Assemble O-ring (23) to housing.

4) Set spacer plate (7) on top and align posi-
tion of bolt holes.
★ The pitch diameter of the bolt holes and
oil holes is different.
7. Assembly of gerotor end

1) Grip the port surface and side surface of the
housing lightly in a vice. (45): 25 mm. Fit
copper sheets in the vice.
★ Be careful not to tighten the vice too
strongly.
5) Turn spool and sleeve assemblly and set

pin (12) and port surface (46) of housing in
parallel.
★ Check that lines (47) are parallel.
6) Insert drive (8) into portion (47).
★ To mate drive yoke and pin (12), carry
out positioning exactly, use a felt pen to
draw line on end face of drive (8) paral-
lel to pin.
HM300-1 30-231
2
7) Assemble O-ring (22) to Gerotor (4). 3) Coat 6 screws (1) and thread of retainer
screw assembly (2) with oil, then assemble
to end cap.
★ Install retainer screw assemblies to bolt
holes where adapter screws have
already been assembled.
★ 14.7Nm {1.5 kg}, then tighten in order to
following torque.
8) Set O-ring at end face of Gerotor (4) at

spacer plate (7) side, align concave portions
(48) of Gerotor star teeth with pin (12), align
withmark drawn on end face of drive (8),
and assemble.
★ Check carefully that lines A, B, C, and
D, are parallel as shown in diagram ★ Order for tightening end cap mounting
below.
screws is as shown in diagram below.
★ Turn Gerotor ring to align bolt holes. Do
not remove mating of drive and Gerotor
star.
★ The above procedure is important for
aligning the valve timing.
★ After tightening to torque given below, install

handle to spool and check that spool
rotates.
Screw tightening torque

8. Spacer and end cap
1) Assemble spacer (5) to spline Gerotor star. Discharge capacity cc/rev Tightening torque (N.m{kgm}
★ Do not assemble spacers to 51 cc/rev
51 - 230 22.6 {2.3}
and 69 cc/rev discharge capacity Orbit-
rolls. 277 23.5 {2.4}
Assemble 2 spacers to 184cc/rev dis- 369 - 737 28.4 {2.9}
charge capacity orbit-roll.
(315 cc/rev. with HM300-1 model)
(315 cc/rev. with HM300-1 model)
2) Assemble O-ring (22) to end cap (3), set on
top of Gerotor, then align bolt holes.
30-232 HM300-1
2
REMOVAL AND INSTALLATION OF FLOW AMP
DISASSEMBLY AND ASSEMBLY VALVE
REMOVAL AND 1. Drain hydraulic oil.
INSTALLATION OF 6 Hydraulic tank: 120 l
FLOW AMP VALVE 2. Open up the engine hood, and tilt the operator's
cab with a crane or with a tilt cylinder and pump
assembly V.
SPECIAL TOOL
a Use 2 shackles so that hook of the sling will
Disti
Mark Part No. Part name
Neces Ske-
Q'ty nctio tch not hit glass of the cab assembly.
sity
n*
care the direction of the lock bar (2).
k Check that the lock lever (2-1) closes and
the operator cab assembly (6) is held

REMOVAL
securely in position by the lock bar (2).
level ground.
knob.
the wheels.
k Set the lock bar to the frame and lock front
and rear frame.
• Precautions in tilting cab

k When tilting the cab, check that the lock lever
is fixed securely.
k Do not start the engine while the cab is tilted.
k When it is obliged to start the engine for test-
ing etc., check that there is nobody under the
cab.
lever.
k Do not tilt the cab while it is loaded. • For further details on removal and installa-
tion of the operator's cab, refer to the sec-
k Disconnect the cable from the negative (–) tion of "METHOD OF TILTING CAB UP" in
terminal of the battery. INSPECTION AND ADJUSTMENT.
the internal pressure of the hydraulic tank.
HM300-1 30-233
(10)
2
REMOVAL AND INSTALLATION OF FLOW AMP
DISASSEMBLY AND ASSEMBLY VALVE
4. Disconnect the following hoses, and disconnect 6. Remove the mounting bolts for flow amp valve
tube (1) (for HP port) of the flow amp valve. assembly (15) and then remove the assembly.
4
• (2) and (3): Discharging hose for steering
Flow amp valve assembly: 35kg
and hoist pump
• (4): Discharging hose for emergency steer-
ing motor
• (5): Hose for centralized pressure check
5. Disconnect hoses (5) to (13) from the flow amp
valve assembly.
• (6): LS port hose
• (7): EF port hose
INSTALLATION
removal.
• Refilling with oil (hydraulic tank)

specified level, then start the engine to let the oil
• (8): P port hose
circulate in the piping and check the oil level
• (9): CL port hose again.
• (10): T port hose
• (11): L port hose l (EO10-CD)
• (12): HT port tube
• (13): CL port tube
• (14): CR port tube
30-234 HM300-1
2(10)
DISASSEMBLY AND ASSEMBLY HOIST VALVE ASSEMBLY
REMOVAL AND 1. Drain hydraulic oil.
INSTALLATION OF 6 l
Hydraulic tank: 120l
HOIST VALVE ASSEMBLY 2. Remove inner cover (1) of the left fender.
SPECIAL TOOL
Disti
Neces Ske-
sity
n*
REMOVAL

k To prevent interference between the cab and 3. Open up the engine hood, and tilt operator's cab
the dump body, set the steering in a straight with a crane or with a tilt cylinder and pump
ahead position and stop the machine on the assembly V.
level ground. a Use 2 shackles so that hook of the sling will
k Lock the dump lever with the dump lever lock not hit glass of the cab assembly.
knob. 4. Pull lock lever (2-1) and set lock bar (2) with the
k Turn the parking brake switch ON and chock care the direction of the lock bar (2).
k Check that the lock lever (2-1) closes and
the wheels.
k Set the lock bar to the frame and lock front the operator cab assembly (6) is held
and rear frame. securely in position by the lock bar (2).
• For further details on removal and installa-
• Precautions in tilting cab tion of the operator's cab, refer to the sec-
k When tilting the cab, check that the lock lever tion of "METHOD OF TILTING CAB UP" in
is fixed securely. INSPECTION AND ADJUSTMENT.
k Do not start the engine while the cab is tilted. 5. Remove the bracket mounting bolts of EPC
k When it is obliged to start the engine for test- valve (2).
ing etc., check that there is nobody under the
6. Disconnect the following piping from the hoist
cab.
k
valve.
Do not operate the gear shift lever or dump
• (3): T port hose
lever.
k
• (4): T port tube
Do not give a large shock to the machine. a Disconnect the tube coupling.
k Disconnect the cable from the negative (–)

terminal of the battery.
the internal pressure of the hydraulic tank.
HM300-1 30-235
(10)
2
DISASSEMBLY AND ASSEMBLY HOIST VALVE ASSEMBLY
• (5): T2 port tube INSTALLATION

• (6): A1 port hose
• (7): A1 port tube • Installation is carried out in the reverse order to
• (8): B1 port tube removal.
• (9): P port tube
• (10): PA port hose • Refilling with oil (hydraulic tank)
a Remove a U clamp and coupling from each Refill with oil through the oil filler port up to the
specified level, then start the engine to have the
tube.
oil circulate in the piping, and check the oil level
again.
l (EO10-CD)
• (11): PB port hose

• (12): A1 port hose
• (13): B1 port hose
a Start the work from the hitch frame side.
a Disconnect U clamps from A1 port tube (7)
and B1 port tube (8).
7. Remove the mounting bolts for hoist valve

assembly (14) and then remove the assembly.
4 Hoist valve assembly: 35kg
30-235-1 HM300-1
2(10)
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER ASSEMBLY
DISASSEMBLY AND 3) Pull out cylinder head and piston rod

assembly (3) from cylinder (4) and remove.
ASSEMBLY OF ★ When the piston rod assembly is pulled
STEERING CYLINDER out from the cylinder, oil will come out,
so catch it in a container.
ASSEMBLY
4) Remove cylinder (4) from tool U1.
SPECIAL TOOL
Dis-
Mar Neces- Ske-
Part No. Part Name Q'ty tinc-
k sity tion* tch
790-502-1003 Cylinder Repair ■ 1

1 Stand
790-101-1102 Hydraulic Pump ■ 1
2 790-102-3802 Wrench Ass'y ■ 1
3 790-102-1320 Socket (width ■ 1

across flats: 70 mm)
790-720-1000 Expander ■ 1
4 796-720-1660 Ring ■ 1
U
07281-01159 Clamp ■ 1
790-201-1702 Push Tool Kit ■ 1
790-101-5021 • Grip 1 2. Disassembly of piston rod assembly
5
01010-50816 • Bolt 1 1) Set piston rod assembly (3) in tool U1.
790-202-1781 • Push Tool 1
790-201-1500 Push Tool Kit ■ 1
2) Using tool U3, remove nut (5).
790-101-5021 • Grip 1
6
01010-50816 • Bolt 1
790-201-1590 • Plate 1
DISASSEMBLY
★ Be careful not to give damage to the rod pack-
ing, dust seal, piston ring, wear ring, etc. during
the work.
1. Piston rod assembly
1) Set cylinder assembly (1) in tool U1.
2) Raise lock of cylinder head nut, and using
3) Remove piston assembly (6) and cylinder
tool U2, remove cylinder head assembly (2).
head assembly (7) from rod (8).
30-236 HM300-1
2
3. Disassembly of piston assembly ASSEMBLY

1) Remove wear ring (9) from piston (10). ★ Clean all parts, and check for dirt or damage.
Coat the sliding surfaces all parts with engine oil
2) Remove wear ring (11) from piston (10). before installing.
1. Assembly of cylinder head assembly
1) Using tool U5, press fit bushing (15) to cylin-
der head (16).
★ Take care not to deform bushing (15)
when press fitting it.
4. Disassembly of cylinder head assembly

1) Remove snap ring (12), then remove dust
seal (13).
2) Remove rod packing (14).
3) Remove bushing (15) from cylinder head
(16). 2) Install rod packing (14).
4) Remove O-ring (17) and backup ring (18). ★ Take care of installing derection.
3) Install backup ring (18) and O-ring (17) in
order.
★ Do not insert the backup ring forcibly,
but heat it in water at about 50 - 60fC,
then insert it.
HM300-1 30-237
2
4) Using tool U6, install dust seal (13) to cylin- 3) Using tool U4, shrink the piston ring.
der head (16).
4) Install wear ring (9).

5) Install snap ring (12).
3. Assembly of piston rod assembly

2. Assembly piston assembly 1) Assemble cylinder head assembly (7) and
1) Using tool U4, expand piston ring (11). piston assembly (6) to piston rod (8).
★ Set piston ring (11) to the tool and rotate
the handle by 8 - 10 turns to expand the
ring.
2) Remove piston rod (11) from tool U4 and
install it to piston (10).
2) Using tool U3, tighten nuts (5).

2 Nut: Thread tightener (LT-2)
3 Nut
: 3.97 ± 0.4kNm {405 ± 40.5kgm}
3) Remove piston rod assembly (3) from tool
U1.
30-238 HM300-1
2
DISASSEMBLY AND ASSEMBLY HOIST CYLINDER ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF
HOIST CYLINDER ASSEMBLY
SPECIAL TOOL
Dis-
sity tion* tch
790-502-1003 Cylinder Repair Stand ■ 1
1
790-101-1102 Hydraulic Pump ■ 1
2 790-102-3802 Wrench Ass'y ■ 1
790-720-1000 Expander ■ 1
4. Piston rod assembly 4 796-720-1660 Ring ■ 1

07281-01159 Clamp ■ 1
1) Set cylinder (4) in tool U1. 790-201-1702 Push Tool Kit ■ 1
2) Assemble cylinder head and piston rod 790-101-5021 • Grip 1
assembly (3) in cylinder (4). 5 01010-50816 • Bolt 1
U
790-201-1831 • Push Tool 1
790-201-1871 • Push Tool 1
790-201-1500 Push Tool Kit ■ 1
790-101-5021 • Grip 1
6 01010-50816 • Bolt 1
790-201-1640 • Plate 1
790-201-1680 • Plate 1
790-102-4300 Wrench Ass'y ■ 1
7
790-102-4310 Pin ■ 1
DISASSEMBLY
★ Be careful not to damage the rod packing, dust
seal, piston ring, and wear ring.
3) Using tool U2, tighten cylinder head assem- 1. Rod assembly
bly (2).
3
1) Set cylinder assembly to tool U1.
Cylinder head nut
assembly (1) from cylinder Y (2).

: 931 ± 93.1Nm {95 ± 9.5kgm} 2) Using tool U2, remove cylinder head
HM300-1 30-239
2
3) Remove cylinder U and rod assembly (3)

from cylinder Y (2).
3. Further disassembling piston assembly
Remove piston ring (14), wear ring (15), O-ring
and backup ring (15a) from piston assembly
(13).
4) Remove snap ring (12) and screw (12a).

4. Cylinder U
Remove snap ring (16) from cylinder U (4),
5) Remove piston assembly (13), using tool
cylinder U (4).
U7, and then sling rod (5) to detach from
then remove dust seal (17), rod packing (18)
6) Remove wear ring (7) from cylinder U (4).

and bushing (19).
2. Further disassembling cylinder assembly

1) Remove snap ring (8), then remove dust
seal (9) and rod packing (10).
2) Remove bushing (11).
3) Remove the O-ring and backup ring (6a).
30-240 HM300-1
2
ASSEMBLY 2. Assembly of piston assembly

★ Clean all parts, and check for dirt or damage. 1) Using tool U4, expand piston ring (14), and
Coat the sliding surfaces of all parts with engine assemble to piston (13).
oil before installing. ★ Set the piston ring on tool, and turn the
1. Cylinder U
handle 8 - 10 times to expand the ring.
2) Set tools U4 in position, and compress pis-
der U (4).
1) Using tool U5, press fit bushing (19) to cylin-
ton ring (14).
3) Install wear ring (15).
4) Fit the O-ring and backup ring (15a).
2) Install rod packing (18).

★ Check the direction of assembly for the
rod packing when installing.
3) Using tool U6 fit dust seal (17) and install
snap ring (16).
HM300-1 30-241
2
3. Assembly of cylinder head assembly 4) Fit snap ring (8), O-ring and backup ring (6).
1) Using tool U5, press fit bushing (11).
4. Rod assembly
2) Assemble rod packing (10) to cylinder head 1) Fit wear ring (7) to cylinder U (4).
(6). 2) Tighten piston assembly (13), using tool U7.
3
★ Check the direction of assembly for the
Piston assembly
rod packing when installing. : 294 ± 29.4Nm {30 ± 3.0kgm}
3) Sling rod (5) to assemble it in cylinder U (4).
4) Tighten screw (12a).
2 Screw
: Liquid adhesive compound (Loctite #262)
3 Screw
: 27.5 - 34.3Nm {2.8 - 3.5kgm}
★ Degrease the threads of the screw suffi-
ciently.
5) Fit snap ring (12).
3) Using tool U6 install dust seal (9).
30-242 HM300-1
2
DISASSEMBLY AND ASSEMBLY BODY ASSEMBLY
6) Assemble the rod assembly of cylinder U in

cylinder Y (2).
REMOVAL AND
INSTALLATION OF
BODY ASSEMBLY
REMOVAL
1. Sling the bottom side of hoist cylinder.

2. Remove bottom pins (1) of the left and right
hoist cylinders.
k When the bottom pin is removed, the hoist
cylinder will swing outward, so fasten the
der Y (2), using tool U2.

7) Install cylinder head assembly (1) to cylin- hoist cylinder with lever lock [1] inwardly.
3 Cylinder head assembly

: 1.23 ± 0.12kNm {125 ± 12.5kgm}
3. Loosen lever block [1] by lowering the crane

and put the hoist cylinder on the wheel.
★ Put block [2] between the hoist cylinder and
wheel.
HM300-1 30-243
2
4. Separate body potentio linkage (2) at the body INSTALLATION

side.
5. Sling the body assembly at 4 points. removal.
6. Remove 2 body hinge pins (3) on the left and
k When matching the pinholes, never put a

right sides.
a Shims are provided, so check their thick-
ness, number in use and installed locations finger into the hole.
beforehand. 3 Cylinder bottom pin mounting bolt
: 16 - 20 Nm {157 - 196 kgm}
a Adjust the body positioner sensor, referring

to the section of "ADJUSTING BODY POSI-
TIONER SENSOR" in MAINTENANCE
AND ADJUSTMENT.
k When matching the pinholes, never put a

finger into the pinhole.
3 Hinge pin mounting bolt
7. Sling body assembly (4) to remove. : 16 - 20 Nm {157 - 196 kgm}
4 Body assembly: 3,500kg
a Adjust the shims in the body mount, refer-
ring to the section of "ADJUSTING THE
SHIMS IN THE BODY MOUNT" in TEST-
ING AND ADJUSTING.
30-244 HM300-1
2(15)
a Adjusting the shims in the body mount

(When new body is installed.)
1) Insert spacer [1] of 58 mm in thickness in
the front end of body (4). (1 each for left and
right)
2) Measure clearance "x" between the center
of bottom mount (5) and the upper surface
of rear frame (6).
a Measure clearance at 4 points of A and
B on the left and right sides.
3) Calculate the shim thickness at A and B
points both on the left and right sides.
• Shim thickness = (x - 26) mm
4) Assemble shim (7) having thickness calcu-
lated in the step 3) above in bottom mount
(5).
• Standard shim thickness: 4mm
3 Shim mounting bolt:

: 1 mm and 3.2 mm
235 – 285 Nm {23.5 – 29.5 kgm}

5) Remove spacer [1] and check that the bot-
tom mount is in contact with the upper sur-
face of the rear frame at all 4 points of A and
B.
HM300-1 30-245
2
(15)
DISASSEMBLY AND ASSEMBLY OPERATOR’S SEAT ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF OPERATOR’S SEAT

ASSEMBLY
a The procedure for disassembling and assembling the operator’s seat assembly {Air suspension (product
made from ISRING HAUSEN)} is shown below.
A: Headrest E : Left-hand armrest

B: Seatback F : Suspension cover
C: Seat cushion G : Sliderails
D: Right-hand armrest
DISASSEMBLY
1. Headrest
1) Referring to the figure, check the positions of
the 2 clips (2) of headrest stay (1) on both
sides.
30-246 HM300-1
(5)
2) Apply force b to part a of each clip (2) in the 2. Seatback

direction of the arrow to turn the clip. Re- 1) Disconnect 3 air hoses (5) from the rear left
lease headrest stay (1) from part d of the clip of seatback (4).
and pull out up headrest (3). a Before disconnecting the air hoses,
check their types.
2) Remove seatback hinge mounting bolt (6)

(M8 bolt).
a Pushing in both clips (2) simultaneously,

remove headrest (3).
3) Bring seatback (4) down forward.
HM300-1 30-247
(5)
4) Apply force E to the right side of seatback (4) 2) Push cushion stopper wire (9) down with
in the direction of the arrow. screwdriver [1], etc.
5) Applying the force to seatback (4), pull its 3) Pull out seat cushion (8) forward and remove
right side up. it.
6) Slide seatback (4) sideway and remove it.
4. Armrest
3. Seat cushion • The procedure for disassembling right-hand
1) Push cushion adjuster lever (7) inward and armrest (10) is shown below.
slide seat cushion (8) to the front end. (Disassemble left-hand armrest (11) similar-
ly.)
30-248 HM300-1
(5)
1) Remove plastic cap (12) from the armrest 6) Remove right-hand armrest (10).
hinge. a There are 2 position adjustment washers
a Use a flat-head screwdriver, etc. to re- (16) installed to each bolt between the
move the cap. armrest and seatback. Take care not
2) Loosen armrest hinge mounting bolt (13). lose them.
3) Remove plastic cap (14), and then remove 5. Suspension cover

lower mounting bolt (15A) (M8 bolt) of right- 1) Remove right-hand hinge cover (17).
hand armrest (10). 2) Remove plastic plate (18) from the rear with
screwdriver [1], etc.
a Take care not to damage the plastic plate
by prying it off forcibly with a screwdriver,
etc.
4) Turn right-hand armrest (10) up by 180 de-

grees.
a If the armrest is not turned, you cannot
apply the tool to upper mounting bolt
(15B).
5) Remove plastic cap (14) and upper mount-
ing bolt (15B).
HM300-1 30-249
(5)
3) Remove 4 suspension cover fixing rings 6) Remove 6 plastic suspension cover clips
(19). (small) (25) and 2 plastic suspension cover
clips (large) (26).
a Clips (small) (25):
Front upper part; 2 places
Each side; 1 place
Rear lower part; 2 places
Clips (large) (26):
Front lower part; 2 places
7) Remove suspension cover (27).
a If you remove the suspension cover with-
out performing the work in steps 5) and
6), the suspension cover may be broken.
4) Remove 4 mounting bolts (20), cushion rear

fixing plate (21), 2 cushion rails (22), and 4
bushings (23).
6. Rails
1) Turn over the seat assembly to set rails (28)
on the upside.
5) Remove 3 metallic suspension cover clips

(24).
30-250 HM300-1
(5)
2) Slide rails (28) to the rear end. ASSEMBLY

3) Remove 1 hexagon socket head bolt (29)
and 1 lock washer (30) from the front part of 1. Rails
each rail. q6 1) Put height adjustment washers (31) between
rails (28) and suspension, and then set rails
(28) in position.
4) Slide rails (28) to the front end.

5) Remove 1 hexagon socket head bolt (29)
and 1 lock washer (30) from the rear part of 2) Set rails (28) to the front end and install 1
each rail, and then remove rails (28). q7 lock washer (30) and 1 hexagon socket head
3 Hexagon socket head bolt:

bolt (29) to each rail.
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
a Take care not to lose height adjustment

washers (31) between the rails and sus-
pension.
HM300-1 30-251
(5)
3) Set rails (28) to the rear end and install 1 lock 2) Install 3 metallic suspension cover clips (24).
washer (30) and 1 hexagon socket head bolt
3 Hexagon socket head bolt:

(29) to each rail.
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
3) Set 4 bushings (23) and 2 cushion rails (22),

and then install cushion rear fixing plate (21),
3 Cushion rail mounting bolt:

and 4 mounting bolts (20).
2. Suspension cover 21.4 – 27.6 Nm {2.18 – 2.82 kgm}

1) Set suspension cover (27) in position and in-
stall 6 plastic suspension cover clips (small)
(25) and 2 plastic suspension cover clips
(large) (26).
a Clips (small) (25):
Front upper part; 2 places
Each side; 1 place
Rear lower part; 2 places
Clips (large) (26):
Front lower part; 2 places
4) Install 4 suspension cover fixing rings (19).
30-252 HM300-1
(5)
5) Install plastic plate (18) to the rear. 2) Tighten lower mounting bolt (15A) lightly and
6) Install right-hand hinge cover (17). turn armrest (10) by 180 degrees.
3) Tighten upper mounting bolt (15B) lightly.
4) Tighten lower mounting bolt (15A) and upper
3 Upper and lower armrest mounting

mounting bolt (15A) permanently.
bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
5) Install 2 plastic caps (14).
3. Armrest
• The procedure for assembling right-hand
armrest (10) is shown below.
(Assemble left-hand armrest (11) similarly.)
6) Tighten armrest hinge mounting bolt (13).

a Tighten the bolt so that the arm will move
smoothly.
• Operating effort at armrest end:
49 – 78.4 N {5 – 8 kg}
7) Install plastic cap (12).
1) Install 2 position adjustment washers (16) for

each bolt and set right-hand armrest (10) in
position.
HM300-1 30-253
(5)
4. Seat cushion 5. Seatback

1) Slide in the seat cushion from the front of the 1) Insert the left side of seatback (4), and then
fitting position. lower and set the right side.
a If seat cushion (8) is slid to the rear, it is
locked by cushion stopper wire (9).
2) Install seatback hinge mounting bolt (6) (M8
3 Seatback hinge mounting bolt:

bolt).
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
30-254 HM300-1
(5)
3) Connect 3 air hoses (5) to the rear left of the

seatback (4).
6. Headrest
1) Insert headrest (3) in seatback (4).
a Check that 2 clips (2) on both sides are
locked securely.
HM300-1 30-255
(5)
OTHERS
90 OTHERS
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM ...................................................................................... 90-2

STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM ........................................................................ 90-3
BRAKE HYDRAULIC CIRCUIT DIAGRAM ................................................................................................... 90-5
BRAKE COOLING HYDRAULIC CIRCUIT DIAGRAM............................................................................... 90-5-2
BRAKE COOLING HYDRAULIC CIRCUIT DIAGRAM (–30°C SPECIFICATION)..................................... 90-5-4
DIAGRAM FOR ELECTRICAL CIRCUIT AIR CONDITIONER .................................................................. 90-5-6
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (1/4)......................................................................... 90-7
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (2/4)......................................................................... 90-9
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (3/4)....................................................................... 90-11
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (4/4)....................................................................... 90-13
DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (1/3)................................................................... 90-15
DIAGRAM FOR ELECTRICAL CIRCUIT EXTERNAL POWER SUPPLY HEATER ................................... 90-21
DIAGRAM FOR ELECTRICAL CIRCUIT HEATER MIRROR ..................................................................... 90-22
HM300-1 90-1
(12)
OTHERS POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
90-2 HM300-1
OTHERS STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM
STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM
HM300-1 90-3
(12)
OTHERS BRAKE HYDRAULIC CIRCUIT DIAGRAM
BRAKE HYDRAULIC CIRCUIT DIAGRAM
HM300-1 90-5
(12)
OTHERS BRAKE COOLING HYDRAULIC CIRCUIT DIAGRAM
BRAKE COOLING HYDRAULIC CIRCUIT DIAGRAM
HM300-1 90-5-2
(12)
OTHERS BRAKE COOLING HYDRAULIC CIRCUIT DIAGRAM
BRAKE COOLING HYDRAULIC CIRCUIT DIAGRAM

(–30°C SPECIFICATION)
HM300-1 90-5-4
(12)
OTHERS DIAGRAM FOR ELECTRICAL CIRCUIT AIR CONDITIONER
DIAGRAM FOR ELECTRICAL CIRCUIT AIR CONDITIONER
HM300-1 90-5-6
(11)
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (1/4)
HM300-1 90-7
(5)
HM300-1 90-9
(5)
HM300-1 90-11
(5)
HM300-1 90-13
(5)
DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (1/3)
HM300-1 90-15
(11)
HM300-1 90-17
(11)
HM300-1 90-19
(11)
OTHERS DIAGRAM FOR ELECTRICAL CIRCUIT EXTERNAL POWER SUPPLY HEATER
DIAGRAM FOR ELECTRICAL CIRCUIT EXTERNAL POWER

SUPPLY HEATER
HM300-1 90-21
(11)
OTHERS DIAGRAM FOR ELECTRICAL CIRCUIT HEATER MIRROR
DIAGRAM FOR ELECTRICAL CIRCUIT HEATER MIRROR
90-22 HM300-1
(12)

HM 300 PDF

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HM 300 PDF

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SEBM024815

Machine model Serial number

HM300-1 1001 and up

• HM300-1 mount the SAA6D125E-3 engine.

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ...... 10-1

20 TESTING AND ADJUSTING ............................................................. 20-1

30 DISASSEMBLY AND ASSEMBLY ................................................... 30-1

90 OTHERS ............................................................................................ 90-1

( ) Page to be deleted Discard

Pages having no marks are not revised at this time.

LIST OF REVISED PAGES

Revision Revision Revision Revision Revision

q 00- 1 (15) 10-10 (9) 10-54 10-102 10-143 (9)

10-177 20-133-3 (10) 20-187 (9) 20-251 (5) 20-356 (6)

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

VOLUMES When a manual is revised, an edition mark

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

k Heavy parts (25 kg or more) must be lifted

• If a part cannot be smoothly removed from the

k Slinging with one rope may cause turning

★ The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, release Type 1

k Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

STANDARD TIGHTENING TORQUE

6 10 11.8 – 14.7 1.2 – 1.5

16 24 235 – 285 23.5 – 29.5

27 41 1150 – 1440 118 – 147

6 10 5.9 – 9.8 0.6 – 1.0

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

14 19 24.5 ± 4.9 2.5 ± 0.5

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque (Nm {kgm})

02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque (Nm {kgm})

08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES

ELECTRIC WIRE CODE

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal

15 84 0.45 13.36 7.0 59 Starting (Glow plug)

40 85 0.80 42.73 11.4 135 Starting

60 127 0.80 63.84 13.6 178 Starting

100 217 0.80 109.1 17.6 230 Starting

CLASSIFICATION BY COLOR AND CODE

METHOD OF USING THE CONVERSION TABLE

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354